XCR40 I

XCR40 Rough Terrain Crane
Maintenance and Service Manual
Xuzhou Heavy Machinery Co., Ltd. XCMG

XCR40 Rough Terrain Crane Maintenance and Service Manual
XCR40 Rough Terrain Crane

Maintenance and Service Manual
PIN
Engine number
Date Year Month
The manual is part of the crane! It must be kept with the crane!
Please read the manual carefully before operating the crane.
This equipment is designed and manufactured in accordance with
Q/320301JAF598-2021
This machine has obtained Chinese Special Equipment Production Permit.
Always use replacement parts made for this machine by the original manufacturer.
In order to insure the continued original performance of the crane, only XCMG supplied replacement
parts should be used.
Fire extinguisher and first aid kit which meet the local requirements must be added to the crane
before putting it to work.
Do not operate the equipment until the effectiveness of these devices has been ensured.
ALL RIGHTS RESERVED
No part of this publication may be reproduced or used in any form by any means-graphic, electronic
or mechanical, including photocopying, recording, taping or information storage and retrieval systems
-without the written permission of XCMG.
1
Contents
Preface........................................................................................................................................................ VII
Chapter1 General safe operation ................................................................................................................ 1-1
1-1 General safety precautions ............................................................................................................ 1-1
Chapter 2 Maintenance and service introduction....................................................................................... 2-1
2-1 Systems that need to be maintained and serviced ......................................................................... 2-1
2-2 Maintenance and service items ..................................................................................................... 2-3
2-2-1 Daily maintenance and service items ..................................................................................... 2-5
2-2-2 Regular maintenance and service items ................................................................................. 2-8
2-2-3 Special inspections ............................................................................................................... 2-16
Chapter 3 Maintenance and service ........................................................................................................... 3-1
3-1 Boom and telescoping system....................................................................................................... 3-1
3-1-1 Part function ........................................................................................................................... 3-1
3-1-2 Working principle and structure ............................................................................................. 3-1
3-1-3 Use and maintenance ............................................................................................................. 3-2
3-2 Winch system ................................................................................................................................ 3-5
3-2-1 Part function ........................................................................................................................... 3-5

3-3 Slewing ring .................................................................................................................................. 3-6
3-3-1 Part function ........................................................................................................................... 3-6
3-3-3 Axial clearance and radial clearance of slewing ring ............................................................. 3-7
3-4 Slewing system ............................................................................................................................. 3-8
3-4-1 Part function ........................................................................................................................... 3-8
3-5 Winch hydraulic motor ............................................................................................................... 3-10
3-5-1 Part function ......................................................................................................................... 3-10
3-5-2 Working principle and structure ........................................................................................... 3-10
Contents I
2-5-3 Common troubles and troubleshooting ................................................................................ 3-10
3-6 Central rotary joint ...................................................................................................................... 3-11
3-6-1 Part function ......................................................................................................................... 3-11
3-6-3 Disassembly and reassembly ............................................................................................... 3-11
3-7 Winch balance valve ................................................................................................................... 3-14
3-7-1 Part function ......................................................................................................................... 3-14
3-7-3 Disassembly and assembly................................................................................................... 3-15
3-8 Slewing buffer valve ................................................................................................................... 3-15
3-8-1 Part function ......................................................................................................................... 3-15
3-9 Elevating balance valve .............................................................................................................. 3-17
3-9-1 Part function ......................................................................................................................... 3-17
3-9-3 Disassembly and assembly................................................................................................... 3-18
3-10 Combined valve for lifting operation........................................................................................ 3-19
3-10-1 Part function ....................................................................................................................... 3-19
3-10-2 Working principle and structure ......................................................................................... 3-19
3-10-3 Disassembly and assembly................................................................................................. 3-20
3-11 Telescoping balance valve spool ............................................................................................... 3-20
3-11-1 Part function ....................................................................................................................... 3-20
3-11-3 Disassembly and reassembly.............................................................................................. 3-21
3-13 Telescoping cylinder ................................................................................................................. 3-22
3-13-1 Part function ....................................................................................................................... 3-22
3-13-2 Structure of telescoping cylinder ....................................................................................... 3-22
3-14 Elevating cylinder .................................................................................................................... 3-23
3-14-1 Part function ....................................................................................................................... 3-23
II Contents
3-15 Jack cylinder ............................................................................................................................ 3-24
3-15-1 Part function ....................................................................................................................... 3-24
3-15-2 Working principle............................................................................................................... 3-24
3-15-3 Jack cylinder ...................................................................................................................... 3-25
3-16 Extension cylinder .................................................................................................................... 3-26
3-16-1 Part function ....................................................................................................................... 3-26
3-16-2 Working principle............................................................................................................... 3-26
3-16-3 Extension cylinder structure............................................................................................... 3-26
3-17 Suspension cylinder .................................................................................................................. 3-27
3-17-1 Part function ....................................................................................................................... 3-27
3-18 Engine and accessory system.................................................................................................... 3-28
3-18-1 Engine ................................................................................................................................ 3-28
3-18-2 Fuel pipeline maintenance ................................................................................................. 3-28
3-18-3 Radiator maintenance ......................................................................................................... 3-30
3-18-4 Air filter .............................................................................................................................. 3-30
3-18-5 Coupler ............................................................................................................................... 3-32
3-19 Transmission ............................................................................................................................. 3-34
3-20 Axle ........................................................................................................................................... 3-35
3-20-1 Part function ....................................................................................................................... 3-35
3-20-2 Structure ............................................................................................................................. 3-35
3-20-3 Maintenance ....................................................................................................................... 3-36
3-21 Pumps........................................................................................................................................ 3-37
3-21-1 Variable pump ................................................................................................................... 3-37
3-21-1-1 Part function.................................................................................................................... 3-37
3-21-1-2 Working principle and structure ..................................................................................... 3-37
2-21-1-3 Disassembly and reassembly .......................................................................................... 3-38
3-21-2 Gear pump .......................................................................................................................... 3-39
3-21-2-1 Part function.................................................................................................................... 3-39
Contents III
3-21-2-2 Working principle and structure...................................................................................... 3-39
2-21-2-3 Disassembly and reassembly .......................................................................................... 3-39
3-22 Outrigger ................................................................................................................................... 3-41
3-22-1 Part function ....................................................................................................................... 3-41
3-22-3 Disassembly and reassembly ............................................................................................. 3-41
3-23 Electric system maintenance..................................................................................................... 3-43
3-23-1 Maintenance of electric system for lifting operation ......................................................... 3-43
3-23-2 Maintenance of electric system for driving operations ...................................................... 3-48
Chapter 4 Oil .............................................................................................................................................. 4-1
4-1 Hydraulic oil ................................................................................................................................. 4-1
4-2 Gear oil ......................................................................................................................................... 4-3
4-3 Engine oil ...................................................................................................................................... 4-6
4-4 Transmission oil ............................................................................................................................ 4-7
4-5 Engine coolant .............................................................................................................................. 4-9
4-6 Grease ......................................................................................................................................... 4-11
4-7 Brand and capacity of fuel and lubricant, etc. ............................................................................ 4-14
4-8 Disposal of oil and antifreeze fluid ............................................................................................. 4-16
Chapter 5 System principle schematics ..................................................................................................... 5-1
5-1 Electric principle schematic of XCR40 ....................................................................................... 5-1
5-1-1 Electric principle schematics for lifting operations .............................................................. 5-1
5-1-2 Electric principle schematics for driving operation ............................................................ 5-23
5-2 Hydraulic principle schematics.................................................................................................. 5-34
Chapter 6 Troubleshooting......................................................................................................................... 6-1
6-1 Common troubles and troubleshooting ........................................................................................ 6-1
6-2 Replacing wire ropes .................................................................................................................. 6-11
6-2-1 Wire rope replacement standard ........................................................................................... 6-11
6-2-2 Requirements of replacing wire rope ................................................................................... 6-11
6-2-3 Wire rope replacement ......................................................................................................... 6-12
6-3 Return filter ................................................................................................................................. 6-16
6-3-1 Notes on operation ............................................................................................................... 6-16
6-3-2 Replacement method ............................................................................................................ 6-16
IV Contents
6-4 Line filters (replacing filter element) .......................................................................................... 6-18
6-5 Tire maintenance and replacement ............................................................................................. 6-18
6-5-1 Basic parameters for tire ...................................................................................................... 6-18
6-5-2 Visual check for tires............................................................................................................ 6-19
6-5-3 Tire pressure check............................................................................................................... 6-19
6-5-4 Control of vehicle speed ...................................................................................................... 6-19
6-5-5 Storage of tires ..................................................................................................................... 6-20
6-5-6 Rim inspection ..................................................................................................................... 6-20
6-5-7 Tire rotation .......................................................................................................................... 6-21
Chapter 7 Inspection of steel structures ..................................................................................................... 7-1
Chapter 8 Appendix ................................................................................................................................... 8-1
8-1 Main parts ..................................................................................................................................... 8-1
8-2 Tightening torque of main bolts and nuts ..................................................................................... 8-2
8-3 Maintenance and check record form............................................................................................. 8-2
Contents V
Blank page
VI
Preface
This manual applies to XCR40 Rough Terrain Cranes.
This manual describes service and maintenance procedures for the XCR40 Rough Terrain Crane
(hereafter called crane) aiming at understanding the each main part's performance and working principles.
The goal is to help the owner better service and perform maintenance on the crane, maximize the crane's
performance, maintain the crane's working efficiency, ensure safety, and prolong its normal service life.
This manual describes the structure of the main parts and diagrams of the crane. Refer to the parts
catalog for the numbers of parts that need replacement.
The maintenance manual and other technical documents are integral parts of the crane. Carefully
preserve this manual and other technical documents. Some parts of the crane require qualified personnel
to perform maintenance on them, and qualified personnel must provide signatures in the manual.
Never perform maintenance on parts without involving qualified personnel. The manufacturer bears no
responsibility if the user does not comply with the maintenance manual.
Disclaimer
All information, illustrations and specifications in this manual are based on the latest information
available at the time of publishing. The illustrations used in this manual are intended as representative
reference views only. Products are under a continuous improvement policy. Thus, information,
illustrations and/or specifications to explain and/or exemplify a product, service or maintenance
improvement may be changed at any time without notice.
This manual contains all configurations and functions of the crane, but some configurations or
functions described in this manual may not be available on your crane or they are only provided for
certain markets.
Preface VII
Symbols and their meanings are as follows:
This safety alert symbol means ATTENTION! Become alert-your safety is involved!
Obey all safety messages that follow this symbol to avoid possible death or injury.
——Identifies hazards that will result in death or serious injury if the message is
ignored.
——Identifies hazards that may result in death or serious injury if the message is
ignored.
——Identifies hazards that could result in death or serious injury if the message is
ignored.
——Without the safety alert symbol, identifies hazards that could result in property
damage if the message is ignored.
or ——It means the operation does not comply with operating practices, which is
prohibited or is likely to cause casualty accident.
—— "Notice" is used to supply indication or additional explanation for
individual items.
VIII Preface
Chapter1 General safe operation Chapter 1
1-1 General safety precautions
Pre-service hazards:
Only trained person may operate and maintain the crane.
Before starting, operating, and maintaining this machine, be sure to read and understand the
content and safety messages in this manual. The operator is responsible for safe operation and
maintenance of the machine.
Be sure all potential users of the machine also understand these instructions. Only operate the
machine according to instructions in this operator's manual and this manual. If any portion of this
manual is not understood, contact your dealer for assistance before operating the machine.
Safety labels are additional reminders for safe operation and maintenance of the machine. All
safety labels must be legible to alert personnel of safety hazards. Replace any illegible or missing
labels immediately.
Inspect the machine's safety devices before operating the machine. Do not operate the machine
if a safety device is damaged or not operating properly.
Make sure you are aware of licenses, laws, and regulations that may be required or in effect
where the machine is operated.
General safe operation 1-1

