RT100 Repaire Manual

RT100 Rough Terrain Crane
Maintenance Manual
RT100 Rough Terrain Crane Maintenance Manual Contents
Contents
Preface.……………………………………………………………………………………………IV
Chapter 1 Service and Maintenance Safety..…………………………………………………………1
Chapter 2 Service and Maintenance.…………………………………………………………………4
2.1 Boom and telescoping system.…………………………………………………………………5
2.2 Winch system..…………………………………………………………………………………8
2.3 Slewing ring……………………………………………………………………………………9
2.4 Slewing system.………………………………………………………………………………10
2.5 Hoisting hydraulic motor..……………………………………………………………………12
2.6 Central rotary joint……………………………………………………………………………13
2.7 Winch balance valve….………………………………………………………………………14
2.8 Elevating balance valve…....…………………………………………………………………15
2.9 Combined valve for lifting operation....………………………………………………………17
2.10 Telescoping balance valve spool.……………………………………………………………18
2.11 Telescoping cylinder...………………………………………………………………………19
2.12 Elevating cylinder...…………………………………………………………………………20
2.13 Jack cylinder…...……………………………………………………………………………20
2.14 Extension cylinder.………………………………………………………………………21
2.15 Suspension cylinder.………………………………………………………………………22
2.16 Engine and accessory system.……………………………………………………………23
2.17 Transmission.……………………………………………………………………………25
2.18 Axle.……………………………………………………………………………………27
2.19 Oil pump.…………………………………………………………………………………28
2.20 Outrigger.…………………………………………………………………………………32
2.21 Maintenance of electric system.…………………………………………………………34
Chapter 3 Coolant and Oil..…………………………………………………………………………46
3.1 Hydraulic Oil…………………………………………………………………………………47
3.2 Gear oil..………………………………………………………………………………………48
3.3 Engine oil…..…………………………………………………………………………………50
3.4 Transmission oil………………………………………………………………………………51
3.5 Engine coolant..………………………………………………………………………………51
3.6 Grease...………………………………………………………………………………………53
3.7 Fuel and lubricant brand and filling amount…………………………………………………56
3.8 Disposal of oil and antifreeze fluid…...………………………………………………………58
II
RT100 Rough Terrain Crane Maintenance Manual Contents
3.9 Fire extinguisher maintenance..….....……………………………………………………58

Chapter 4 System Principle Scheme...………………………………………………………………59
4.1 Electric principle scheme……………………………………………………………………60
4.2 Hydraulic principle scheme…………………………………………………………………78
Chapter 5 Common Trouble and Troubleshooting..…………………………………………………80
5.1 Common trouble and troubleshooting..………………………………………………………81
5.2 Hydraulic system and electric wires powered for driving operation…………………………91
5.3 Replacing wire ropes….………………………………………………………………………91
5.4 Return filter…...………………………………………………………………………………96
5.5 Line Filters (replacing filter element)…...……………………………………………………97
5.6 Tire maintenance and replacement...………………......……………………………………98
Chapter 6 Appendix....……………………………………………………………………………101
6.1 Main parts list.………………………………………………………………………………102
6.2 Wear parts list..………………………………………………………………………………103
III
RT100 Rough Terrain Crane Maintenance Manual
Preface
This manual applies to RT100 Rough Terrain Crane.
This manual describes the ways of service and maintenance for RT100 Rough Terrain Crane
(hereafter called crane) aiming at understanding the each main part performance and working
principle so as to serve and maintain the crane better, give full rein to the crane high performance,
increase crane’s working efficiency, ensure safety and prolong its normal service life.
In this manual, main parts structure and principle diagram of the crane are attached. During
maintenance, users can check out the code of spare parts that need to be replaced conveniently
according to its parts catalogue.
This maintenance manual and other technical documents are integral parts of the crane. Please
carefully preserve them as the basis of using and maintaining this crane. To the parts that need
qualified personnel to maintain and signed in the manual, users must invite qualified personnel to
maintain them, and the maintenance by yourself is prohibited. And we don’t take any
responsibilities due to the nonobservance of the maintenance manual.
The machine has a 12-month warranty from the date that the machine is delivered to
customers. In case of maintenance, the qualified personnel of our company will provide
door-to-door service or please go to the appointed service center of our company.
Due to the product modification and improvement, what described in this manual may vary
from the real item; we reserve the right to modify the design without notice, expecting your
understanding. The photos and illustrations in this manual are just for your reference.
XUZHOU HEAVY MACHINERY CO., LTD.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA
Add: No. 165 Tongshan Road, Xuzhou, Jiangsu Province, China
Tel: 0086-0516-83462242 83462350
Fax: 0086-0516-83461669
Post Code: 221004
Service Tel: 0086-0516-83461183
Service Fax: 0086-0516-83461180
Spare Parts Tel: 0086-0516-83461542
IV
Chapter 1 Service and Maintenance Safety
1
Notes of inspection and maintenance for the crane:

— Be careful. During maintenance, the crane must stop working with or without load, and
repairing the crane is prohibited during crane operation.
— Only the trained and qualified personnel can maintain the crane.
— Never perform any maintenance when the operator is unable to do work normally due to bad
health or drinking alcohol or taking medicine.
— Any improper maintenance or carelessness will cause injury or death of persons and damage
to the crane.
— Comply with road travel and crane operating regulations in the place where you are
working.
— Before maintenance, if the outrigger is needed to extend, make sure there are no obstacles
around the crane. After the extension of outrigger, outrigger hydraulic system maintenance is
prohibited.
— Before maintenance, confirm that the machine has been set up well, and a warning board of
“In maintenance, no operation” in the operator’s cab must be present.
— Before maintenance, understand the condition and failures of crane to avoid danger in
maintenance.
— Personal protective equipments such as spectacles, protective clothing and safety shoes have
to be worn during maintenance.
— When test the vehicle during maintenance, no person is allowed to stay outside of the
driver’s cab.
— When test the vehicle during maintenance, observe the conditions of instrumentation and
warning lamp in the driver’s cab. If any abnormality occurs, park the vehicle in a safe place
in time.
— The vehicle testing during maintenance should be carried out on flat ground. If the vehicle
has to be maintained on a slope in some special cases, wedge must be applied under the
wheels.
— Prior to maintaining the engine and other moveable parts, the battery must be disconnected
(the negative cable first), and all condensers be discharged in order to prevent accidental
engine starting.
— Before welding the oil can and oil tank, clean them with water or cleaning agent, and
uncover the sealed cap, otherwise accidents will easily occur.
— In order to avoid being stifled or frostbite, maintenance of fuel system and air conditioner
system must be carried out in a well-ventilated environment.
— When the vehicle has to be towed, the propeller shaft connected with the front and rear
2
output-end of transmission must be disengaged. Otherwise, the transmission will be

damaged.
— Prior to sheet metal and electric (gas) welding, maintenance personnel should not only clean
up the inflammable and explosive materials around the working site but check whether the
fire-fighting devices such as fire extinguisher are in good condition as well.
— Prior to disassembling pipelines, connectors or related parts, release the pressure in them to
prevent injury to person. Never check leakage of pressure with hand.
— In order to avoid scald, watch out for scorching parts and pipelines as well as liquid and gas
in pipelines and cavities.
— Hydraulic oil is toxic and flammable. Keep out of reach of children in order to prevent
swallowing internally by mistake.
— Avoid breathing in evaporative emission or contacting used oil for a long time. Clean skin
with soap and water as soon as possible after touching oil. If there is oil entering into eyes,
rinse with water for 15 minutes and then see a doctor.
— The maintenance which is not carried out according to the instruction will result in the
damage of the parts and increase the risk of vehicle accidents.
— Welding operation under the condition of vehicle with electricity is prohibited. Before
welding, the positive cable (+) and negative cable (－) must be removed from the battery.
The distance between the welded parts and earth wire should not exceed 500 mm.
— The damage of crane’s boom or jib will cause serious accidents. The damage of chord, the
bending or loss of pin shaft, or the crack of welding seam will weaken the intensity of lattice
jib and boom. Check the boom daily to see whether it is damaged. It is not allowed to use
boom when it is broken.
As the boom is made of high-tensile steel, special maintenance methods are required.
Please consult your manufacturer.
— Maintain or adjust the crane when there is heavy goods hung on the hook block or the boom
has extended will cause accidents, because the heavy goods or boom may have dangerous
movement.
— Before maintenance, lower the heavy goods to the ground and lower the boom to the
appropriate bracket.
— The pressure in hydraulic system will maintain for a long time, and should be released
before adjustment or maintenance. If not, the pressure will cause dangerous movements of
the crane or result in the high-speed spray of hot oil and pipe union.
3
Chapter 2 Service and Maintenance
4
2.1 Boom and telescoping system

2.1.1 Parts function
1. Boom and its telescoping system
Boom is the main component to which force is applied; it bears the weight of heavy goods,
wind load and other loads during working. Telescoping system is the necessary system to realize
the boom length changing.
2. 5300 balance valve
5300 balance valve is located at the rear of telescoping cylinder which can prevent retraction
of the cylinder when the control lever is in the neutral position, but also make the retracting
speed of boom stable when the boom is retracting. 5300 balance valve also has the safety
protective function of preventing oil cylinder from rapid retracting when the hose of boom
telescoping pipeline blow out suddenly.
2.1.2 Working principle and structure
The crane has five boom sections, the 2nd, 3rd, 4th and 5th boom sections driven by two
telescoping cylinders telescope sequentially and synchronously. That is the first-stage cylinder
drives the 2nd boom section with 3rd, 4th and 5th boom sections in it to stretch out, after that,
second-stage cylinder and ropes drive 3rd, 4th and 5th boom sections to extend sequentially and
synchronously; when retract boom sections, the second-stage cylinder and ropes drive 3rd, 4th
and 5th boom sections retract sequentially and synchronously, and then the first-stage cylinder
drives the 2nd boom section with 3rd, 4th and 5th boom sections in it to retract. The pressure of
pressure-limited valve is adjusted to 25MPa in order to avoid piston rod crooking because of too
high pressure when the boom is extending.
2.1.3 Use and maintenance
1. Adjustment of cables
During operation of boom, the length of wire rope will change due to the force applied to
ropes or cables. So the boom telescoping system should be checked and adjusted monthly.
If the boom could not be extended and retracted synchronously or vibration
appears, it must be adjusted in time. Operation is not allowed before the trouble is removed.
Otherwise, wire ropes or cables may fall out of groove or break; consequently serious result
will be induced.
In order to keep normal operation, please do periodic adjustment. The method is as follows:
Extend all sections out after elevating the boom to 60°, and retract them in fully, repeat several
times.
Lower the boom down after 3rd, 4th and 5th sections are respectively extended a little, and
adjust the nuts on thin ropes II of 5th section synchronously as well as nuts on thin ropes I of 4th
5
section, till 3rd, 4th and 5th sections can be telescoped synchronously and no shaking. Tighten
nuts on thin ropes. (See Fig 2-1, 2-2)
Nuts on thin rope II
Nuts on thin rope I
Fig. 2-1 Telescoping system (boom head)
Thin rope II
Fig 2-2 Thin cable on boom head

If there is a clearance of more than 1-2 mm between adjacent boom sections while the boom is
retracted fully, insert adjusting shims to compensate it, otherwise the force applied to oil cylinder
and rope will be influenced.
6
 If boom shakes while adjusting, coat sliding surface of slide block with grease.
 It is not allowed to extend all boom sections out for coating, only two or three sections
may be extended out and then lowered down for each coating. Please refer to
performance plate or load chart.
 Prevent the cable from rotating while nut is tightened.
2. Adjustment of slide block
The slide blocks have all been adjusted well when the crane is delivered to the consumers. No
adjustment is needed only when boom crooking, lateral loading and deflection because of serious
frictional damage or some other reasons. Users can adjust the slide block on the boom head by
adjusting the slide block bolt to control the clearance by themselves; as for the adjustment of
slide block on the base boom, the boom must be dismantled and the adjustment be carried out by
increase or decrease the number of washer under the slide block to control the clearance, see Fig.
2-3.
Adjust the bolt
Fig 2-3 Adjustment of slide block
 Before the adjustment of slide block on the boom head, the boom should be retracted
fully.
 The slide block on the base boom must be adjusted by qualified personnel.
7
2.2 Winch system

Winch system is the control parts to realize the hoisting and lowering movement of the load
through wire ropes.
Winch system consists of winch drum and reducer. This reducer is a 2-stage planetary gear
reducer mechanism, and the type of internal lubrication is oil-bath lubrication. The output shaft
of reducer is connected with winch drum through bolts, and wet brake is installed on the input
shaft.
Wire rope wedge
Reducer
Bearing block
Winch drum
Fig. 2-4 Diagram for winch reducer