Chapter 1
Fire and explosion hazard:

Diesel fuel is extremely flammable and explosive under certain conditions.
When you remove any fuel system component to perform maintenance (such as changing the
fuel filter), place an approved container under the opening to catch the fuel.
Never use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive.
Wipe up any spills immediately.
Wear eye protection. The fuel system is under pressure and fuel could spray out when you
remove any fuel system component.
Only use the key switch to start the engine.
Never crank the engine by jumping the terminals on the starter solenoid.
Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.
Never use diesel fuel as a cleaning agent.
Never remove the fuel cap with the engine running.
Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire
and will damage the engine.
Never refuel with the engine running.
Keep sparks, open flames or any other form of ignition (match, cigarette, static electric source)
well away when refueling.
Never overfill the fuel tank.
Store any containers containing fuel in a ventilated area, away from any combustibles or
sources of ignition.
Piercing Hazards:
Never allow skin contact with high-pressure hydraulic fluid caused by a broken hydraulic hose.
High-pressure hydraulic fluid can penetrate your skin and result in serious injury. If you are exposed
to high-pressure hydraulic fluid spray, obtain medical treatment.
Never check for a hydraulic fluid leak with your hands. Always use a piece of wood or
cardboard. Have your authorized dealer or distributor repair the damage.
1-2 General safe operation

Chapter 1
Modification Hazard:
Never modify controls and components of this machine. Any modification can affect the
safe operation of the machine. The controls of this machine have been correctly set at the factory.
Modification to the machine may affect warranty coverage.
Exposure Hazards:
Always wear personal protective equipment, including appropriate clothing, gloves, work
shoes, and eye and hearing protection while operating the machine.
Never wear jewelry, unbuttoned cuffs, ties, or loose-fitting clothing while working near moving
or rotating parts. Always tie back long hair.
Never operate the machine while wearing a headset to listen to music or radio as it will be
difficult to hear alert signals.
Asphyxiation hazard:
All internal combustion engines create carbon monoxide, a colorless, odorless, poisonous gas,
during operation.
Special precautions are required to avoid carbon monoxide poisoning:
Never block windows, vents, or other means of ventilation if the machine is operating in an
enclosed area.
Always ensure that all exhaust systems are in good operating conditions before starting the
machine.