1. General description
During working, observe whether there is any oil leakage on the page of brake and motor, and
loose of bolts and screws. Deal with the failure phenomena in time.
Replace oil after a new vehicle works for 100 hours, and then replace oil for the second time
after 500 hours. Hereafter replace lubrication oil every 1000 hours or one year (replace oil every
year if the vehicle works no more than 1000 hours in one year). It is better to operate the crane
for 15 minutes before replacing oil so as to exhaust lubrication.
2. Replacement of lubrication
Check the oil level of winch reducer and refill lubrication in time when the crane in horizontal
state. Replace the lubrication if necessary and the replacement procedures are suggested as
8
follows:
a) Place a container for the used oil
b) Loosen the oil level check plug
c) Remove the thread plug of the oil drain
d) Drain the used oil into the prepared container
Dispose the used oil in an environmental protection way.

e) Screw the cleaned thread plug on the oil drain
f) Remove the thread plug of oil filler
g) Refill fresh oil with flexible funnel until the oil outflow from the oil level check hole
h) Tighten the oil level check plug
i) Remove the funnel
j) Screw on the thread plug of oil filler
2.3 Slewing ring

Slewing ring connects the superstructure and carrier of the crane. The slewing parts of
superstructure, the weight of load and the overturning moment during lifting operation will be
delivered to carrier through slewing ring.
The structure type is four-point contact ball slewing ring. The outer circle of the slewing ring
is connected with turntable and the inner circle is connected with crane frame. Steel ball is
installed between the outer and inner circles to contact with circular arc sliding track by 4 points;
it can bear axial force, radial force and overturning moment at the same time. The tightening
torque of the bolt is 1700N.m～2000N.m. Check it after the slewing bearing works 500 hours
and lubricate sliding track once every 100 hours.
2.3.3 Axial clearance and radial clearance of slewing ring
Item
Axial Clearance Radial Clearance
Diameter
2242 0.10~0.55 0.016~0.55
9
Fig. 2-5 Slewing ring structure diagram
 The bolts connecting with slewing ring must be high-tensile bolts. Users should buy
high-tensile bolts when replace the slewing ring bolts so as to ensure the security of
slewing ring.
 Lubricate slewing ring every week, and put lubrication into the lubricating hole with
grease pump.
2.4 Slewing system

Slewing system is the drive unit to realize the slewing movement of crane superstructure.
Slewing system is installed on the turntable; this mechanism consists of slewing reducer and
hydraulic motor. High-speed hydraulic motor drives 3-stage planetary reducer to output power
through pinion, which does external meshing action with the slewing ring, fixed on the frame. Its
rotation and revolution drive the superstructure rotating.
The brake in slewing mechanism is multi-disc wet brake that is in constant-closed state. The
brake stays in open state when the pressure oil is filled into it, so the mechanism can work freely.
Refer to the part of slewing mechanism in parts catalogue for structure details.
10
Fig. 2-6 Slewing system structure diagram

1. General description
Check the pinion every week; especially check whether there is leakage of oil, and abnormal
sound. The ambient temperature should be in the specified scale, and pay attention to the
trademark of the lubrication oil and replacement period.
Only when the slewing system is in stop state and the oil temperature is
close to the ambient temperature can check the oil level.
2. Replacement of lubrication
The lubrication replacement procedures of slewing system are suggested as follows:
a) Remove the oil filler plug and dipstick
b) Loosen the oil drain plug and drain the oil into the prepared container
Dispose the used oil in an environmental protection way.

c) Before fill fresh oil, wash the gear system with diesel oil or kerosene
d) Wash the oil drain plug, and tighten it
e) Fill fresh oil to the marked middle position
f) Tighten the oil plug and dipstick
11
 When there is failure, overheating and maintain the fixed disk brake, the following
components must be replaced: friction disc, spring and seal.
 Slewing reducer has the function of eccentric adjustment. When slewing meshing
clearance is not appropriate, it can rotate the installation position of slewing reducer
to adjust the meshing clearance.
2.5 Hoisting hydraulic motor

Hydraulic motor with bend axial piston type design is variable motor. It is the actuator part of
system which is responsible to change hydraulic energy into mechanical energy.
Fig. 2-7 Hydraulic motor diagram

The hydraulic motor works when an inclination exists between cylinder and output shaft.
Changing the inclination between cylinder and output shaft can change the oil suction quantity of
hydraulic motor in order to change the rotation speed and torque of the motor (see the figure).
The torque of hydraulic motor depends on its working volume, input pressure and flow. When
input pressure is certain, working volume is larger, torque of hydraulic motor is bigger. When
input flow is certain, working volume is smaller, rotation speed of hydraulic motor is higher.
This is the basic working principle of variable hydraulic motor.
12
2.5.3 Common troubles and troubleshooting

1. No pressure in hydraulic motor
Open the leakage oil pipe of the motor to check the leakage. The motor without troubles has
very low leakage; if the leakage is high, troubles of no pressure will be caused.
2. Loads cannot be elevated with normal pressure and no motor leakage.
The variable mechanism is out of order, or the bolts are adjusted incorrectly.
2.6 Central rotary joint

It connects the hydraulic pipes and electric lines and ensures the regular transfer of electricity
and liquid between superstructure and carrier during the slewing of superstructure.
Refer to the part of central rotary joint in parts catalogue for structure details.
2.6.3 Disassembly and reassembly
1. Central rotary joint
1) O-ring, sealing stuffing and sealing ring
New parts should be replaced in principle. Coat hydraulic oil or grease before reassembly, and
pay attention not to break or damage them when assembling.
2) Sealing ring
For the assembly of the sealing ring, first squeeze the O-ring into the trough, and then push the
sealing stuffing into the trough at full tilt.
3) Test after assembly
After the reassembly of central rotary joint, pressurization test need be carried out to ensure
every oil line can work normally. The testing pressure of each joint is the 1.3 times of the
pressure in principle scheme.
2. Slip ring
1) Angle encoder
Replacing with new parts if angle encoder is broken. Mounting the angle encoder in the right
position when assembly.
13
2.7 Winch balance valve

This valve is used to avoid the runaway of hydraulic motor’s rotating speed caused by the
weight of lifting loads (the rotating speed of hydraulic motor exceeds oil supply quantity).
When the hydraulic motor is working for lowering load, the hydraulic oil on the descending side
flows into hydraulic motor and acts on the piston of balance valve through choke as the pilot
pressure.
When this pressure exceeds spring tension, the piston is pushed upwards, the hydraulic oil that
flows from port A to B keeps the pressure caused by loads, and the loads are descending at the
same time.
Fig. 2-8 Winch balance valve diagram
No. Part name No. Part name No. Part name

1 O-ring 2 O-ring 3 Bolt
4 Plug 5 Bolt 6 Plug
7 Plug 8 Filter screen 9 Sealing nut
10 Plug 11 Plug 12 O-ring
13 Bolt 14 Bolt 15 Bolt
16 Bolt 17 O-ring 18 Bolt
14

1. Sealing ring
2. Valve rod, piston and choke
Check whether the choke is blocked.
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth
or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check whether the motion is smooth.
2.8 Elevating balance valve

This valve is used to avoid the runaway of elevating cylinder’s descending speed caused by
the weight of lifting loads (the hydraulic cylinder cannot descend steadily).
When the elevating cylinder is descending, the proportional electromagnet of elevating
balance valve will be energized to work. At the same time, the pilot oil acts on the piston of
balance valve through choke as the pilot pressure.
When this pressure exceeds spring tension, the piston is pushed upwards, the hydraulic oil that
flows from port A to B keeps the pressure caused by loads, the loads are descending at the same
time.
15
Fig. 2-9 Elevating balance valve diagram
No. Part name No. Part name No. Part name

1 O-ring 2 O-ring 3 Bolt
4 Plug 5 Bolt 6 Plug
7 Plug 8 Filter screen 9 Sealing nut
10 Plug 11 Plug 12 O-ring
13 Bolt 14 Bolt 15 Bolt
16 Bolt 17 O-ring 18 Bolt
2.8.3 Disassembly and Reassembly

(1) Sealing ring
(2) Valve rod, piston and choke
Check whether the choke is blocked.
beforehand, and pay attention not to rotate them.
16
After the valve rod and piston are inserted into valve, check whether the motion is smooth.
Common troubles and causes:
(1) No movement when descending
At this time, open the Mx port of elevating balance valve to check whether there is outflow of
pressure oil; if there is no outflow, check whether the proportional electromagnet of elevating
balance valve is energized and whether the choke is blocked; if it is, check whether the
proportional electromagnet of main valve is energized.
(2) Descending too fast
Adjust the proportional electromagnet current of elevating balance valve.
2.9 Combined valve for lifting operation

The combined valve can complete the action of hydraulic loop for lifting operation, and
realize the function of telescoping system, elevating system, main winch and auxiliary winch. It
also can realize the composite proportional hydraulic control of direction, flow and pressure, and
achieve proportional stepless speed governing of several actuators when operating
simultaneously with different loads.
Fig. 2-10 Structure diagram of combined valve for lifting operation

17
2.9.3 Disassembly and Reassembly

(1). Valve block
Don’t grease on the O-rings among each block.
(2). Sealing ring
New parts should be replaced in principle.
Install the oil seal into valve rod from the both ends, and don’t put oil seal through the recess
of valve rod.
(3). Valve rod and check valve
beforehand, and pay attention not to rotate them. After the valve rod and piston are inserted into
valve, check if the motion is smooth. After some valve blocks are disassembled, the valve rod
should be assembled in the original valve block.
2.10 Telescoping balance valve spool

Ensure that the telescoping mechanism of crane can stop at any height, and take the effect of
closedown no matter the engine stops working or not and the time is long or short.
A B
1 2 3 4 5 6 7 8 9 10
1-Controlled piston 2-Sleeve 3-Controlled piston 4-Check valve spring 5-Check valve
6-Balance valve spool 7-Balance valve spool outer spring

8-Balance valve spool inner spring 9-Rear cover 10--O-Ring
Fig. 2-11 Telescoping balance valve spool structure diagram

18
Working principle:
(1). Telescoping cylinder extension
The oil entering from port B opens the check valve and flows to port A, that means oil flows
to large chamber of telescoping cylinder; the telescoping cylinder is in extending operation.
(2). Telescoping cylinder retraction
The oil liquid in large chamber of telescoping cylinder flows to port A and is blocked by check
valve. At this time, the oil liquid in small chamber of telescoping cylinder acts on port K of
control piston and impulses the balance valve spool compressing two main springs to move right
as the figure shows with a pressure of 45 bar. The flow from port A to port B realizes the
retraction of telescoping cylinder.
2.10.3 Use and Maintenance
(1) Dismounting and remounting telescoping balance valve
After the cylinder is fully retracted, the telescoping balance valve can only be disassembled
and assembled after confirming that there is no pressure in large chamber of telescoping cylinder.
Never put head above telescoping balance valve during disassembling, lest the overbottom
pressure springs the valve element out and causes injury to maintenance personnels.
(2) Installation of telescoping balance valve
The specification of O-ring 10 is ф50×3.1，push CCBH140/350 telescoping balance valve in
after buttering on the O-ring.
2.11 Telescoping cylinder

During lifting operation, it can realize the change of boom length with the help of wire ropes.
And it is also the holding device of boom length during operation.
2.11.2 Structure of telescoping cylinder I
Refer to the part of telescoping cylinder in parts catalogue for structure details.
2.11.3 Structure of telescoping cylinder II
Refer to the part of telescoping cylinder in parts catalogue for structure details.
(1) When the piston rod assembly is pulled out from cylinder, pay attention not to damage the
surface of piston rod, piston and sealing ring.
(2) In order to make the piston rod cover easy to rotate, the cylinder should be aimed at the
central of piston rod.
(3) Support ring, sealing ring
19

(4) Piston rod, piston and cylinder
If small scratch is found on the sliding surface, use fine oilstone to polish it.
When the piston rod assembly is inserted into cylinder, coat enough hydraulic oil on the
sliding surface beforehand to avoid the damage of support ring, sealing ring, etc.
2.12 Elevating cylinder

Elevating cylinder is the drive unit to realize the change of boom radius through its
telescoping. It is also the holding device of boom radius during lifting operation.
Refer to the part of elevating cylinder in parts catalogue for structure details.
2.13 Jack cylinder

Jack cylinder is a hydraulic cylinder to control the vertical movement of construction crane
outrigger jack. It is used to support crane’s own weight and the vertical pressure during work.
Jack cylinder impulses the cylinder piston rod to telescope through the action of hydraulic oil,
and produces pushing force or tension force, driving the parts connected with cylinder to
telescope.
The telescoping principle of jack cylinder is as shown in Fig. 2-13 and Fig. 2-14, and the
direction of arrowhead is the flow direction of hydraulic oil. In Fig. 2-13, hydraulic oil enters
from port A, and pushes the piston to move right; the piston rod retracts and the hydraulic oil
flow out from port B; in Fig. 2-14, hydraulic oil enters from port B and push the piston to move
left; the piston rod extends and the hydraulic oil flow out from port A.
20
Fig. 2-12 Cylinder retraction diagram Fig. 2-13 Cylinder extension diagram
2.13.3 Structure of jack cylinder