Chapter 1
Entanglement/Sever hazards:
Ensure all guards and covers are attached properly to the machine before starting the engine.
Verify there are no people, obstacles, or other equipment near the machine before starting the
engine.
Never leave the key in the ignition switch and follow guidelines for lock-out-tag-out
procedures when servicing the machine. Someone may accidentally start the engine.
Drugs/Alcohol Hazard:
Never operate the machine while under the influence of drugs or alcohol or when ill. Workers
under the influence of narcotics and/or intoxicants are a hazard to both themselves and others
around them.
Burn Hazard:
Keep hands and other body parts away from hot surfaces. Wear heat-resistant gloves if working
around hot surfaces.
Scald hazard:
Never remove the radiator cap if the engine is hot. Steam and hot engine coolant will spurt out
and seriously burn you.
Allow the engine to cool down before you attempt to remove the radiator cap.

Chapter 1
Fall hazard:
Always maintain a three-point contact when entering or leaving the cab of the machine. Never
jump off the machine to the ground.
Do not climb on the outriggers, boom, or other machine surfaces.
Never carry riders on the machine.
Crush Hazards:
Always keep bystanders away from the work area while deploying or adjusting the outriggers
and while the machine is operating.
Always keep body parts clear of the machine's components while operating.
Never operate or move the machine unless you have a clear view of the job site. Have a partner
on the ground guide you if necessary.
Always lower the load fully to the ground before you leave the operator's position.
Never allow anyone to walk or stand under a load that is suspended.

Chapter 1
Battery Hazard:
Always read and comply with the battery manufacturer's recommendations for procedures
concerning proper battery use and maintenance.
Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen
gases. Keep any device that may cause sparks or flames away from the battery in order to prevent
explosion.
Always wear protective glasses or goggles and protective clothing when working with
batteries.
You must follow the battery manufacturer's instructions on safety maintenance and installation
procedures.
Coolant hazard:
Wear eye protection and rubber gloves when handling engine coolant. If contact with eyes or
skin should occur, flush eyes and wash skin immediately with clean water.
Tool hazard:
Ensure that all tools and other objects are removed from the machine before starting the
engine.

Chapter 1
Follow the guidelines of the EPA or other governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel fuel, and engine coolant. Consult the local authorities
or reclamation facility.
Clean all accumulated dirt and debris away from the machine before inspecting the machine
or performing preventative maintenance/repairs. Operating a machine with accumulated dirt and
debris will cause premature wear of machine components. Accumulated dirt and debris also hinders
machine inspection.
Only use replacement parts specified by the manufacturer. Other replacement parts may affect
the operation of the machine and warranty coverage.

Notes for the crane:

Chapter 1
1. Stop operation of the crane during maintenance, whether or not the crane has a load. Never repair
the crane during crane operation.
2. Improper maintenance or carelessness will cause injury or death to people and damage to the
crane.
3. Comply with laws, regulations, and your company's practices regarding road travel and crane
operation.
4. Before maintenance, if the outrigger needs to extend, clear the area of obstacles. Never maintain
the outrigger hydraulic system after extending the outrigger.
5. Before maintenance, confirm that the machine has been set up properly and provide a written
a warning message on the door of the operator's cab that states: “Crane undergoing maintenance, no
operation allowed”.
6. Before beginning maintenance, understand the crane's condition and failures to avoid danger.
7. When testing the vehicle during maintenance, keep people away from the area outside of the
driver's cab.
8. When testing the vehicle during maintenance, observe the conditions of the instruments and the
warning lamps in the operator's cab. If any abnormality occurs, park the vehicle in a safe place promptly.
9. Perform vehicle testing during maintenance on level ground. If vehicle maintenance must be
performed on a slope, apply a wheel chock under wheels.
10. Prior to maintaining the engine and other movable parts, disconnect the battery (the negative
cable first), and discharge all condensers in order to prevent accidental engine start-up.
11. Before welding the oil can and oil tank, clean them with water or cleaning agent, and uncover the
sealed cap. Otherwise, accidents will occur.
12. Perform maintenance on the fuel system and air conditioner system in a ventilated environment
to avoid the dangers of gases vapors or frostbite.
13. When the vehicle has to be towed, disengage and secure the driveshafts at the front and rear
axles. Otherwise, the transmission will be damaged.
14. Prior to welding, remove flammable and explosive materials from the area. Keep fire fighting
devices close by and in good condition.
15. Prior to disassembling pipelines, connectors or related parts, release the pressure in them to
prevent bodily injury. Never use hands to check for pressure leaks.
16. To avoid scalds, guard against scorching parts and pipelines as well as liquid and gas in pipelines

and cavities.
Chapter 1
17. Hydraulic oil is toxic and flammable. Keep it out of the reach of children in order to prevent
accidental swallowing.
18. Avoid breathing in evaporative emission or having contact with used oil for long periods of time.
Clean skin with soap and water as soon as possible after touching oil. If oil comes into contact with eyes,
immediately flush eyes with water for at least 15 minutes before seeing a doctor.
19. Failing to perform maintenance according to the instructions in this manual will result in
damage to the crane and will increase the risk of vehicle accidents.
20. Never allow welding operation while the vehicle has electricity. Before welding, remove the
positive cable (+) and negative cable (－) from the battery. The distance between the part to be welded
and the grounding cable connection should not be more than 500 mm.
21. Damage to the crane's boom or jib will cause serious accidents. Chord damage, bent or lost
pin shafts, or cracked welding seams will weaken the lattice jib and boom. Examine the boom daily for
damage. Never use a broken boom or jib.
As the boom is made of high-tensile steel, special maintenance methods are required.
22. Never repair or adjust the crane with a load hanging on the hook block or with the boom
extended. Otherwise accident will occur due to the movement of the load or the boom.
23. Lower the load to the ground and rest the boom to a proper support.
24. The hydraulic system will maintain pressurized for a long period of time. Release the pressure
before adjustments or maintenance. Otherwise, the pressure will cause dangerous movements of the crane
or will result in the high-speed spray of hot oil.

Chapter 1
1-10
Chapter 2 Maintenance and service introduction
Before performing any service, review General Safe Operation on page 1-1.
2-1 Systems that need to be maintained and serviced Chapter 2
See Figure 2-1 for the systems that should be maintained and serviced.
● Proper daily maintenance and regular inspection are helpful to ensure operation safety and
to maintain good equipment status, as well as to find faults in early stage and prevent accident from
occurring.
● Remove any trouble at once if it is found.
Maintenance and service introduction 2-1

Chapter 2
2-2
Maintenance and service instructions
Figure 2-1
No. Name No. Name
1 Safety device 2 Boom
3 Power system 4 Elevating cylinder
5 Driver's cab 6 Slewing system
7 Turntable 8 Winch system
9 Counterweight and its erecting system 10 Rear outrigger beam
11 Hydraulic system 12 Transmission system
13 Travel system 14 Steering system
15 Braking system 16 Front outrigger beam

17 Air conditioning device 18 Electrical system
19 Hook
2-2 Maintenance and service items
The crane has been tested and commissioned at the factory, but some deviation will occur during
operation due to wear, corrosion and environmental change, as well as damage due to external forces
and service condition changes. After delivery, the crane must be checked every year by an experienced
Chapter 2
professional technician. If the crane is sold to the country or region abroad, local related standard should
be observed.
An experienced professional technician is a person who is trained on the machines to be serviced and
has experience with the maintenance of cranes and is familiar with their unique standards and regulations.
A professional engineer means the one who engages in crane design, has abundant experience in
manufacturing and maintaining cranes, is familiar with related standards and regulations and able to
identify if the crane is in a safe condition through inspection.
After delivery the crane should be checked at least one time every four years by experienced
professional engineers. After being used for 12 years, the crane should be checked every year by
experienced professional engineers.
After overhaul of crane or maintenance of dynamic load-bearing members and before reuse, the
crane must be approved by professional technical personnel from XCMG, otherwise XCMG does not
take any liability for any accidents.
XCMG will not be responsible for any unfavorable results due to modification without
permission of XCMG.
Maintenance and service instructions 2-3

Re-inspection of crane is visual check of crane and its parts, made by a professional engineer/
technician. Potential safety hazard may be found in time through re-inspection, thus accidents may be
avoided. Any potential safety hazard found by professional technician/expert should be put on record, and
the crane should be removed from service until repairs are made and a re-inspection is performed.
Chapter 2 The important items that should be rechecked are listed as follows. Other items are determined by
professional technicians/experts according to the conditions of the crane, which will not be listed in this
chapter.
1. Outrigger structure;
2. Crane mechanisms: boom swinging, elevation and telescoping and rope winding;
3. Braking systems;
4. Electrical system;
5. Safety devices.
If there is any doubt, please consult XCMG customer service department.
If don't abide by the following check principle or don't follow the inspection interval, serious
accidents will be caused.
2-4 Maintenance and service instructions

2-2-1 Daily maintenance and service items
No. Inspection items Example Remark

Visually check the
crane to ensure
that there are no Chapter 2
oil, water and
1
rubbish remained
on the crane, and
no tools left on the
crane.
Visually check
safety devices to
make sure that
2
they are secured
and in good
condition.
Check fire
extinguisher and
first aid kit (if
3
fitted) to make
sure that they are
in good condition.
Visually check
indicating signs,
plates and warning 起重��下
��
��人
4 decals to make 产品识别代码

PIN
徐�州�工�程�机�械�集�团�有�限�公�司�制�
造
MADE IN XUZHOU CONSTRUCTION MACHINERY GROUP CO.,LTD.
越野轮胎起重机
sure that they are

品牌徐工牌型号
BRAND XCMG MODEL ROUGH TERRAIN CRANE
发动机型号额定功率千瓦/(转/分)

ENGINE MODEL ENGINE RATED POWER kW/(r/min)
最大额定总起重量×工作幅度千克米
MAX.RATED LIFTING CAPACITY×WORKING RADIUS kg m
最大设计总质量千克整车整备质量千克
MAX.DESIGNED TOTAL MASS kg TOTAL VEHICLE MASS kg
制造日期年月
DATE OF MANUFACTURE YEAR MONTH
徐州工程机械集团有限公司�徐州重型机械有限公司
legible and no
XUZHOU CONSTRUCTION MACHINERY GROUP CO.,LTD. XUZHOU HEAVY MACHINERY CO.,LTD.
地址中国江苏省徐州市铜山路165号电话（Tel) +86-516-83462242 83462350
missing.
Visually check all

control levers to
make sure they are
5
flexible without
blockage, and
return to neutral.


Visually check
power supply and
switch, lighting
devices, indicator
Chapter 2 6
lamps, gauges and
wipers to make
sure that they are
functional.
Visually check In winter,
every system to inspect the
make sure that there anti-freezing
is no water (or air or condition of
7 oil) leakage, as well pneumatic
as no looseness, no circuit
distortion, no broken system.
and aging sign in
pipelines.
Visually check the

levels of engine
8 coolant, fuel and
lubricant to ensure
they are sufficient.
Check tires to
make sure that tire
pressure conforms
9
to the specifications
and no foreign
body in tire groove.
Clean the dust cup

of the air filter;
10
drain the water in
fuel filter.

Check the seat, horn,

etc. as well as control
11 valve and safety valve
to make sure that they Chapter 2
are functional.
Check braking system

12 to make sure it is
operational.
Visually check the

lifting rope and rope
socket, etc. to ensure
they are in good
13
condition and secured,
and the rope around
sheave and drum is
properly wound.
If any sign
is found,
contact
Check structural professional
members to see if there to inspect.
14
are distortion, cracks
and paint peeling off.
Use the
same type
Check pins and spring of part that
clips. Supplement or was used
15 previously.
replace if any of them
is missing or broken.

2-2-2 Regular maintenance and service items
First check and maintenance of systems for lifting operations should be done after delivery for two
months.
Inspection results should be recorded in inspection record, which will facilitate maintenance.
Chapter 2
● Please supply PIN, serial No., engine serial No. and delivery date when professional
maintenance is required. Refer to the preface for details.
● Shorten the interval if the crane is used in severe operating conditions and working
environment, which mean that the crane is under heavy load and/or working in dusty environments.
● Never maintain, repair and manually lubricate the crane while it is working.
● Prior to maintenance and repair, turn off main power source and position all control levers
to neutral positions. A warning board should be present where it can be easily seen.
● Use the replacement parts that have the same performance and materials as the original
parts.

Table 2-1 General inspection
Daily Periodic inspections

No. Inspection items Inspection method and requirement Solution Remark
checks Weekly Monthly Quarterly Yearly
1 Supplied documents Check the supplied drawings, manuals, product Take measures to ○
certificate to ensure they are complete improve
2 Inspection record Check the inspection records to ensure they are Take measures to ○
Technical complete, and all troubles are removed improve
documents Check the maintenance records to ensure they are Take measures to
3 Maintenance record complete, and all troubles are removed. improve ○
4 Other files Check the other files involved in equipment Take measures to ○
installation, modification, maintenance and register improve
Deal with the
matter according
Check the working environment to make sure there to the enterprise
5 Working environment is no unfavorable factor that affects operation safety. management ○
system and
operation
procedures
Complete Visually check the crane to ensure that there are no
6 machine rubbish remained on the crane, and no tools left on Clean ○
the crane.
7 Appearance Visually check the crane to ensure that there are no Clean
oil and water remained on the crane. ○
Visually check the crane to ensure that there are no Take measure
8 serious corrosion, damage and paint peeling off for corrosion ○ ○ ○
prevention/repair
Boom, turntable, frame, Visually check the load-bearing structural members Take measure
outrigger, counterweight to ensure that there are no corrosion, cracks and for corrosion
9 and its connecting device, ○ ○ ○ ○
lattice jib, mechanism plastic deformation, and the requirements in clause prevention/
Metal 3.9 in GB 6067.1-2010 are met. repair/replace
structure supports, etc.
Visually check the exposed welding seams of load-
10 Welding seams bearing structural members to ensure that there are Repair ○ ○ ○ ○
no cracks.
Connecting parts for Visually check the connecting shafts, plates and
counterweight, travel bolts of counterweight, transmission, transfer
11 system, main load- gear, main load-bearing structural members and Tighten/replace ○ ○ ○
bearing structural safety devices for tightness, and the requirement of
members and safety tightening torque is met.
devices
Connecting Connecting parts for Visually check the connecting bolts of winch
12 parts lifting, slewing and reducer, drum, slewing reducer, elevating cylinder, Tighten/replace ○ ○ ○
elevating mechanisms, brake and coupling for tightness, no missing, and

and braking device. the requirement of tightening torque is met
Connecting parts for Visually check the connecting bolts of engine,
13 power, hydraulic and pumps, motors, valves, center rotary joint, electric Tighten/replace ○ ○ ○
2-9
electric systems motor and electric control box for tightness, and no
missing
Chapter 2
Chapter 2
Table 2-2 Safety devices
2-10
No. Inspection items Inspection method and requirement Solution checks Weekly Monthly Quarterly Yearly Remark
1 Load moment limiter ○