Refer to the part of jack cylinder in parts catalogue for structure details.
(1) When disassemble and reassemble the guide sleeve and piston seal, prevent the radial hole
of cylinder from damaging the seal.
Try best to ensure the cleanliness when change the cylinder on-site, avoiding causing
secondary pollution.
2.14 Extension cylinder

Extension cylinder is a hydraulic cylinder to control the horizontal movement of construction
crane outrigger beam. It is used to support the horizontal pressure during work.
The working principle of extension cylinder is the same with that of jack cylinder.
2.14.3 Structure of extension cylinder
Refer to the part of extension cylinder in parts catalogue for structure details.
21
2.15 Suspension cylinder

Suspension cylinder is a hydraulic cylinder to connect frame and axle, which can ease the jolt
and vibration during vehicle driving and is the important component of suspension hydraulic
system.
The working principle of suspension cylinder is opposite to that of jack cylinder. It impulses
the flow of hydraulic oil in cylinder through the telescoping of piston rod, and the flow resistance
of oil fluid can ease the vibration of suspension cylinder.
The principle of suspension cylinder is as shown in Fig. 2-12 and Fig. 2-13, and the direction
of arrowhead is the flow direction of hydraulic oil. In Fig. 2-12, piston rod move right and make
the hydraulic oil suck in from port A, and flow out from port B; in Fig. 2-13, piston rod move left
and make the hydraulic oil suck in from port B, and flow out from port A.
Refer to the part of suspension cylinder in parts catalogue for structure details.
22
2.16 Engine and accessory system

2.16.1 Engine
Maintain engine strictly according to Engine Operation and Maintenance Manual.
Contact Cummins engine service center for help about irremovable troubles.
2.16.2 Fuel pipeline
Check tightening condition of fuel pipeline as well as leakage. In engine oil inlet pipeline,
there is a fuel water filter (see Fig. 2-15) fitted above the fuel tank and under the deck.
Water filter
housing
Drain valve
Water level
sensor
Fig. 2-14 Fuel water filter

(1) Method of draining water
Water will settle at the bottom of the filter as water is heavier than oil. Water level sensor is
mounted at the bottom of filter housing and can check the conductibility of surrounding solution.
When there is enough water assembled at the bottom of the filter to replace the fuel around, the
senor will detect the change of conductibility and the display in driver’s cab will show fault code
418. At this time, turn the drain valve counterclockwise to drain water, and then close the valve
after operation by turning it clockwise.
(2) Replacement of filter element
Frequency of replacing element depends on the level of impurity in diesel fuel. The element
will be clogged with impurity during operation of engine, and the flow resistance of fuel will
increase gradually, eventually engine power decreases obviously and /or it is difficult to start. It
is recommended that replace element every 500 hours of operation or when engine power
decreases, whichever expires earlier. It is recommended to take a spare element on board, so that
replacement could be performed in time when fuel filter is blocked by the dirty diesel fuel in
tank.
(3) Troubleshooting
The main reason of engine power decreasing or difficult to start is that air enters into fuel
23
system.
If oil can’t be pumped or no pressure built in the system, first check drain valve for tightness,
and then fuel filter housing. After that, check all connectors for confirming that fuel pipeline is
not stuck or clogged by impurity. If problem remains after a new filter element is replaced,
please contact the maintenance and service center of Xuzhou Heavy Machinery Co. Ltd. .
2.16.3 Radiator
Check and rectify the liquid level. If the consumption of coolant is abnormal, check the reason
and remedy. Check pipeline and hoses for damage and leakage. Repair or replace radiator if
damage or trouble is found.
Make sure that all pipelines and hoses are not damaged and scratched,
and secured correctly.
(1) Check the outside of radiator and clean
The radiator should be cleaned after use in dusty circumstance for a long time. Blow impurity
(dust, dead insects, etc.) out of radiator pipeline by compressed air, or remove foreign body on
the back of radiator by water (opposed to the flow direction of cooling air). Clean the radiator
with proper pressure, otherwise radiator pipeline may be damaged. During cleaning, move water
gun continuously and never aim directly at the following in order to avoid components damage:
 Electric components
 Connectors
 Sealing
(2) Clean radiator water line
Add solution with 5% of density formed by water and light alkaline cleaning compound into
cooling system, preheat engine with proper speed to approximately 82℃(coolant thermostat
begins to open), and shut down the engine after running about 5 minutes. When the engine cools
to around 50℃, drain out the cleaning solution, and refill with clean water. Start and preheat
engine, drain out water after 5 minutes and then repeat the operation again.
2.16.4 Air filter
Carry out maintenance of air filter every 3 months or 250 working hours or red line appears in
the air filter negative pressure indicator. The interval of maintenance should be shortened in
dusty circumstance.
Check for confirming that the connector between air filter and engine is sealed well before
refill fuel every day, as well as all hose connectors and air filter cover. If any crack is found,
repair immediately and keep record in maintenance book.
Second-stage filter called safety element is mounted in first-stage filter. It is not recommended
to clean the second-stage filter, otherwise they will be damaged. Never disassemble second-stage
24
filter before replacement.

Pay more attention when disassemble first-stage filter to avoid dust entering into filter housing.
It is recommended to replace safety element one time after replacing first-stage filter element 3
times. If safety element looks clean and it’s not time to replace it, don’t loosen fly nut and never
change its location.
When clean filter with old safety element fitted, remove dust dropping from safety element.
But never use compressed air for cleaning (refer to Fig. 2-16). When replace safety element, take
out element carefully from the housing after removing fly nut and washer. Before install new
safety element, clean the inner surface of filter housing with a clean and wet cloth.
Fig. 2-15 Air filter cleaning diagram
Air filter is easy to be damaged during filtering air due to the shock of dust particles.
Replace filter element in time if excessive oil consumption, great quantity of exhaust and
smoke, as well as low power are found. Otherwise, it is harmful to engine.
2.17 Transmission
Replacement of oil in transmission should be performed when it is under hot state for
completely draining. At the same time, the oil in cooling circuit should be drained out. The
drained oil should be in a container and the disposal of waste oil should be done according to the
environmental protection requirements in the place where you are working.
Clean the drain plug and tighten it with specified tightening torque. (See Fig. 2-17)
25
Pay more attention to avoid scald from hot transmission oil and parts, and
avoid contacting kindling so as to prevent catching fire.
Replace the transmission oil according to the following procedures:
1. Refill oil
Before starting, refill the oil according to specified oil amount and trademark. Pay attention
to cleanness and prevent impurity particles from entering the oil tank with oil. Refer to Fig.
2-4 for the position of oil filler
2. Check the oil level in cold state
Rotate the turntable anticlockwise 90°, let engine run at idle speed for 3～5 minutes, and
then check the oil level which should be above the mark of “COLD” on the transmission
dipstick. If the oil level is lower than the mark of “COLD”, refill the oil, and if it is more than
the mark, there is no need to draw the oil out.
3. Check and adjust the oil level in working temperature
When the oil temperature of transmission reaches to working temperature (80℃-90℃), run
the engine at idle speed for 2～3 minutes. Check whether the oil level is in the mark area of
working temperature on the dipstick (in the area of “HOT”), and refill or decrease the oil
accordingly.
The oil level in working temperature should be checked weekly.
Oil filling
port
Oil draining
port
Fig. 2-16 Oil filling plug Fig. 2-17 Oil draining plug
26
2.18 Axle
The front and rear axle of RT100 are steering driving axle. Wheels are mounted on both ends
of axle, and the middle of axle is connected with frame by suspension. The basic function of axle
is to increase the torque passed from propeller shaft, distribute the torque to left and right driving
wheels, and make them have the differential function which is demanded in automobile
travelling kinematics. Axle also support the longitudinal force, lateral force, vertical force and
moment between frame and wheels.
2.18.2 Structure
Axle consists of main reducer, differential, rim reducer, half shaft, brake, axle housing and
other components.
Fig. 2-18 Main reducer

1. Input flange 2. Main reducer input shaft 3. Main reducer housing 4. Differential
5. Main reducer bevel gear 6. Sliding sleeve 7. Inter-wheel differential
27
Fig. 2-19 Rim reducer

1. Rim reducer 2. Half shaft II 3. Hub 4. Brake 5. Kingpin
6. Half shaft I 7. Axle housing
2.18.3 Maintenance
The maintenance of axle is carried out by the appointed service station or personnel of axle
factory.
2.19 Oil pump

2.19.1 Variable pump
1. Parts function
A11VL0 variable plunger pump is used for telescoping, elevating and hoisting of lifting
operation.
2. Working principle and structure of variable pump
Pump is the device transforming mechanical energy into hydraulic energy. Its output flow is in
proportion to the rotating speed of drive shaft, and the input rotational moment increases with the
increase of pressure difference between high pressure side and low pressure side. When the
engine drives the main shaft of pump rotating, the connecting rod plunger and cylinder are
rotating together, and cylinder rotates on the distributing. Because there is certain intersecting
angle between main shaft and cylinder axial line, the plunger gets an oil suction stroke when it
moves from bottom dead center to top dead center and sucks oil into the cylinder by oil suction
port and distributing plate waist type hole. When the plunger moves from top dead center to
28
bottom dead center, it gets an oil extrusion stroke and squeezes the oil that fully filled in the
cylinder to output port so that executive elements are driven. The variable pump works by
changing the inclination angle between main shaft and cylinder axial line through variable
mechanism. Changing the inclination angle can change the oil suction volume of variable pump.
The torque of variable pump depends on its working volume, output pressure and flow. When
output torque is given, the smaller the working volume is, the bigger the pressure of variable
pump is. When output rotation speed is given, the larger the working volume is, the higher the
variable pump flow is. This is the basic working principle of variable pump.
Top dead center

Connecting rod Plunger
Main shaft
Distributing plate
Cylinder
Bottom dead center
Fig. 2-20 Variable pump

3. Replacement of variable pump
If the variable pump must be replaced due to something wrong with it, pay attention to the
contamination of the system in the process of dismounting and remounting and try to minimize
the contamination. The oil ports should be covered with plastic cloth. After finishing the
installation of new oil pump, hydraulic oil must be filled in from the two pressure oil ports of the
pump until the oil tank is full. When the pipelines are connected, the oil pump can work after
rotating for 15 minutes at idle speed.
29
2.19.2 Gear pump

1. Parts function
a. Supply pressure oil for outrigger hydraulic system, and ensure the extension and retraction
of outrigger beam and outrigger jack.
b. During lifting operation, it supplies pressure oil for slewing system.
c. Supply pressure oil for transmission hydraulic radiating system.
d. When vehicle steers or pivot steers, supply pressure oil for steering cylinder to boost the
steering cylinder so as to reduce the operation force on steering wheel.
2. Working principle and structure
The concept of gear pump is simple. Its basic form is that two gears of the same size mesh
with each other and rotate in a tightly fitted housing. The interior structure of housing is similar
to “8” with two gears in it, and the outside diameter and two sides of the gear are tightly fitted
with the housing. The hydraulic oil from hydraulic oil tank enter the middle of the two gears
from the suction port, permeate this space, move with the rotation of gear along the housing, and
discharge when the two gears are meshing.
From the perspective of terminology, gear pump is also named oil discharge unit which is similar
to a piston in a cylinder. When one tooth enters the liquid space of another, liquid will be
extruded mechanically. Because liquid is incompressible, and it cannot occupy the same space
with tooth at the same time. Therefore, liquid is extruded. As the teeth mesh continuously, this
phenomenon occurs sequently. As a result, a continuous discharge volume is formed at the exit
of pump, and the discharge volume of each rotation of pump is the same. With the uninterrupted
rotation of driving shaft, liquids are discharged from the pump continuously. The flow volume of
pump is related to its rotation speed directly.
30
Extrude oil Suck oil
Fig. 2-21 Working principle of gear pump

Fig. 2-21 is the working principle diagram of external meshing gear pump. From the diagram,
it can be seen that a pair of external meshing gears are mounted in the housing of this kind pump.
As the gap formed by gear end face and housing end cover is very small, and the gap formed by
the tooth top of gear and inner surface of housing is also small, it can be regarded that the gear
pump housing is divided into left and right sealed chamber. When the gear rotates as shown in
the figure, the gear on right side disengages from mesh gradually, and intertooth space will show
up. Consequently, the volume of sealed chamber on this side increases, forming partial vacuum.
Oil liquid under the action of atmospheric pressure enters this chamber through the oil suction
port, thus this chamber is called suction chamber. With the rotation of gear, the oil liquids in
every intertooth flow from right to the left. In the left sealed chamber, gear teeth are meshing
gradually, decreasing the volume of this left sealed chamber and extruding the oil liquids in
intertooth from output port. And this chamber is called exhaust chamber. When the gear pump
rotates continuously, the oil suction port and output port suck and extrude oil accordingly,
realizing the process of delivering oil liquids to hydraulic system. In gear pump, oil suction area
and oil discharge area are divided by meshing gear teeth and pump. Therefore, there is no
independent oil distribution mechanism.
31
Fig. 2-22 Structure of gear pump

1. Gear, rolling bearing 2. Side panel 3. Housing 4. Front end cover
4.1. Rear end cover 5. Shaft head seal, external bearing 6. Secondary sealing ring
7. Oil suction side 8. Pressure side 9. Driving gear 10. Driven gear
11. “3” type sealing
3. Disassembly and Reassembly
It is not recommended to disassemble by yourself. If trouble occurs, replace the whole unit.
2.20 Outrigger
Enlarge the support basis of crane, compensate the inclination and unevenness of working site
ground, and increase the anti-overturning stability of crane and the hoisting capacity.
Every crane has four outriggers disposed as “H” with two hydraulic cylinders each: horizontal
hydraulic cylinder and vertical hydraulic cylinder, which realize the outrigger movements of
telescoping and lifting. In working state, the outriggers extend to the ground and clear the crane
off the ground, supporting the whole weight of crane. When travelling, the outriggers are
retracted to reduce the outline dimension and increase its pass ability.
Refer to the part of outrigger assembly in parts catalogue for structure details.
1. Disassembly of outrigger
The procedures are as follows:
32
Hydraulic
oil port
Outrigger
box
(1) Remove the outrigger box (2) Disassemble the hydraulic pipeline, and
must take protective methods on pipeline
port to ensure its cleanliness
Adjusting
bolt Outrigger
lock pin
支腿锁销
(3) Remove adjusting bolts (4) Pull out outrigger lock pin
Cylinder
fixed pin
(5) Remove cylinder fixed pin

(6) Choose appropriate equipment, and pull
out outrigger horizontally and steadily
Fig. 23 Assembly and disassembly of outrigger
2. Reassembly of outrigger
The procedures of reassembly are opposite to the procedures of disassembly, and the methods
are the same.
33
2.21 Maintenance of electric system

2.21.1 Maintenance of electric system for lifting operation
The crane electric system for lifting operation consists of power supply circuit, starting
circuit, pilot control circuit, unloading circuit, rope-end limiter circuit, instrument indicating
circuit, lighting circuit, moment limiter system and auxiliary circuit, etc.
This manual provides detailed explanations on the causes and solutions of some common
electric troubles of crane.
Common troubles and troubleshooting
1. None electricity in crane superstructure
Circuit composition: Fuse → superstructure starter switch → power supply relay →
superstructure electric load→ ground cable.
From the electric principle scheme, it can be seen that the power supply circuit is composed of
battery, fuse F2, starter switch, power supply relay, fuse F6, generator and connecting cables (see
carrier electric principle scheme). Any problem in one of them will cause no current in crane
lifting operation.
Cause and Solution:
No. Trouble Solution
1 Fuse F2 or F6 burned-out Replace
Repair (take terminal Acc instead of
2 Starter switch out of order
terminal Br) or replace
3 Power supply relay broken Replace
4 Lead disconnected or virtual connected Reconnect wire or lay cables
5 Bad earth Reground
2. Trouble in lamp circuit
Circuit composition: power supply→ fuse→ switch→ lamp→ ground cable
Causes and Solutions:
1 Bulb damaged Replace
2 Fuse burned Replace
3 Earthing faulty Repair
4 Lead disconnected Repair
5 Switch inoperative Replace or repair
34
3. Anti-two block inoperative

1 Cord reel faulty Replace
3 Anti-two block switch inoperative Replace
4 Weight rope broken Replace
5 Anti-two block switch earthing faulty Repair
6 Moment limiter faulty Contact our service center
4. Wiper inoperative
Circuit composition: power supply→ fuse→ switch→ wiper motor
1 Fuse burned Replace
2 Switch inoperative Replace
3 Motor damaged Replace
4 Earthing faulty Repair
5. Rope-end limiter inoperative
Fig. 2-24 Rope-end limiter
Circuit composition: power supply→ fuse→ bridging switch→ rope-end limiter switch (main
winch), (auxiliary winch) →controller
Causes: ① The rope-end limiter switch has not been set in place or inoperative;
② Fault in the circuitry.
35
Solutions: ① Open the rear cover of rope-end limiter and readjust 3~5-turn position of wire
rope to make it inosculate with switch contact or repair and replace
② Check the circuitry and repair.
6. Lifting operation does not work

1) Faults in electric proportional safety control switch or circuit
Circuit composition: power supply→ fuse→ electric proportional safety control switch→ load
moment limiter
Causes: something wrong with fuse, control switch or circuit.
Solution: check and repair circuit, and replace the fuse or toggle switch
2) Faults in control lever
Circuit composition: power supply→ fuse→ control lever
Causes: ① Power supply circuit of lever control is disconnected, virtual connected or the lever
is damaged.
② Display fault codes, lever communication fault, (find out the specific failure of
lever according to the hint).
Solution: ① Check the repair of circuit, and replace the lever;
② Enter the page of “System Inquiry” → “Control Parameter Inquiry” from the
main page
Enter the page of “Lever failure code inquiry” to check whether there is lever communication
fault.
System main page System inquiry main page
36
Control parameter inquiry page Lever failure code inquiry page

Fig. 2-25 Lever failure inquiry page
3) Extension mainframe (Load moment limiter) fault
a. Enter the page of “CANBUS state inquiry” to check whether there is communication fault
of extension mainframe.
Fig. 2-26 CANBUS state inquiry page

b. Handle the left and right lever, and observe the state of safety control switch in “Control
parameter inquiry” page, and if there is a change of input current value corresponding to the
open degree of lever, and the output current value of corresponding pump or valve supplied by
current movement controller. Then enter “Input/ output terminal state inquiry” page of D-1、D-2、
A-1、P-1 extension mainframe from the “Control parameter inquiry” page: observe whether there
is a change of corresponding input/ output terminal state parameter supplied by current
movement controller when handle the left and right lever, and try to find out whether the input
and output of extension mainframe is in order.
4) Fault in the circuit between extension mainframe and its corresponding solenoid valve and
solenoid valve itself.
Circuit composition: Load moment limiter→ control solenoid valve
Causes: Problems in plug-in, connecting cables or solenoid valve itself
Solution: check and repair cables, and replace plug-in or solenoid valve
37
2.21.2 Maintenance of electric system for driving operation

1) No current in crane and carrier electric systems
Analysis: Power supply circuit consists of battery, breaker F1 or fuse F2, starter switch, power
supply relay coil (control circuit) and main contact (main circuit), ammeter, breaker F6,
generator, and connecting cables. So any problem in one of them will cause no current in crane
and carrier electric systems.
Table 1-2
Trouble Cause Remedy
No current in battery or connecting Charge the battery or
cable disconnected. reconnect cable.
Breaker F1 tripping. Check and reset.
Starter switch faulty. Repair or replace.
No current in crane and
Breaker F6 tripping or fuse F2 Replace fuse.
carrier electric systems
blown.
Cables between components Reconnect cables, re-plug in
broken, plug-in comes off. components.
Bad earth. Reground.
2) Starter doesn’t work

Analysis: most starting circuit troubles are from starter switch, second from starting circuit,
neutral and starting coil.
Solution:
1) Regular check: First put the control lever of transmission in “N”. Only when the lever is in
“N”, “N” will be shown on the display of transmission state, and then starting is permitted. If
other information is shown on the display, remove the transmission trouble according to
transmission instructions. If transmission is normal, do the following check. First, check
absorbing coil. If there is sound in the coil, that means the coil is normal, it is necessary to check
holding coil. If there is no sound in the absorbing coil, that means the absorbing coil is broken, it
needs to repair or replace. Second, check battery and main electric circuit. If there are no
problems in battery and main circuit, that means there is problem in starting motor, repair or
replace starting motor.
2) Remove trouble in CANBUS: press key F5 for “Carrier trouble diagnosis” in “Driving
page” to enter the page as shown in Fig.2-27. Get to know the working conditions of every
communication node in the page of “Carrier trouble diagnosis” as shown in Fig. 2-29 and
observe whether EPEC bus communication is normal or not. If “P1 fault” is shown, measure
whether the resistance between the two CAN cables (X104:2, X104:6) at EPEC controller with
AVO meter is 60Ω or not (if the value measured is in the range of 56~62Ω, it is considered
38
normal). If “EPEC and TTC fault” is shown, observe whether there is fault between EPEC and
TTC. The remedy method is to check the two 120Ω resistors and CANbus plug. If “Engine or
Transmission fault” is shown, observe whether is fault between engine and transmission, and the
remedy method is the same as that previously described. If it cannot be started after treatment,
check the K7 neutral relay and the connection. If all the above are normal, it is the problem of
starter. Repair or replace the starter motor.
变速箱 1 2 3 4 5 6 7
发动机 1 2 3 4 5 6 7
S02 S03 S01 S014 S011 S012 S06 S02 S03 S01 S014 S011 S012 S06
V V V V
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
S09 S016 S08 S05 S020 S017 S018 S019 S33 S013 S09 S016 S08 S05 S020 S017 S018 S019 S33 S013
V V
S15 S14 S16 S17 S12 S07 S34 S15 S14 S16 S17 S12 S07 S34
FL FR FL FL FR FL
S20 S18 S21 S19 S24 S22 S20 S18 S21 S19 S24 S22
RL RR
RL RL RR
RL
P P
26 27 28 29 30 31 32 26 27 28 29 30 31 32
Fig. 2-27 Carrier trouble diagnosis page

3) Generator does generate electricity
Solution: Check if it is a mechanical problem or an electric problem.
Mechanical problem: belt or screw loose, generator bearing faulty. Repair or replace.
Electric problem: check with an AVO meter. The voltage from generator should be more than
27V. If the voltage is lower than 27V and no change after increasing accelerator, which means
there is problem in generator. Repair or replace.
4) Starter motor burned out
① Starter motor is not parallel with the center of flywheel gear ring, re-install the motor.
② Starting cable and power cable short circuit, check circuit and repair.
③ Starter motor faulty.
5) Instrument faulty
39
Fig. 2-28 Driving main page

Signals on the instrument in driving state are read from CAN bus in SAE J1939 format. If no
indication on engine tachometer, water temperature and oil pressure gauge, check CAN bus
communication through display system and PI, P2 power supply. If communication is normal,
instruments should indicate actual values. If it is not normal, all instruments do not indicate. At
this time, check the connections of communication circuit. If communication is normal, but one
of instruments does not work normally, it means that there is trouble in engine.
6) Lamp is not light
Solution:
① Check lamp circuit:
First, check whether the power supply of P1 controller is normal, and then check switch and
bulb. After that check ground cable, plug-in and cables. Repair or replace according to actual
conditions.
② Check communication CANBUS:
See the second item in Starter doesn’t work.
Plug-in is small component which is the most applied in electric system,

and easy to have trouble. The problems are mainly bad contact or reed cracked or
deformation. When any one of problems occurs, replace the component.
7) Overload protector tripping F1, F6
Overload protector is used as fuse, so do not press the “Reset” button after it tripped until the
vehicle power source main switch is turned off and no electricity on both terminals of overload
40
protector is ensured. If the overload protector continues to trip, measure the output load of the
overload protector. If there is short circuit present, remove it in time. Only when the vehicle
power source main switch is turned off, the “Reset” button of overload protector can be pressed
to make it work.
8) Outrigger could not work
① Observe if there is fault through the “Carrier trouble diagnosis” of driving main page;
P1 is the main controller, from which command is send out to control carrier outrigger
operation. Data of driving main page also comes from P1 controller. In case of fault in P1
controller CAN bus, carrier operation will not be finished.
P2 controller is used to control outrigger valve, illumination, hydraulic system pressure valve,
axle disconnected valve and suspension valve, etc. In case of error in P2 controller CAN bus,
pressure will not be built in hydraulic system, thus outriggers could not work.
② Enter P1 and P2 to see whether there is input or output on the corresponding terminal by
referring to electric system schemes.
P1 Terminal State
Fig. 2-29 Input and output of P1 terminal
P2 Terminal State
41
Fig. 2-30 Input and output of P2 terminal

If there is input or output on the corresponding terminal during operation, green color will be
shown on the terminal state column.
9) Rear axle steering system (electric) fault
① Steering system fault
If there is fault in steering system, “Steering system fault” will be shown in “system state”
column in Fig. 2-31, and fault code will be shown in “System fault” column: 29～90.
多轴电控转向监控
Multi-axle electric controlled steering
当前模式小转弯目标模式小转弯
系统状态系统故障
行驶参数
时速转速
前桥后桥
Fig. 2-31 Multi-axle electric controlled steering
Steering system fault and parameter description
故障描述
代码故障描述端子号描述状态
29 前轴 A 传感器故障号136 一桥 A 当前角度