Check the load moment limiter by function test to make Adjust/replace
sure that it is secured and operational.
2 Anti-two block ○
Check the anti-two block by function test to make sure Adjust/replace
that it is secured and operational.
3 Lowering limiter ○ ○
Check the lowering limiter by function test to make sure Adjust
that it is secured and operational.
4 Level gauge ○ ○ ○ ○ ○
Visually check the level gauge to make sure that there is Repair/replace
no damage and it is operational.

After the emergency stop switch is actuated, the engine
stop. The switch shall not automatically reset.
5 Emergency stop switch should Repair/replace ○ ○
After manually resetting, the engine can be restarted
and run properly.
Outrigger jack locking ○ ○ ○
Check the locking device to make sure that there are no Repair/replace
6 device deformation, damage and looseness and it is operational.
7 Slewing locking device Check ○
the locking device to make sure that there are no Tighten/replace
deformation, damage and looseness.
8 Warning ○ ○ ○
device (Audio Check the warning device by function test to make sure Adjust/replace
and visual alarm) that it is functional.
Check the grounding device to make sure that it is in
9 Grounding protector Repair/replace ○ ○ ○
good condition and functional.
Visually check the electric fuses, which may prevent
short circuit, loss of voltage, zero position and over-
10 Electric fuses Replace ○
current from occurring to make sure that they are in
good condition.
check the indication and warning labels to
and warning Visually
11 Indication make sure that they are clearly identifiable, and there Clean/replace ○ ○ ○ ○ ○
labels are none missing.
guardrail and
12 Ladder, ○
Check the ladder, guardrail and walkway to make sure Tighten/repair
walkway that they are in good condition and are secured.
13 Fire equipment ○
Visually check the fire equipment to make sure that it is Adjust/replace
properly located and not expired.
Table 2-3 Electric system

1 Battery Test the battery to make sure it is functional. Clean/refill ○ ○ ○ ○ ○

Visually check all buttons to make sure they are flexible and
Repair/
2 effective, and check the insulation protection of control levers to ○ ○ ○ ○ ○
replace
make sure that there is no damage.
Visually check all control levers to make sure they are flexible Adjust/
3 Control devices ○ ○ ○ ○ ○
without blockage, and zero lock effective replace
Visually check manual power source switch to make sure
Repair/
4 its housing is complete without damage, control buttons are 　 ○ ○ ○ ○
replace
functional and labels are legible.
Main power Repair/
5 Check the main power switch to make sure it is functional. ○ ○ ○ ○ ○
switch replace
Visually check control cabinet door make sure that it is easily Adjust/
6 　　 ○ ○ ○
opened and closed and door lock is reliable. replace
Visually check the electric circuit and components in the control
7 cabinet and make sure that there is no overheating, burning and Replace 　　 ○ ○ ○
melting signs, and there is no damage on component appearance.
Visually check the electric connection and grounding cable to
Adjust/
8 Control cabinet/ make sure that they are reliable and there are no cracks and 　　 ○ ○ ○
station and replace
damage on the cable.

electrical
Visually check each section of wire to make sure that wire Clean/
9 facilities 　　　 ○
marking is clear and wiring is secured. tighten
Check the electric circuit by function test to make sure that there
Repair/
10 is no overheating sign and insulation resistance and grounding 　　　 ○
replace
resistance conform to requirements.
Check terminals, contactors and relays by function test to make Adjust/
11 　　　 ○ ○
sure that they are in good condition. replace
Check the communication between the main machine and center
12 Communication Maintain ○ ○ ○ ○ ○
control compartment by function test to make sure that it is free.

Lighting and Visually check the lighting and signaling devices to make sure Repair/
13 ○ ○ ○ ○ ○
signaling devices they are functional. replace
2-11
Chapter 2
Chapter 2
Table 2-4 Hydraulic system
2-12
Visually check the hydraulic system to make sure that it
1 System Maintain ○ ○ ○ ○ ○
works properly, and there are no noise and overheating sign.
Visually check the hydraulic pipelines to make sure that there Repair/
2 Pipelines ○ ○ ○ ○ ○
are no damage, leakage, looseness, deformation and aging. replace
3 Visually check the level of oil in the hydraulic tank. Refill ○ ○

Filter/
4 Check and replace hydraulic oil according to JB/T9737. ○
Hydraulic oil tank replace
Check the hydraulic oil tank to keep its inner clean; check Clean /
5 ○
sight glass to make sure that it may indicate properly. replace
Check and maintain suction filter, return filter, air filter, and Clean /
6 Filters ○ ○
replace filter elements. Replace
Check the radiator by function test to make sure that it works Repair/
7 Radiator ○ ○
properly. replace
8 Accumulator Check accumulator pressure. Adjust ○ ○
Table 2-5 Power system

No. Inspection Inspection method and requirement Solution Remark
items checks Weekly Monthly Quarterly Yearly
1 Engine Check and maintain the engine strictly according to the Maintain According to Engine Maintenance Manual
instructions in Engine maintenance manual.
2 Visually check engine system to make sure that there are no Clean/ ○ ○ ○ ○ ○
water leakage, oil leakage, air leakage and electric leakage. maintain
System Check the engine by no load test to make sure that it is running
3 smoothly, gauges are indicating properly. Check engine electric Maintain
system to make sure that there are no abnormal phenomenon ○ ○ ○ ○ ○
and smell.
The fuel pipeline
Visually check the air inlet and exhaust circuits, fuel pipelines Repair/ should be replaced
4 Pipelines and connectors to make sure that there are no looseness, ○ ○ ○ ○ ○ every 10,0000 km
torsion, damage and blockage. replace at most or every 3
years. (whichever
is first to come)
5 Visually check the levels of coolant and fuel to make sure that Refill ○ ○ ○ ○ ○
they conform to related requirements.
6 Visually check engine oil, and replace the oil and oil filter Replace ○ ○
Engine oil, element if necessary.
coolant and
7 fuel Visually check engine oil level to make sure that it conforms Refill ○ ○ ○ ○ ○
to requirement.
8 Regularly replace coolant. Drain out the used coolant and Clean / ○
clean the cooling system before refilling new coolant. replace

9 Check fuel filter and oil filter, and replace filter elements Clean / ○ ○
according to maintenance interval. replace
10 Clean the dust cup of air filter Clean ○ ○
Filters Visually check the pressure differential indicator of the air
filter. Clean the main element of the air filter when the pressure Clean/
11 differential indicator indicates. Replace the main element and Replace ○ ○ ○
safety element of the air filter after 2 times of cleaning the
main filter element or when the main element is damaged.
12 Fuel tank Clean the inner of the fuel tank. Clean ○ ○