29 前轴 A 传感器故障 136 一桥 A 当前角度
30 前轴 B 传感器故障 137 一桥 B 当前角度

9 29 前轴 A 传感器故障 136 一桥 A 当前角度
31 后轴 A 传感器故障 138 二桥 A 当前角度

32 后轴 B 传感器故障 139 二桥 B 当前角度

47 后桥右电磁阀故障 286 二桥左转阀开口

48 后桥左电磁阀故障 288 二桥右转阀开口

55 最高车速限制
57 前轴传感器误差大
58 后轴传感器误差大
62 多开关操作
65 通信故障
Fig. 2-32 Steering system fault description
42
Solution: Click “Fault parameter” to enter Fig. 2-32 for finding out the corresponding fault
description, and carrying out repeated repair. For example, when the code shown is 47, the
corresponding fault description is “Rear axle right steering solenoid valve faulty”. At this time,
check and repair according to the following: first, check if plug Y816a is in place, if yes,
measure whether there is current in P8 controller plug X894:88 with AVO meter. After repair,
turn off key switch, and then turn it on again, and observe whether there is fault. After each
repair, it is necessary to turn the key switch off and turn it on again for checking if fault is
removed. At the same time, check other fault. Checking should be done according to the process
shown in Fig.2-33, until “Steering system normal” is shown on “System state”.
Start
Read fault
Is there fault?
Yes
Resolve fault
Turn off, and then

No turn on again
Finish
Fig. 2-33 Fault solution process
43
Angle sensor Axle washer

Pulling rod
Pulling rod
Adjusting nut
Adjusting nut
Fig. 2-34 Angle sensor adjusting diagram

② Angle indicated is not correct (refer to Fig. 2-34)
Cause: the location of steering pulling rod is changed, angle sensor signal error.
Solution: turn all axles to neutral, and adjust sensor according to the following way: loose the
adjusting nut I and nut II on pulling rod, rotate the pulling rod left and right to adjust the position
of pulling rod and nut until the steering angle of the rod shows 0°on the display in operator’s
cab (target value is 0°, permissible error ±0.3°). Lock the adjusting nut I and adjusting nut II,
and seal them with thread sealing compound.
③ No motion in rear axle
No motion in steering proportional valve
Turn “steering mode selector switch” to gear 3, after 3 seconds, the current mode is changed to
crab walk. At this time, if rotate the steering wheel, all axles will turn towards the same direction,
and the angle value of each axle shown in Fig. 2-31 should be the same. If not, please remove
trouble as following:
Solution: First, check solenoid valve for incorrect connection, loose or unconnected plug. If
there are no previous problems, check the output voltage of each solenoid valve corresponding to
the previous modes with AVO meter, to see if it complies with the value output from each
terminal of P2 solenoid valves. If not, check the harness for short circuit or broken circuit.
44
Rear axle independent

steering lever
Steering mode
selector switch
Fig. 2-35 Steering mode selector switch
Multi-axle electric controlled steering
当前模式小转弯目标模式小转弯
系统状态系统故障
行驶参数
时速转速
前桥后桥
1 2 3 4 5 6
Fig. 2-36 Multi-axle electric controlled steering

10) Please refer to “Fault information code table” in engine and transmission operation manuals
for standard fault information.
45
Chapter 3 Coolant and Oil
46
3.1 Hydraulic oil

1. Filtration and replacement schedule
3 months Every 6 months Afterwards filter or replace the oil every 6

months. Hydraulic oil should not be used
beyond 24 months, even if has been filtered.
Delivery date Filter or replace
a. Whenever oil becomes excessively contaminated, filter or replace it even before the
scheduled filtration or replacement time. Hydraulic oil is replaced according to
JB/T9737.3.
b. Use suitable oil depending on the ambient temperature.
2. Hydraulic oil temperature
The oil temperature should always be below 80°C.
During operation,
hydraulic oil level
cannot be below the
red line.
Fig. 3-1 Liquidometer

3. Quantity of hydraulic oil
See Table 3-2 for the filling amount and brand of hydraulic oil (excluding the oil in pipelines
and oil cylinders).
Checking hydraulic oil level: Check the oil level with the crane put in the traveling
configuration; the liquidometer not only can show the oil level, but also the hydraulic oil
temperature; when checking the oil level, make sure that the oil level is above the middle mark
47
of the liquidometer. If the oil level is lower than the middle mark, add hydraulic oil.
Draining method: clear out the dust and sundries on the oil cylinder, and then remove the oil
filler cap at the top of oil cylinder. Use pumping unit to draw the hydraulic oil from the oil
cylinder into the specified container, and drain the hydraulic oil that cannot be drawn by
pumping unit through the oil-drain at the bottom of hydraulic oil cylinder.
Filling method: clear out the dust and sundries on the oil cylinder, remove the oil filler cap at the
top of oil cylinder, and then add hydraulic oil.
Oil filler
Oil drain
Fig. 3-2 Hydraulic oil cylinder
When adding hydraulic oil, cleanness should be ensured. Dust and sundries are
forbidden to be brought into oil cylinder. Otherwise, oil pump and valves may be damaged.
3.2 Gear oil

1. Replacement schedule
3 months 12 months Afterwards replace the oil every 12

months.
Delivery date Replace the oil
a. Whenever oil becomes excessively contaminated, replace it even before the scheduled
time of replacement.
b. Frequently check the oil pressure, and refill if the level is lower than the specified level.
48
2. Winch system
See Table 3-2 for the filling amount and brand of oil.
Filling method: reveal drum bottom, and then remove the plug and refill enough oil.
3. Slewing system
Filling method: remove the plug and refill enough oil according to the slewing system
indicator plate.
4. Main reducer for drive axle
Draining method: remove the oil drain plug at the bottom of main reducer body, and then drain
the oil into the specified container. After that, clean the oil drain plug and oil drain, and reset the
oil drain plug according to the specified force moment.
Filling method: clear out the dust on the main reducer for drive axle. Remove the oil filler
plug, and add oil until the oil level is the same with the level of oil filler lower edge. After that,
clean the oil filler plug and oil filler, and reset the oil filler plug according to the specified force
moment.
Oil drain
Oil filler
Fig. 3-3 Oil drain at the bottom of main reducer Fig. 3-4 Oil filler at main reducer
body body
5. Rim reducer for drive axle

Draining method: turn the wheels to make oil drain plug on rim reducer body at the lowest
part, then clear out dust and sundries near oil drain. Remove oil drain plug to drain the oil into
the specified container, and then clear out the oil drain plug and oil drain, and reset oil drain plug
according to the specified force moment.
Filling method: Turn the wheel to make oil drain plug on rim reducer body at the lowest part,
49
then clear out dust and sundries near oil filler, and remove oil filler plug to add oil until the oil
level is the same with the level of oil filler lower edge. After that, clean the oil filler plug and oil
filler, and reset the oil filler plug according to the specified force moment.
Oil filler
Oil drain
Fig. 3-5 Rim reducer

3.3 Engine oil
Oil level check method: after turning the turntable about 45°clockwise or anticlockwise, open
the upper cover plate of engine hood, and pull out the engine oil dipstick to check whether the
engine oil level is in accordance with requirements. Refer to Engine Operation and
Maintenance Manual for details.
Engine oil
dipstick
Fig. 3-6 Engine oil dipstick

Draining method: Remove the oil drain plug on the engine oil sump through the oil drain at
the bottom of frame, and drain the oil into the specified container. After that, clean the oil drain
plug and oil drain, and reset the oil drain plug according to the specified force moment.
Filling method: After turning the turntable about 45°clockwise or anticlockwise, open the
upper cover plate of engine hood, and add engine oil from the oil dipstick or the oil filler on
engine cylinder head.
50
3.4 Transmission oil

Replacement interval
100h~500h At least once a year
Oil level check method: after turning turntable 45° anticlockwise, turn the upper part of
transmission in the middle of turntable anticlockwise and pull out the oil dipstick to check
whether the oil level is in accordance with the requirements. Refer to Transmission Operation
and Maintenance Manual for details.
Draining method: Remove the transmission oil drain plug, shown in Fig. 3-8, and drain the oil
into the specified container. After that, clean the oil drain plug and oil drain, and then reset the oil
drain plug according to the specified force moment.
Filling method: After turning turntable 45°anticlockwise, pull out the oil dipstick and add
lubricating oil from the dipstick port.
Oil dipstick Oil drain
Fig. 3-7 Transmission oil dipstick Fig. 3-8 Transmission oil drain
3.5 Engine coolant
See Table 3-2 for the filling amount and brand of coolant.
Check method: open the back engine hood, and the sight hole cap of expansion water tank.
The coolant liquid level should be the same with the level of sight hole lower edge. If the coolant
liquid level is too low, add coolant.
51
Sight hole
Engine hood
Fig. 3-9 Expansion water tank sight hole

Filling method: after slewing turntable about 45°clockwise or anticlockwise, open the back
engine hood, remove filler cap of expansion water tank. Then add specified coolant slowly from
filler until coolant level is the same with the level of sight hole lower edge.
Filler
Engine hood
Fig. 3-10 Filler of expansion water tank
52
3.6 Grease
1. Grease points
Fig. 3-11 Grease points for lifting operation
53
Grease nozzle for

Grease nozzle
the pin shaft of
for the pin shaft
rear axle (O)
of rear axle (O)
a. Grease points for universal joint and the pin shaft of rear axle
Grease nozzle for

Grease nozzle for the two ends of steering
universal joint of cylinder (S)
transmission shaft (P)
b. Grease points for the pin shaft of steering cylinder
Grease nozzle
Grease nozzle for for two ends of
two ends of rear steering
axle suspension kingpin (T)
cylinder (R)
c. Grease points for two ends of suspension cylinder and steering kingpin
Fig. 3-12 Grease points for driving operation
54
Refer to grease points comparison table (Table 3-1)

Table 3-1 Comparison Table for Grease Points
Greasing
No. Greasing Points Grease Methods
interval
Weekly or ZL45-2 Lithium base
Main hook trunnion Grease pump
before use grease
A
Weekly or ZL45-2 Lithium base
Auxiliary hook trunnion Grease pump
before use grease
B Main hook pulley - - Self-lubricating bearing
C Boom head pulley - - Self-lubricating bearing
Molybdenum disulfide
D Boom head slide block Weekly Coat
grease
Sliding surfaces of slide
E block between 2nd, 3rd, 4th Weekly Coat
grease
and 5th boom sections
F Boom tail slide block Weekly Grease pump
grease
G Boom rear pivot Weekly Grease pump
grease
H Jib pulley - - Self-lubricating bearing
No.2 Lithium base
I Jib guide roller Before use Grease pump
grease
Upper and lower pivots of No.2 Lithium base
J Weekly Grease pump
the elevating cylinder grease
ZG-3 Calcium base
K Slewing bearing 100 hours Grease pump
grease
Tooth surface of pinion in No.2 Lithium base
L Weekly Coat
slewing system grease
No.2 Lithium base
Wire rope Weekly Coat
grease
M
Wire rope (for telescoping No.2 Lithium base
Weekly Coat
boom) grease
Bearing seats of the main No.2 Lithium base
N Weekly Grease pump
and auxiliary winches grease
No. 2 Lithium base
O The pin shaft of rear axle Weekly Grease pump
grease
The universal joint of No. 2 Lithium base
P Weekly Grease pump
transmission shaft grease
The pin shaft of steering No. 2 Lithium base
Q Weekly Grease pump
cylinder grease
The pin shaft of rear axle No. 2 Lithium base
R Weekly Grease pump
suspension cylinder grease
No. 2 Lithium base
S Steering main pin Weekly Grease pump
grease
Upper and lower surface of No. 2 Lithium base
T Weekly Coat
outrigger beam grease
55
 Clean the grease cup and the surface to be coated with grease before greasing.
 The sliding surfaces, which are not indicated in the list above, also require periodic
greasing.
 Monthly apply a thin coat of grease to the exposed portion of the elevating cylinder
piston rod with the boom placed on the boom rest.
3.7 Fuel and lubricant brand and filling amount

3.7.1 Fuel and lubricant brand and filling amount (refer to Table 3-2)
Table 3-2
Name Brand Capacity
CH-4 15W-40 (above -10°C)
Engine oil 18 L
CH-4 5W-30 (below -10°C)
0# Light diesel fuel (above 5°C)
Engine fuel -10# Light diesel fuel (-5°C~5°C) 300 L
-35# Light diesel fuel (below -5°C)
Engine coolant Compleat TM premixed coolant 35 L
Transmission lubrication CH-4 15W-40 (ambient temperature above -15°C)
oil CH-4 0W-30 (ambient temperature between -40°C and 0°C) 48 L
Lubrication oil for
GL-5 80W/90 (ambient temperature above -25°C)
drive axle and wheel 58 L/6.8 L
GL-5 75W/90 (ambient temperature below -25°C)
reducer of drive axle
AE46 anti-wear hydraulic oil (ambient temperature above -15℃)
Hydraulic oil tank
HS22 hydraulic oil (ambient temperature ≤ -15℃, in an
(including steering ,
braking, and hydraulic extremely cold area) 1250 L
system) For special applications, add hydraulic oil according to actual
conditions
Main winch reducer and Mobil SHC220 Gear oil in winter 4 L for each
auxiliary winch reducer L-CKD220~320 Gear oil in summer one
l Mobil SHC220 Gear oil in winter
Slewing reducer 4.5 L
L-CKD220~320 Gear oil in summer
Superstructure parts such
as boom, slewing ring
and pulley; carrier parts
such as the pins for rear L-XCCHA2 Lithium base grease 6 kg
axle, steering cylinders
and suspension cylinders,
and steering link.
Note: the filling capacity shown in the table is theoretical value, for actual capacities refer to the
readings at dipstick, inspection apertures and sight glass.
56
3.7.2 Comparison between oil brands abroad and domestic

Table 3-3 Comparison between oil brands abroad and domestic
Boom, slewing
ring, pulley, the
pins for rear axle,
Hydraulic Winch reducer
Category Engine Axle steering cylinders
system Slewing reducer and suspension
cylinders, and
steering link
Anti-friction Heavy load No. 2 Lithium base

Name Engine oil Fuel Gear oil
hydraulic oil industrial gear oil grease
0#, 10#,
-10#,
CNPC, AE46, L-CKD220,
CF -20#, -35# GL-5 No. 2
Sinopec HS22 L-CKD320
Light
diesel fuel
Mobil DTE
Delvac Mobilger630,
MOBIL The same Mobiube HD 11M, 13M, No. 2
super Mobilger632
15M
Rimula X
Tellus 22, 32, Omala220,
SHELL 15W-40 The same Spirax A No.2
46 Omala320
CH-4
Thuban Rando oil HD Meropa220,
CALTEX EDLA500 The same No.2
GL-5EP 32, 46 Meropa320
Hyspin AWS
RX
Multitrax 15, 32, 46; Alpha Max220,
CASTROL 15W/40, The same No.2
85W/140 Hyspin AWH Alpha Max320
RX Super
15, 32, 46
Transmisssio AZOLLAZS Carter EP220,
TOTAL Rubia XT The same No.2
n TM 80W/90 32, 46 Carter EP320
Bartran HV
Venellus Hypo Gear 22, Energol Energol GR-XF220,
BP The same No.2
c3 Extra EP HLP-HM 32, Energol GR-XF320
46
a. Oil and coolant are important design factor, which will affect the operational and service
life of all parts in the vehicle. Please refill them according to stipulations.
b. More information will be gained by contacting Cummins and ZF Transmission Service
centers.
57
3.8 Disposal of oil and antifreeze fluid

Various lubricants, greases, fuels and antifreeze fluids used in cranes will cause direct or
indirect pollution to environment. Antifreeze fluid and hydraulic oil are toxic. If they can’t be
used, dispose them according to the laws in the place where you are working. Recover used
antifreeze fluid and hydraulic oil with permissible disposal equipment (including disposal
equipment in service station and those supplied by automobile service station). Any doubt,
contact local environmental protection department for help.
3.9 Fire extinguisher maintenance

There is a fire extinguisher equipped in the cab. Follow the operating instructions on the fire
extinguisher.
Have the fire extinguisher serviced by trained personnel before the service interval indicated on
the label expires.
Caution:
The fire extinguisher is no longer guaranteed to function properly after the service interval on the
label has expired.
58
Chapter 4 System Principle Scheme
59
4.1 Electric principle scheme

4.1.1 Electric principle scheme for driving operation (Equipped with Cummins engine and
IFLEX E5 LMI)
Fig. 4-1 Electric principle scheme for driving operation (Page 1/9)
60
61
62
63
64
65
66
67
68
4.1.2 Electric principle scheme for lifting operation

1. Electric principle scheme for lifting operation (Equipped with Cummins engine and
IFLEX E5 LMI)
Fig. 4-2 Electric principle scheme for lifting operation (Page 1/9)
69
70
71
72
73
74
75
76
77
4.2 Hydraulic principle scheme

4.1.1 Hydraulic principle scheme for driving operation
78
4.1.2 Hydraulic principle scheme for lifting operation
79
Chapter 5 Common Trouble and

Troubleshooting
80
5.1 Common trouble and troubleshooting

Section Trouble Cause Remedy
Visually check whether there is
air in fuel pipeline. If
Air in suction pipeline. necessary, tighten and replace
fuel pipe connector, fuel pipe
and fuel filter.
Engine can’t be Check generator or replace
Too low battery voltage.
battery.
started
Too low oil level in oil tank. Check oil level and add oil.
Replace fuse and check the
Power is off, fuse broken.
line.
Contact Cummins service
Engine inner fault.
station for repair.
Vehicle cannot be started after releasing
Check the line
Vehicle cannot be hand brake
started Signal cables between engine and
Check the line
Drive Line transmission are not connected well.
Radiating system pipeline clogged. Check and clean pipeline.
Check oil level, and refill or
Incorrect oil level.
Excessive oil drain oil.
Deteriorated oil. Replace with new oil.
temperature in Fan of transmission oil cooler
Check and repair.
transmission inoperative
Add lubricant according to
Unqualified lubricant.
stipulation .
Check each plug-in for loose;
if the plug-ins are not loose,
Speed-jump, disorder Signal transmission faulty.
contact professional service
station for repair.
speed
Contact ZF transmission
Transmission inner fault.
service station for repair.
Large vehicle Loose connection of propeller shaft. Check and tighten.
vibration Rubber support of engine damaged. Check and replace.
Other troubles Refer to Engine Operation and Maintenance Manual for details.
Lubricant level too low. Refill enough lubricant.
Contact professional service
Abnormal noise in Improper clearance of gear in drive axle.
station for repair.
drive line
Parts in axles worn or damaged.
station for repair.
Axle and
Oil seal worn, loose or damaged. Replace oil seal.
Suspension
Tighten the plug or replace
Drain plug loose or lining damaged.
Lubricant leakage lining.
Breather clogged or damaged. Clean or replace the breather.
Axle case deformed due to overload. Rectify or replace axle case.
Insufficient brake Insufficient pressure or air for braking. Check pneumatic circuit and
81
force all air valves.

Brake disc and brake caliper faulty.
station for repair.
Improper clearance between brake disc
Check and adjust.
and brake caliper
Too long brake time or frequent brake Stop engine for radiating
High brake
Adjust the brake clearance
temperature Insufficient brake clearance
according to stipulation.
Steering on one side Repair the steering gear by
Leakage in one side of steering gear.
is heavy expert.
Friction caused by deformed steering
drive shaft or misalignment between
Rectify or replace.
steering drive shaft and connected
spline.
Improper pressure in steering hydraulic
Adjust the pressure.
It is heavy to steer system.
Leakage in steering gear too large. Repair the steering gear.
Insufficient oil pressure or flow in oil
Repair or replace oil pump.
pump.
Boost cylinder inner leakage or
Repair or replace cylinder.
damaged.
Engine works Priority valve stuck Replace or repair priority valve
normally, but steering Switching valve stuck Replace switching valve
movements doesn’t Adjusting pressure of X port of prefill Adjust the spring pressure of X
come valve too large port of prefill valve
Steering Loose matching of the steering wheel
Tighten loose parts.
and steering shaft.
System Large free stroke of Loose bolt for fixing steering gear and
Tighten loose parts.
steering wheel its support.
Adjust or repair the steering
Improper adjustment of steering gear.
gear.
Hydraulic steering gear damaged Repair steering gear
Oil level in oil tank is too low. Refill according to stipulation.
Noise in steering gear Find out how the air enters,
Air entering into oil circuit.
or oil pump during repair and release air.
steering Remove deposit and clean
Oil tank screen or pipeline blocked.
pipeline.
Oil pump worn or damaged. Replace oil pump.
Avoid driving at high speed for
Overheating of Excessive oil flow in pump.
a long time.
steering gear (65°C
Oil flow impeded due to folded oil hose Arrange hoses reasonably or
more than
or internal blockage. replace oil hose.
atmospheric
The time for steering to limit position is Avoid the time to be more than
temperature)
too long. 5 seconds.
See Maintenance of carrier electric
Rear axle steering
system: Rear axle steering system
faulty
(electric) fault and troubleshooting
1. Check whether oil return
During normal
There is pressure oil in the brake pipeline is clogged or not.
traveling, brake disc
Brake cylinders for each axle. 2. Check oil inlet pipeline for
overheating
leakage.
System Check the pressure of
Parking brake cannot Insufficient pressure of pressure oil in
accumulator in oil return
be released parking brake
circuit of parking brake.
82
Adjust the brake clearance of

Bad parking brake Insufficient tightness of parking brake
parking brake according to the
performance disc
stipulation.
Check relief valve for normal
Relief valve faulty.
operation.
The pressure of sequence valve doesn’t Adjust the pressure of
Outriggers will not
reach designed value. sequence valve.
extend/ retract or
Solenoid valve faulty. Check.
movement is sluggish
Oil cylinder piston sealing damaged. Replace sealing.
Pilot operated check valve of jack
Repair or replace.
cylinder doesn’t work normally.
Relief valve pressure setting too low. Readjust.
Pressure too low
Serious leakage in oil pump. Replace oil pump.
Jack retract or extend
Internal leakage in cylinder. Replace sealing or cylinder.
automatically
1. Insufficient oil. Add oil.
2. Air entering through suction line. Repair and bleed air.
3. Mounting bolt loose. Tighten.
Noise in hydraulic
4. Contaminated hydraulic oil. Replace or filter.
Hydraulic pump
5. Propeller shaft vibration. Repair.
system
6. Universal joint worn. Replace.
7. Hydraulic pump faulty. Repair or replace.
1. Internal leakage in main pump. Check and repair.
2. Relief valve in multi-way valve
Check and repair.
faulty.
Overheat hydraulic
3. Counterbalance valve opening
oil, low speed of Check and repair.
pressure too high.
functional parts.
4. Leakage in winch motor. Check and repair.
5. Relief valve pressure setting in main
Check and repair.
pump too low.
1. Designed pressure in relief valve too
Low system pressure Readjust the pressure.
low
and designed value
2. Oil pump leakage too large Change oil pump.
1. Relief valve pressure setting faulty in
Adjust.
Outriggers carrier multi-way valve.
inoperative. 2. Dirt blocks up relief valve element. Disassembly and clean.
3. Control valve faulty. Repair.
Movement is 1. Inner of control valve faulty. Repair.

Outrigger
sluggish. 2. Relief valve pressure setting too low. Adjust.
System
Clean or replace double-way
1. Double-way hydraulic valve faulty.
Jack automatically hydraulic valve.
retracts or extends 2. Internal leakage in cylinder. Replace sealing or cylinder.
during operation or
3. External leakage in cylinder. Repair.
road travel.
4. Pilot operated check valve of jack Repair or replace check valve.
83
cylinder doesn’t work normally.
1. Brake lining worn or oil on brake

Repair or replace.
Slewing brake lining.
ineffective. 2. Air entered brake oil circuit. Bleed air.
3. Brake cylinder faulty. Repair.
1. Relief valve in main valve pressure
Repair and adjust.
setting too low or stuck.
2. Main valve inoperative. Repair.
3. Motor faulty. Repair or replace.
Boom will not slew.
4. Slewing reducer faulty. Repair or replace.
5. Pilot valve faulty. Repair.
6. Relief valve in pilot oil circuit faulty. Repair.
7. Pilot oil circuit blocked. Repair and adjust.
1. No pressure in hydraulic system or
pressure too low: If the outriggers work
normally, such a condition is not related
to hydraulic pump and the relief valve in
chassis multi-way valve. It needs to
check whether the control lever for
Slewing outrigger valve in chassis multi-way
valve is in neutral position and it needs Repair or replace.
System
to check the central rotary joint, relief
valve in superstructure multi-way valve
Sluggish slewing and the slewing valve. However, if the
outriggers work abnormally, check
whether the pressure of hydraulic pump
and relief valve in chassis multi-way
valve accords with the stipulated value.
2. Hydraulic motor leakage. Repair or replace.
3. Insufficient pressure in control circuit
Check and repair.
or pilot valve faulty.
4. Internal leakage in main valve or
Check and replace sealing.
change faulty.
1. Pilot valve faulty. Check and repair.
Big starting shock
2. Too much air charged in accumulator. Adjust.
Unsteady slewing 1. Slewing brake faulty. Check and repair.
brake 2. Main slewing valve faulty. Check and repair.
Free-sliding of 1. Solenoid valve stuck and change
slewing system faulty or solenoid valve electric circuit Check and repair.
inoperative and faulty.
84
free/lock change Adjust pressure relief valve