13 Check the radiator by function test to make sure that it works Repair/ ○ ○
properly. replace
Radiator
14 Clean the radiator/ let it counterclockwise rotate for dedusting Clean/ ○ ○ ○ ○ ○
2-13
maintain
15 Other Check the tension of belt. Adjust ○ ○ ○
Chapter 2
Chapter 2
Table 2-6 Maintenance and service of systems for lifting operations
2-14
No. Inspection items Inspection method and requirement Solution checks Remark
Weekly Monthly Quarterly Yearly
1 Winch system ○ ○ ○ ○ ○
Check the winch system by no load test to make sure that it runs Maintain
smoothly, and there are no abnormal noise and vibration
the elevating system by no load test to make sure that it
2 Elevating system Check Maintain ○ ○ ○ ○ ○
runs smoothly, and there are no abnormal noise and vibration
3 ○ ○ ○ ○ ○
Check the slewing system by no load test to make sure that there Maintain
Systems Slewing system are no abnormal noise and vibration
Boom
4 telescoping Check the boom telescoping system by no load test to make sure Maintain ○ ○ ○ ○ ○
that there are no abnormal noise and vibration.
system

Outrigger Check the outrigger extending system by no load test to make
5 Maintain ○ 　 ○ ○ ○
extending system sure that there are no abnormal noise and vibration.
Check the hook block to make sure that there are no wear and Repair/
6 　　 ○ ○ ○
deformation that will impair safety, and no abnormal sound. replace
Visually check the pin shaft of the hook block to make sure that Tighten/ 　　 ○ ○ ○
7 repair/
it is tightened and secured replace
Visually check the safety latch of the hook to make sure that it is Adjust/
8 repair/ 　　 ○ ○ ○
functional replace
Hook block Check the surface cracks, deformation, wear and corrosion of the Repair/
9 hook block to make sure that the requirements in clause 3.2 in 　　　 ○ ○
replace
GB/T 10051.3-2010 are met.
Check the trunnion of the hook block to make sure that there are Repair/
10 　 ○ ○ ○ ○
no cracks and plastic deformation on it replace
Key parts
Adjust/
11 Check the swivel to make sure it is functional ○ ○ ○ ○ ○
replace
Visually check the other parts of the hook to make sure that there Repair/
12 ○ ○ ○ ○ ○
is no damage. replace
Check the wire rope for broken wire,wear and corrosion to make
13 sure that the requirements in the clause 3.5 in GB/T 5972-2009 Replace 　　 ○ ○ ○
are met.
Visually check the wire rope sections around the drum and Tighten/
14 Wire rope ○ ○ ○ ○ ○
sheave to make sure that there is no rope out of groove. adjust
Visually check the end attachment of wire rope to make sure the Tighten/
15 　　 ○ ○ ○
requirements in the clause 4.2.1.5 in GB 6067.1-2010 are met. adjust
16 Lubrication of wire rope Maintain ○ ○
Table 2-6 Maintenance and service of systems for lifting operations (continued)

No. Inspection items Inspection method and requirement Solution checks Weekly Monthly Quarterly Yearly Remark
Visually check the drum to make sure that the requirements in the clause
17 Drum 4.2.4 in GB 6067.1-2010 are met and there is no deformation on drum Replace 　　　 ○ ○
flanges.
Visually check the sheave to make sure that the requirements in the Repair/
18 　　　 ○ ○
clause 4.2.5 in GB 6067.1-2010 are met. replace
Lubricate/
19 Sheaves Visually check the sheave to make sure that it moves smoothly. 　　　 ○ ○
adjust
Repair/
20 Visually check rope guard to make sure that it is functional. 　　　 ○ ○
replace
21 Check the flexibility of each slewing and swing point Adjust 　 ○ ○ ○ ○
Check the brake by no load test to make sure that it is sensitive and
22 Maintain 　 ○ ○ ○ ○
reliable, and works properly.
Brake
23 During slewing, check the reliable separation of the brake Adjust ○ ○ ○ ○
Visually check the brake to make sure the requirements in 4.2.6 in GB
24 Replace 　 ○ ○ ○
6067.1-2010 are met.
Visually check the coupling to make sure that there is no defect, Tighten/
25 Coupling looseness and oil leakage, and there are no abnormal vibration and noise 　 ○ ○ ○ ○
adjust
Key during operation.
parts Visually check the running reducer to make sure that there are no Tighten/
26 　　 ○ ○ ○
abnormal vibration and noise, oil leakage and overheating. repair
Reducer Check the level of reducer oil to make sure that it conforms to the
27 Refill 　　 ○ ○ ○
relevant requirement.
28 Replace the reducer oil Replace ○
Visually check the gear teeth to make sure there are no plastic
deformation, cracks, tooth surface spalling and pitting corrosion, etc.; and
29 Replace 　　　 ○　 ○
the requirements in the clause 4.2.8 in GB 6067.1-2010 are met in terms
Gear of tooth root wear.
Adjust by
30 Check the meshing clearance of the open gear. ○
professional
Visually check the bearing to make sure that there are no abnormal Repair/
31 Bearing 　　　 ○ ○
sound. replace

Visually check the connecting parts of cabs to make sure that there are no Tighten/
32 　　 ○ ○ ○
sealing off, looseness and cracks. repair
Driver's
Visually check the doors, windows, wipers, protective railings and door Clean/
33 　 ○ ○ ○ ○
2-15
locks to make sure that they are in good condition, and glasses are clean. Replace
cab
Visually check the tilting cylinder of the operator's cab to make sure that Tighten/
34 　 ○ ○ ○ ○
it is safe and reliable. repair
Chapter 2
In order to facilitate to maintain and service the crane, to maintain the working efficiency of the
crane and ensure safety and normal service life, instructions for check, adjustment and replacement of
main crane parts are supplied as follows. Don't use the crane with any faults or abnormalities. What you
should always keep in mind is “Safety Is a Top Priority”!
Chapter 2 2-2-3 Special inspections
1. Inspection conditions
After a lifting appliance itself or outside environmental condition changes or after a standstill for a
long time, before reuse, special inspections are required. Special inspections should be carried out:
a. If any of the following items change:
1) Safety devices.
2) Rated load;
3) Main load-carrying members;
4) Mechanisms;
5) Control cabinet and control system;
6) Power source;
7) Wire rope or short lifting chain;
8) Lifting attachment;
9) Chassis, base and support structure.
If the said items are maintained and repaired in our company, all inspections will be performed
and then the crane can be directly put into service. If the said items are repaired or replaced by users,
necessary tests must be done so as to ensure that the crane may normally work and run smoothly.
b. If the outside environmental condition changes, which is not suitable for normal operation:
1) Extreme weather conditions (such as rainstorm, etc.);
2) Earthquake;
3) Foundation (crane rail included);
4) Fire, flood;
5) Non-normal operations such as overload, emergency stop or impact.

A crane's structural parts and mechanisms may become damaged due to storm, earthquake or
accident. This may result in reduced strength, rigidity, and stability.