2. Brake pressure of inlet circuit too
system inoperative. and relief valve of pilot oil
low.
circuit.
3. Pressure of free-sliding relief valve
Adjust.
too high.
1. Check whether the bolt on valve rod
of swing valve is loose, valve rod Tighten and adjust
Slewing to only one
cannot reach one direction.
direction.
2. Damaged valve plate in one direction
on the slewing motor and high leakage.
1. Relief valve pressure setting too low
Adjust.
in superstructure multi-way valve.
2. Internal leakage in control valve,
Check, repair and adjust.
control pressure too low.
Boom elevation 3. Internal leakage in cylinder. Check and repair.
cylinder will not 4. Master pump pressure too low. Check and repair.
extend. 5. No pressure in pilot oil circuit,
Check, repair and adjust.
solenoid valve faulty.
6. Pilot valve faulty. Check and repair.
7. Unloading solenoid valve faulty. Check and repair.
8. LMI faulty, unloading signal remains. Check and repair.
1. That is same as items 5, 6, 7 and 8 in
Boom elevation cylinder will not Check and repair.
extend.
2. Counterbalance valve faulty. Check and repair.
Elevating 3. Back pressure of main return oil
Check and repair.
System circuit too high.
Boom elevation
cylinder will not 4. Internal leakage in cylinder and over
retract. low pressure cannot open the balance

valve so that oil in the chamber without Check and repair.
rod cannot return to oil tank or the oil
tank will extend outward.
5. Over low pressure adjustment of
secondary relief valve on elevating Adjust
valve in multi-way valve.
1. Seized control piston in elevating
Elevating pressure is balance valve cannot push the slide Repair
normal, but boom valve.
cannot be lowered. 2. Blocked throttle bore on control
Clean
piston of elevation balance valve.
1. Internal leakage in cylinder. Repair or replace.
Cylinder retracts
2. Counterbalance valve faulty. Repair or replace.
during operation.
3. Control system pressure too high. Check and repair.
No pressure or too 1. There’s no pressure or too low Check pump and safe valve in
85
low pressure for pressure in elevating system. multi-way valve (check it at

elevating the same time with telescopic
system).
2. Internal leakage caused by damaged
Check and repair.
elevating valve in multi-way valve.
3. Separated damper of confluent valve
Check and repair
in multi-way valve.
4. Internal leakage in elevating cylinder. Check and repair
5. Faulty confluent valve in multi-way
Check and repair
valve.
1. Vibration in both elevation raising
and lowering. Vibration and noise in
both elevation raising and lowering,
especially in the situation of over high
oil temperature and environmental
temperature. Elevating cylinder is over Check and repair
tight, mainly because the guide sleeve in
the elevating cylinder or nylon
supporting ring on the piston are
Vibration in elevation
influenced by the environmental
temperature and expand.
2. Elevation vibrating during lowering:
over high opening pressure in balance
valve. Over big throttle hole on the
control piston of balance valve. Over Check and repair
high pressure adjustment of secondary
relief valve on elevating valve of
multi-way valve.
1. Too low pressure setting of relief
valve in telescoping control valve in Adjust.
Boom will not superstructure multi-way valve.
extend. 2. It is the same as items 2, 3, 4, 5, 6, 7
and 8 in Boom elevation cylinder will Check, repair and adjust.
not extend.
1. Relief valve in superstructure
multi-way valve pressure setting too Adjust.
low.
Boom will not retract. 2. Counterbalance valve faulty. Check and repair or replace.
3. It is the same as items 2, 4, 5 and 6 in
Boom elevation cylinder will not Check, repair and adjust.
Telescopic
extend.
System
1. Counterbalance valve faulty. Repair.
2. Internal leakage in cylinder. Repair.
Boom retracts during
3. External leakage in cylinder, valve or
operation. Repair.
piping joints.
4. Balance valve opens because of high
Check and repair.
pressure in control system.
1. The guide sleeve in the elevating
cylinder or nylon supporting ring on the
Adjust or replace.
Vibrated boom piston are influenced by the
telescoping environmental temperature and expand.
2. Over tight slide block on boom, bad
Adjust.
lubrication
86
Boom section (s) will 1. Inner damage of telescopic cylinder. Adjust or replace.
extend out 2. Counterbalance valve damaged. Replace.
automatically after
engine shutdown: i.e.
3rd, 4th and 5th boom
sections will extend
out automatically
while 2nd boom
3. Extending/retracting switch-over
section is been Check and repair.
valve faulty.
retracted, or the 2nd
one will extend out
automatically while
the 3rd, 4th and 5th
ones are been
retracted.
No extension and 1. Valve spool is stuck or control circuit
retraction of 3rd, 4th Check and repair.
is broken.
and 5th boom
sections and high 2. Main valve spool is stuck in opening
Check and repair.
pressure. position
No extension and 1. Solenoid valve spool is stuck in

Check and repair.
retraction of 2nd opening position.
boom section and 2. Main valve spool is stuck in the
high pressure: Check and repair.
position where oil cylinder is coupled.
1. Too low pressure setting of relief
Adjust.
valve in superstructure multi-way valve.
2. Hydraulic motor faulty. Check and repair.
3. Internal leakage in main valve. Check and repair.
4. Main pump pressure too low. Check and repair.
Winch will not hoist 5. No pressure in pilot oil circuit. Check and repair.
up loads. 6. Pilot handle faulty. Check and repair.
7. Unloading solenoid valve faulty, in
Check and repair.
unloading state.
8. LMI faulty, unloading signal
Check and repair.
continuous.
Winch
9. Winch brake faulty. Check and repair.
system
1. Counterbalance valve faulty. Check and repair.
2. Control oil circuit of counterbalance
Check and repair.
valve blocked.
3. Winch brake faulty. Check and repair.
Winch will not let out
1. Check change valve.
rope in power
4. No pressure in brake inlet circuit. 2. Check pressure reduction
hoist-down mode.
valve and relief valve
5. No pressure in pilot oil circuit. Check and repair.
6. Pilot valve faulty. Repair or replace.
7. Leakage in winch motor. Repair.
Brake is ineffective. 1. Oil on brake friction disc. Clean.
87
2. Friction disc worn. Adjust or replace.

3. Air entered in brake oil circuit. Bleed the air.
4. Master cylinder faulty. Repair
1. Low volumetric efficiency in pump. Check and repair.
2. Diffluent valve in multi-way valve
Adjust
isn’t closed.
3. Inoperative confluent valve in
Hoist speed not Check and repair
multi-way valve
reaching designed
4. Faulty multi-way valve. Check and repair
requirements with no
load 5. High leakage in main safe valve. Adjust.
6. High leakage in hydraulic motor. Adjust.
7. If the motor is variable hydraulic
motor, check whether the displacement Check.
is in the specified minimum value.
1. Not fully opened brake. Check and repair
2. Faulty multi-way valve. Check and repair
3. Faulty hydraulic motor. Check and repair or replace.
4. Faulty counterbalance valve. Check and repair or replace.
Winch vibrating
5. Over high pressure adjustment of
secondary relief valve on winch valve in Adjust.
multi-way valve.
6. Unsteady winch system. Adjust.
1. High leakage in main safe valve. Adjust.
Rotation speed
3. Low oil displacement in hydraulic
decreasing when Check and repair.
pump.
winch is in operation
4. Faulty multi-way valve. Check and repair or replace.
5. Overload. Adjust.
1. High counter pressure in return
Adjust
Winch automatically circuit.
lowers when load is 2. Inoperative brake. Check and repair.
lifted 3. High leakage in hydraulic motor. Adjust.
4. Faulty counterbalance valve. Check and repair.
1. Damaged hydraulic motor. Check and repair or replace.
2. Damaged speed reducer. Check and repair or replace.
3. Faulty counterbalance valve. Check and repair or replace.
Abnormal noise in
4. High oil viscosity. Replace.
winch operation:
5. Air entering. Adjust.
6. Influence of outside vibration. Adjust.
7. Contaminated oil. Replace.
88
8. Over high pressure adjustment of

Adjust.
secondary relief valve on winch valve.
1. Low volumetric efficiency in pump. Check and repair.
2. Diffluent valve in multi-way valve
Check and repair.
isn’t closed.
3. Inoperative confluent valve in
Hoist speed not Check and repair
multi-way valve
reaching designed
requirements with
5. High leakage in main safe valve. Adjust.
heavy load
7. If the motor is variable hydraulic
motor, check whether the displacement Check.
is in the specified minimum value.
1. Faulty main safe valve. Check and repair.
No winch rotation 2. High leakage in hydraulic motor. Adjust.
because of low 3. Little internal leakage in hydraulic
Adjust.
pressure: pump.
1. Overload. Adjust
2. Inoperative brake, brake friction plate
serious worn, contaminated brake
No winch rotation
friction plate, air in the brake piping, Check and repair.
when pressure is
leakage of brake liquid or defect in
normal
brake piping.
3. Faulty hydraulic motor Check and repair.
4. Faulty speed reducer. Check and repair or replace.
Inching control, 1. Pressure in control oil circuit too low. Adjust.
Functional controllable and 2. Pilot pressure relief valve faulty. Check and repair.
Parts proportional function
3. Main valve faulty. Check and repair.
insensitive.
Work lamps will not 1. Bulb burned out. Replace.
light 2. Fuse blown. Replace.
Boom lamp will not 3. Earthing faulty. Repair.
light. 4. Wire broken. . Repair.
Room lamp will not
Electric light. 5. Switch faulty. Repair or replace.
System 1. Fuse blown. Replace.

2. Switch faulty. Replace.
Wipers inoperative. 3. Motor faulty. Replace.
4. Earthing faulty. Repair.
5. Wire broken. Repair.
89
1. Earthing faulty. Repair

2. Switch inoperative. Replace.
3. Relay faulty. Replace.
Buzzer will not sound
4. Wire broken. Repair
5. Buzzer faulty. Repair or replace.
6. LMI faulty. Contact our service station.
Starter will not be 1. Main fuse blown or loose. Repair or replace.
operated from crane
2. Wire broken, switch faulty. Repair or replace.
operator’s cab
1. Fuse blown. Replace.
2. Relay inoperative. Replace.
LMI faulty 3. Solenoid valve inoperative. Repair or replace.
4. Solenoid valve earthing faulty. Repair.
5. Others. Contact our service station.
2. Cord reel faulty. Repair or replace.
3. Conducting wire broken. Repair.
4. Anti-two block switch faulty. Replace.
Anti-two block
5. Weight rope broken. Replace
inoperative.
6. Solenoid valve faulty. Repair or replace.
7. Solenoid valve earthing faulty. Repair.
8. Anti-two block switch earthing faulty. Repair.
9. LMI faulty. Contact our service station.
Chassis front 1. Bulb damaged. Replace
headlight doesn’t 2. Conducting wire short circuit, switch
Repair or replace
light inoperative
1. F15 fuse blown Replace.
Radio inoperative 2. Transformer burned or broken circuit Repair or replace.
3. Horn burned or broken circuit. Repair or replace.
1. Starting key inoperative. Repair or replace.
Engine cannot start
1. Dome light switch inoperative. Replace.
Dome light doesn’t
light
3. Bulb damaged. Replace.
90
5.2 Hydraulic system and electric cables powered for driving operation
Table 5-1 Table for outrigger hydraulic system movements and electric cable codes
Codes of cables
Outrigger movements Outrigger movements Codes of cables powered
powered
Front right outrigger jack Front right outrigger
-Y261, -Y201a -Y261, -Y203a
extended beam extended
Rear right outrigger jack Rear right outrigger
-Y261, -Y401a -Y261, -Y403a
Front left outrigger jack Front left outrigger
-Y261, -Y207a -Y261, -Y205a
Rear left outrigger jack Rear left outrigger beam
-Y261, -Y201a -Y261, -Y405a
extended extended
Front right outrigger jack Front right outrigger
-Y261, -Y201b -Y261, -Y203b
retracted beam retracted
Rear right outrigger jack Rear right outrigger
-Y261, -Y401b -Y261, -Y403b
Front left outrigger jack Front left outrigger
-Y261, -Y207b -Y261, -Y205b
Rear left outrigger jack Rear left outrigger beam
-Y261, -Y201b -Y261, -Y405b
retracted retracted
Table 5-2 Table for other devices movements and electric cable codes
Device movements Codes of cables powered Device movements Codes of cables powered
Radiating fan -Y270 Accelerator fills liquid -Y261, -Y210
Rear axle spring
Differential lock -Y213, -Y214 -Y211, -Y212
suspension
5.3 Replacing wire ropes

5.3.1 Wire rope replacement standard
Wire ropes are fatigued with use, and to continue to use them without paying attention to
fatigue is very dangerous. Inspect and replace wire rope according to GB/T5972-2009
Cranes-Wire ropes-Care, maintenance, installation, examination and discard, and replace any
wire ropes which fall into one or more of the categories below.
1) Wire ropes of which 10 percent or more of all the wires (excluding filler wires) are broken in
91
one rope lay.

2) Reduction in diameter exceeds 7 % of the nominal diameter.
3) Kinked wire ropes.
4) Excessively deformed (indented strand, protrusion of wires, bird-caging) or corrode wire
ropes.
5) Wire ropes with an abnormal rope end.
5.3.2 Requirements of replacing wire rope
In general, replace wire rope with the same type and size as the original one. If the rope is not
the same type, the rope performance not less than the original one’s should be ensured, and fit
grooves on drum and sheaves.
If the rope is taken by cutting from a longer rope, the rope ends have to be securely seize before
cutting.
5.3.3 Wire rope replacement
Take the replacement of main winch rope as an example.
(1) Set up the crane on firm, level ground.
(2) Fully retract the boom, and then replace wire rope according to the following procedures.
No. Procedure Note Tools

Place the main hook block on the ground. Avoid disorderly rope winding on
the drum.
Disconnect the rope socket from the Keep the parts carefully so as not Wrench
boom head or main hook block. to lose them.
92

Remove the rope from the rope socket. Keep the parts carefully so as not Bar
to lose them. Hammer
Wrench
Let out the rope by turning the winch Pull the rope.
under power.
Remove the rope end from the winch Keep the wedge. Bar
drum. Hammer
Reeve the new rope over all the pulleys. Through the correct route. Wire or vinyl
Bind the rope end with a wire or tape
vinyl tape.
93

Install the rope end to the winch drum. 1. Put the wedge in the correct Hammer
orientation.
2. The rope end must not
protrude from the external
periphery of the drum.
Wind the rope on the drum. 1. Avoid disorderly rope Wire or vinyl
winding on the drum. tape
2. Bind the rope end with a
wire or vinyl tape.
8
Reeve the rope over the pulleys at the Exercise care to route the rope
boom head and the hook block. correctly.
94

Attach the rope socket and rope clamp to Put the wedge in the correct Hammer
the rope. orientation. Wrench
10
Attach the rope socket to the boom head Wrench

or the hook block depending on the
number of parts of line.
11
Raise and extend the boom, then lower Don’t lower the hook block Bar
12 the hook block until no turn of the rope excessively. Otherwise the rope Hammer
remains on the winch drum. may be damaged.
Wind the rope on the drum while hoisting Hammer
Do not exceed the total rated
a weight which applies aprox.30% of the Wrench
13 load. The load limit for winch
“maximum permissible load for winch
rope: 2800kg.
rope” to the rope.
14 Remove the weight from the hook.
95
5.4 Return filter

5.4.1 Notes on operation
a. Stow the boom.
b. Stop the pump.
Replace the filter element at the intervals shown below:
Vehicle Replace Replace

delivery 3 months element Every 6 months element
date
5.4.2 Replacement of return oil filter

Remove the cover. Wrench
Remove the filter assembly. Keep the parts carefully so as not

to lose them.
Remove the snap pin, loosen the nut and Wrench

remove the filter element.
96

Replace the filter element and assemble Tighten the nut gradually. After Wrench
the filter. the sealing surface makes contact
with the element evenly, further
tighten the nut within one turn
and insert the snap pin.
Install the filter assembly.
Install the cover. Wrench
5.5 Line Filters (replacing filter element)

Notes on operation:
a. Stow the boom.
b. Stop the pump.
Replace the filter element at the intervals shown below.
Replace
Vehicle
element
delivery Every 12 months
date
97
5.6 Tire maintenance and replacement

5.6.1 Basic parameters for tire
Tire specification: 33.25R29 Tubeless
Tire max. speed: 35 km/h
Standard inflation pressure: 0.65-0.70Mpa
Rated load-bearing capacity of tire: 46000 kg (0 km/h), 34000kg (3 km/h), 23000 kg (35
km/h)
The inflation pressure means the pressure when the tire is cool, i.e. when the vehicle does not
begin to drive or 3 hours after stopping. If measure the tire pressure when it is hot, the pressure
will be higher 5% or 10% than that measured in cool state.
5.6.2 Visual check for tires
1) The tread depth of tire crown is not less than 5 mm.
2) The tire ply should not be exposed due to the partial wear of tire tread face.
3) There should not be crack and cut and ply exposed depth on tire tread face and side wall.
When mount tires, the following should be done:
1) Type and tire tread of tires on an axle should be the same.
2) Tires renewed should not be used.
5.6.3 Check of tire pressure
Before crane travelling and operation, make an overall check of the tire pressure, if pressure
reduces too quickly, check the reason of air leakage (for instance, check whether tire is punctured,
lacerated and valve mouth leaks).
5.6.4 Control of vehicle speed
There is a limit of tire max. speed, so never drive the vehicle more than the limit. Driving at
over-speed for a long time will result in tire overheating, and thus the tire’s service life will be
shortened. During driving, the driver should pay attention to drive, if there is obstacle in the front
of the vehicle (e.g. pit etc.), please response in advance to avoid knocking it. If it is not possible
to avoid, please decrease the vehicle speed as low as possible.
5.6.5 Storage of tire
Tire should be placed vertically. It should be stored in a shady and dry room, not open-air
depot. Being exposed to the sun for a long time will cause rubber aging before the due date. Tire
is made of rubber, so during driving and stopping the vehicle or storing tire never let it contact
with chemicals such as oil, acid and hydrocarbon, etc.. Otherwise, corrosion, deformation and
softening of tire will occur. During storing, transporting and mounting tire, it must be avoided to
damage the bead toe, otherwise, air tightness will be destroyed and the tire could not be used.
98
5.6.6 Rim inspection

The rim is one of the important parts in vehicle traveling system. When changing the wheels,
the following items should be checked:
1) Rim rustiness;
2) Rim defection and deformation;
3) Rim cracks;
4) Opening of rim flange, mounting hole and rim bolts and nuts.
After checking, repair or replace the parts damaged or deformed at once, if paint stripped,
repaint after rust is removed.
Never weld connections of rim bolt. Never repair deformed rim bolts. Replace old parts
with new ones.
5.6.7 Wheel replacing
1) After 10000 km of traveling, tires should be transposed. Refer to Fig. 5-1.
Forward direction
Fig. 5-1 Tire transposition diagram

2) Do not scratch bolt thread when replace wheels. No painting, grease and other dirty on the
touching face between brake drum and rim.
3) Keep pressing faces of wheel nuts clean.
4) Coat threads of wheel bolts and nuts with a little grease, oil or other anti-engaging agent.
5) Threads of all wheel nuts are right-handed. With tires mounted and wheels suspended, tighten
nuts in the order of diagonal transposition. Lower wheels on the ground, and tighten wheel nuts
with tightening torque of 600~660 N.m.
99
6) After tires are remounted, retighten wheel nuts once every 50km of travelling according to
stipulations.
7) The replacement of tires must be permitted by equipment manufacturer, use the tires
conforming to load bearing capacity, speed and operating conditions.
100
Chapter 6 Appendix
101
6.1 Main parts list

Table 6-1 Main parts list of RT100
No. Code Name Manufacturer Remark
1 125301009 Slewing ring Xuzhou Rothe Erde Slewing Bearing Co., Ltd.
Main winch
800300284 Bosch Rexroth (Beijing) Hydraulic Co., Ltd.
reducer
2
Auxiliary
8000300284 Bosch Rexroth (Beijing) Hydraulic Co., Ltd.
winch reducer
Main winch Equipped
800300103 Tai'an Taishan Fushen Gearbox Co., Ltd.
reducer with
3
Auxiliary Shanghai
800300103 Tai'an Taishan Fushen Gearbox Co., Ltd.
winch reducer engine and
Slewing HC4900
4 125301127 Tai'an Taishan Fushen Gearbox Co., Ltd.
reducer LMI
Slewing
5 125301008 Bosch Rexroth (Beijing) Hydraulic Co., Ltd.
reducer
6 803001806 Slewing motor Bosch Rexroth (Beijing) Hydraulic Co., Ltd.
Motor for
main winch
7 125200007 Bosch Rexroth (Beijing) Hydraulic Co., Ltd.
and auxiliary
winch
8 803006995 Main valve Bucher Hydraulic Co., Ltd.
Wire rope for
main winch
9 125101035 ArcelorMittal
and auxiliary
winch
10 800105028 Engine Cummins (China) Investment Co., Ltd.
11 800306687 Transmission ZF (China) Investment Co., Ltd
125300593
12 Axle KESSLER
125300594
13 819909850 Operator’s cab Hubei Qixing Cabin Manufacturing Co., Ltd.
102
6.2 Wear parts list

Table 6-2 Wear parts list of RT100
No. Code Name Material Qty Assembled Position Remark
Guide pulley on last boom
1 125300276 Pulley MC nylon 9
section head, Fixed pulley
Head of 1st, 2nd and 3rd boom
2 125300455 Slide block MC nylon 84
sections (lower)
Head of 1st and 2nd boom
sections (upper)
The upper cover plate on basic
4 125300451 Sliding plate MC nylon 1
boom body near boom tail
Pressure Latch for basic boom head
5 125300447 MC nylon 2
plate pulley
6 125201055 Block MC nylon 1 Front end of basic boom
7 125201050 Sleeve MC nylon 10 Lower roller on basic boom
On top of basic boom head
plate
9 125201054 Block MC nylon 1 Front end of basic boom
10 125300455 Slide block MC nylon 2 Tail of 2nd boom section
Underside of 2nd, 3rd, 4th, 5th
boom section tail
12 125300182 Sliding plate MC nylon 4 Side of 2nd boom section tail
Top of 2nd boom section head
plate
Pressure Latch for 2nd boom section
14 125300184 MC nylon 2
plate head pulley (lower)
Sliding
15 125300034 MC nylon 2 Tail of third boom section
block
16 125300040 Sliding plate MC nylon 1 Third boom section head plate
Pressure Latch for third boom section
17 125300039 MC nylon 2
plate head lower slide block
Sliding Upper slide block on 3rd boom
18 125300044 MC nylon 2
block section head
Sliding
19 125300180 MC nylon 2 Side of 3rd boom section tail
block
Sliding Upper slide block on 4th boom
20 125300073 MC nylon 2
block section tail
Lower slide block on 4th boom
section head
section head
23 125300079 Slide block MC nylon 1 Lower slide block on 4th boom
103
section head
section head
section head
Pressure Latch for lower slide block on
26 125300088 MC nylon 2
plate 4th boom section head
Upper slide block on 4th boom
27 125300086 Slide b1lock MC nylon 1
section head
28 125300181 Sliding plate MC nylon 2 Side of 4th boom section tail
section head
30 125300091 Sliding plate MC nylon 1 4th boom section head plate
section head
section head
section head
section head
section tail
Side of 5th boom body, near
36 125300225 Guide track MC nylon 2
boom tail
Cable support on 5th boom
section tail
38 125300224 Slide block MC nylon 2 Side of 5th boom section tail
Interior side of 4th boom
39 125300516 Rope guard MC nylon 8
section tail
40 125300495 Slide block MC nylon 1 4th boom section tail
Upper telescoping cylinder head
gripper carrier
Lower telescoping cylinder
42 125300531 Roller MC nylon 2
head gripper carrier
Basic boom body near boom
43 125301401 Roller MC nylon 1
head plate
Adjusting Adjusting position for outrigger
44 144600272 —— 12
bolt beam
Cylinder-sup Supporting position for
45 137100940 Nylon 4
porting roller outrigger beam cylinder
104

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RT100 Rough Terrain Crane

3.9 Fire extinguisher maintenance..….....……………………………………………………58

XUZHOU HEAVY MACHINERY CO., LTD.

Chapter 1 Service and Maintenance Safety

Notes of inspection and maintenance for the crane:

output-end of transmission must be disengaged. Otherwise, the transmission will be

Chapter 2 Service and Maintenance

2.1 Boom and telescoping system

Nuts on thin rope II

Nuts on thin rope I

Fig. 2-1 Telescoping system (boom head)

Fig 2-2 Thin cable on boom head

Adjust the bolt

Fig 2-3 Adjustment of slide block

2.2 Winch system

Wire rope wedge

Fig. 2-4 Diagram for winch reducer

Dispose the used oil in an environmental protection way.

2.3 Slewing ring

Fig. 2-5 Slewing ring structure diagram

2.4 Slewing system

Fig. 2-6 Slewing system structure diagram

2.4.3 Use and maintenance

Dispose the used oil in an environmental protection way.

2.5 Hoisting hydraulic motor

Fig. 2-7 Hydraulic motor diagram

2.5.3 Common troubles and troubleshooting

2.6 Central rotary joint

2.7 Winch balance valve

Fig. 2-8 Winch balance valve diagram

No. Part name No. Part name No. Part name

2.7.3 Disassembly and reassembly

2.8 Elevating balance valve

Fig. 2-9 Elevating balance valve diagram

No. Part name No. Part name No. Part name

2.8.3 Disassembly and Reassembly

2.9 Combined valve for lifting operation

Fig. 2-10 Structure diagram of combined valve for lifting operation

2.9.3 Disassembly and Reassembly

2.10 Telescoping balance valve spool

6-Balance valve spool 7-Balance valve spool outer spring

Fig. 2-11 Telescoping balance valve spool structure diagram

2.11 Telescoping cylinder

pay attention not to break or damage them when assembling.

2.12 Elevating cylinder

2.13 Jack cylinder

2.13.3 Structure of jack cylinder

2.14 Extension cylinder

2.15 Suspension cylinder

2.16 Engine and accessory system

Fig. 2-14 Fuel water filter

filter before replacement.

Fig. 2-15 Air filter cleaning diagram

The oil level in working temperature should be checked weekly.

Fig. 2-18 Main reducer

Fig. 2-19 Rim reducer

2.19 Oil pump

Top dead center

Bottom dead center

Fig. 2-20 Variable pump

2.19.2 Gear pump

Extrude oil Suck oil

Fig. 2-21 Working principle of gear pump

当前模式小转弯目标模式小转弯

29 前轴 A 传感器故障号136 一桥 A 当前角度

当前模式小转弯目标模式小转弯