Chapter 2
c. After a standstill for a year or more, before reuse.
If an equipment stands idle for a long time, the grease on part pivots and tire pressure will
become insufficient.
2. Inspection guideline
After a lifting appliance itself or the outside environmental condition changes, inspections
corresponding to the change or damage degree should be done; after an accident, the inspection items
should be determined according to accident consequence; after a standstill for a long time, before reuse,
the inspection items should be determined according to the characteristics of the related lifting appliance.
Load test must be done to the crane, which itself or the outside environmental condition has changed
or it has experienced overhaul or an accident before reuse. Visual check and no-load test are required
before the load test.
The said overhaul means removal or replacement of main load bearing structural members, or repair
of whole mechanism or control system, but the performance parameter and specifications are not altered.
Visual check, no-load test and load test should be performed according to the requirements in GB/
T 6068. Tests should be carried out by qualified persons. After tests, load moment indicator should be
calibrated so as to meet the requirements specified.
An inspection report is required for the special inspections.
3. Special inspection items
Refer to Table 2-6 for special inspection items.

Chapter 2
Table 2-6 Special inspection items
2-18
No. Special inspection conditions Inspection items Inspection method and requirement Solution Remark
Changed type or specifications Safety protective Check the changed safety protective devices according to
1 See section 2-2-2.
of safety protective devices devices the requirements in section 2-2-2 in the manual.
Strengthen the effected
Mechanism and Check all performances of the crane by static load test and mechanism and metal
2 Changed rated load
metal structure dynamic load test. structure/reduce lifting
load.
Check the changed metal structure according to the
3 Changed cross-section features See section 2-2-2.
requirements in section 2-2-2 in the manual.
or material quality of main Metal structure
Check the effected metal structure by static load test and Strengthen the effected

4 load-bearing members
dynamic load test. metal structure.
Check the changed mechanism or parts of the winch
5 system according to the requirements in section 2-2-2 in See section 2-2-2.
Changed type or specifications the manual.
Winch system
of winch system Replace the winch
6 Check all performances of the crane by dynamic load test. system/reduce lifting
load.
Check the changed mechanism or parts of the control
7 system according to the requirements in section 2-2-2 in See section 2-2-2.
Changed type or specifications the manual.
Control system
of control system
Check the control performance of the crane by function
test.
Changed type or specifications Check the changed power source or its parts according to
9 Power source See section 2-2-2.
of power source the requirements in section 2-2-2 in the manual.
Changed wire rope Visually check the wire rope, drum and sheave to make
10 Wire rope See section 2-2-2.
performance sure the relevant requirements in GB/T 5972 are met.
Strengthen the effected
Mechanism and Check all performances of the crane by static load test and mechanism and metal
11 Changed fixed slings
metal structure dynamic load test. structure/reduce lifting

load.
Mechanical parts Check the effected mechanical parts and electric control
12 Subjected to waves or flood and electric control system according to the requirements in section 2-2-2 in See section 2-2-2.
system the manual.
Table 2-6 Special inspection items (continued)
No. Special inspection conditions Inspection items Inspection method and requirement Solution Remark
Check the items for yearly inspection specified in section
Earthquake intensity beyond 2-2-2 Yearly 2-2-2.
designed range inspected items Check all performances of the crane by function test, load
test, static load test and dynamic load test.
Check the mechanism and metal structure according to the
requirements in section 2-2-2 in the manual.
Mechanism and
Overloading Repair the effected
metal structure Check all performances of the crane by static load test and
16 mechanism and metal
dynamic load test.
structure.
Emergency stop that causing
17 Winch system Check the winch system and its parts by load test. See section 2-2-2.
abnormal shock to mechanism
Visually check the main load-bearing members, all
Main load-bearing
mechanisms, and check all performances of the crane by
18 Impact accident members, all See section 2-2-2.
function test, load test, static load test and dynamic load
mechanisms
test.
Main load-bearing
members, all Visually check the affected items, and carry out function
19 General fire safety mechanisms, and test and load test to make sure the requirements in section See section 2-2-2.
electric control 2-2-2 in the manual are met.

system
Yearly inspected
The crane has been idle for a Check the items for yearly inspection specified in section
20 items specified in See section 2-2-2.
year or more, before reuse 2-2-2.
section 2-2-2
Note: prior to static load test or dynamic load test, make sure that the test conditions are met.

2-19
Chapter 2
Chapter 2
2-20
Chapter 3 Maintenance and service
3-1 Boom and telescoping system

3-1-1 Part function
1. Boom and its telescoping system
The boom is the main component to which force is applied; it bears the weight of loads, wind loads Chapter 3
and other loads during operation. The telescoping system activates changes in the boom's length.
2. Balance valve
The balance valve sits at the rear of the telescoping cylinder and prevents the retraction of the
cylinder when the control lever is in the neutral position. The valve also stabilizes the retraction speed
of the boom. The balance valve also performs a safety protective function by preventing the oil cylinder
from quickly retracting should a failure of a hose or fitting occur between the boom cylinders and the
control valves.
3-1-2 Working principle and structure
The crane has a four-section boom. The 2nd, 3rd and 4th boom sections are synchronously extended
and retracted in sequence by a one-stage telescoping cylinder plus ropes and sheave system. The
pressure relief valve has been adjusted to 18 MPa in order to prevent the piston rod from bending due to
excessively high pressure during boom extension.
There is a balance valve equipped in the oil circuit in order to ensure smooth boom retraction and
reliable stop.
Maintenance and service 3-1

3-1-3 Use and maintenance
1. Adjustment of ropes
During operation of the boom, the length of the wire rope will change due to the force applied to the
ropes. Examine and adjust the boom telescoping system monthly.
Never operate the crane if the boom cannot be extended and retracted synchronously or if
vibration is noticed. Do not operate until problems are corrected. Otherwise, wire ropes may fall out
Chapter 3 of the groove or break.
To maintain normal operation, make periodic adjustments. The method for adjusting is as follows:
Extend all sections out after elevating the boom to 60º, and retract them in fully; repeat several times.
Lower the boom down after 2nd, 3rd and 4th sections are extended for a distance, and then
respectively adjust the nuts on thin ropes (Ⅱ) of 4th section synchronously as well as nuts on thin ropes
(Ⅰ) of basic section until the 2nd, 3rd and 4th sections can be telescoped synchronously without shaking.
Tighten the nuts on the thin ropes, see Figure 3-1 and Figure 3-2.
If there is more than 1 – 2 mm of clearance between adjacent boom sections while the boom is fully
retracted, insert adjusting shims to compensate. Otherwise, the force applied to the hydraulic cylinder and
rope will be affected.
Thick rope I
Nuts on the thin rope II
Nuts on the thin rope I
Thick rope II
Figure 3-1 Telescoping system (boom head)
3-2 Maintenance and service

Thin rope II
Chapter 3
Figure 3-2 Location of thin ropes on boom head
● If the boom shakes during adjustments, coat the sliding surface of the slide block with grease.
● Do not fully extend the boom for coating, refer to performance plate or table.
● Prevent the rope from rotating while the nut is tightened.

2. Adjustment of sliders
The sliders have been adjusted in place before delivery. Never adjust the sliders unless the boom has
been bending, lateral loading has taken place, or deflection due to serious frictional damage has occurred.
If adjustments are necessary, adjust the slider on the boom head by adjusting the slider bolt to control the
clearance. To adjust the slider on the boom tail, dismantle the boom and increase or decrease the number
of shims under the slider to control the clearance (see Figure 3-3).
Chapter 3
Adjust the bolts
Figure 3-3 Adjustment of the slider
Tipping Hazard!
Before adjusting the slider on the boom head, fully retract the boom.
Only qualified personnel should adjust the slider on the boom tail.

3-2 Winch system
3-2-1 Part function
The winch system's parts control hoisting and lowering movements of the load through wire ropes.
The winch system consists of the winch drum and reducer. This reducer is a two-stage planetary gear
mechanism and has internal, oil-bath lubrication. The output shaft of the reducer connects with the winch
Chapter 3
drum through bolts. The wet brake sits on the input shaft.
Rope wedge
Reducer
Bearing base
Drum
Figure 3-4 Winch reducer

1. General description
Observe whether or not oil leaks on the face of the brake and motor, and examine the system for
loose bolts and screws. Address any problems immediately.
Replace oil once a new machine has operated for 100 hours, and then replace oil for the second time
once the vehicle has been operated for 500 hours. Thereafter replace lubrication oil every 1000 hours or
one year (replace oil every year even if the vehicle works no more than 1000 hours in one year). Operate
Chapter 3 the crane for 15 minutes before replacing oil in order to warm the oil for complete draining.
2. Replacement of oil
Examine the oil level of the winch reducer when the crane is in a horizontal position and refill the oil
immediately if it is insufficient. Follow the suggested replacement procedure:
a. Position an approved container to catch the used oil.
b. Loosen the oil level check plug.
c. Remove the oil drain plug.
d. Drain the used oil into the approved container.
e. Install the oil drain plug.
f. Remove the oil filler plug.
g. Refill with fresh oil using a flexible funnel until the oil flows from the oil level check hole.
h. Tighten the oil level check plug.
i. Remove the funnel.
j. Install the oil filler plug.
waste oil.
3-3 Slewing ring
3-3-1 Part function
The slewing ring connects the superstructure and carrier of the crane. The slewing ring allows the
superstructure to rotate on the carrier. The weight of the load, and the over-turning moment during lifting
operations are transmitted through the slewing ring into the carrier.

The slewing ring has a four-point contact ball structure. The outer race of the slewing ring connects
to the carrier frame and the inner race connects to the turntable. The steel ball sits between the outer and
inner races to make contact with the circular arc sliding track at four points. It can bear axial force, radial
force, and over-turning moment at the same time.
See Appendix for the tightening torque of bolts. Examine the pre-tightening force of the bolts after
the slewing ring initially operates for 100 hours. Thereafter, examine the bolts every 500 operating hours
and make sure the pre-tightening force is sufficient. Lubricate the sliding track once every 100 hours. Chapter 3
3-3-3 Axial clearance and radial clearance of slewing ring
Items Axial clearance Radial clearance

Diameter of track center circle
1501 0.08~0.45 0.08~0.45
Oil cup
Figure 3-5 Slewing ring
● The bolts connecting with the slewing ring must be high-tensile bolts. Always use high-
tensile bolts when replacing the slewing ring bolts to ensure the security of the slewing ring.
● Lubricate the slewing ring every week using a grease pump. Apply grease through the
lubricating hole.

3-4 Slewing system
3-4-1 Part function
The slewing system is the drive unit that controls the slewing movements of the crane's
superstructure.
The slewing system sits on the turntable; this mechanism consists of the slewing reducer and
Chapter 3
hydraulic motor. The high-speed hydraulic motor drives the three-stage planetary reducer to output power
through the pinion gear which engages with the gear teeth on the slewing ring to rotate the super structure.
The brake in the slewing mechanism is a multi-disc wet brake. The brake is off when oil pressure
is applied, which allows the slewing mechanism to rotate. Refer to the slewing mechanism in the Parts
Catalog for structure details.
Hydraulic motor
Braking oil inlet
Oil drain
Reducer output pinion
Figure 3-6 Slewing system structure diagram

1. General description
Examine the pinion every week. Inspect for
oil leakage and abnormal sounds. Pay attention

Check oil level only when the slewing
to ambient temperature, lubricating oil brand
system is in stationary state and oil
and replacement period. Check the tightening
temperature is close to ambient temperature.
torque for mounting bolts of reducer, when the
mechanism working every 500h. Chapter 3
2. Replacement of oil
Follow these suggested oil replacement
procedures for the slewing system:
a. Remove the oil filler plug and dipstick;
b. Loosen the oil drain plug and drain the oil Follow the guidelines of the EPA or
other governmental agencies for the proper
into the prepared container;
disposal of waste oil.
c. Prior to refilling new oil, clean the gear
mechanism with diesel or kerosene;
d. Clean the drain plug and tighten it;
e. Fill with fresh oil to the marked middle
position;
f. Tighten the oil plug and install the ● When the fixed disc brake is
dipstick. failing, over-heating or having maintenance
performed, replace the following
components: friction disc, spring, and seal.
● The slewing reducer is eccentrically
adjusted. When the slewing meshing
clearance is not correct, it can rotate the
position of the slewing reducer and change
the meshing clearance.

3-5 Winch hydraulic motor
3-5-1 Part function
The hydraulic motor is an actuator in the hydraulic system, which is responsible for changing
hydraulic energy into mechanical energy.
Chapter 3
Figure 3-7 Hydraulic motor diagram
When the pressurized oil from hydraulic pump enters into the piston bores of cylinder through valve
plate, piston extend out under oil pressure against the swash plate, which then produces a normal reaction
force on pistons. This force can be further decomposed into axial branch force Fx and vertical branch
force Fy. Fx is balanced out with the pressure acting on the pistons, while Fy develops a torque with
respect to the cylinder center, which causes a counter clockwise rotation of motor shaft.
2-5-3 Common troubles and troubleshooting
1. No pressure in the hydraulic motor

Examine the oil pipe in the motor for leakage. The motor can still work without troubles if small
leakage exists. Large oil leakage severely reduces pressure in the motor.
2. Load cannot be lifted
If the load cannot be lifted and pressure appears normal with no external motor leakage, the problem
is an internal motor problem.

3-6 Central rotary joint
3-6-1 Part function
The central rotary joint is an essential part for rough terrain cranes. The central rotary joint transmits
the hydraulic oil flows and electrical current between the carrier and super structure while allowing
continuous rotation.

Chapter 3
Refer to the central rotary joint in the Parts Catalog for structure details.
3-6-3 Disassembly and reassembly
1. Dismounting of the central rotary joint
a. Disconnect the quick connector between the electric brush circuit and chassis electric system,
and cut off the straps for securing wiring harnesses on the frame with a diagonal cutting pliers;
Cut off all straps and adhesive tape for securing wiring harnesses with a diagonal cutting pliers
or scissors. Take care not to damage any elements. Disconnect the quick connector for connecting the
electric brush assembly and chassis wiring harness with a screwdriver or a special tool.
Electric brush connectors
No. Name No. Name

1 70A sheath 2 40A sheath
3 Empty module 4 17-pin sheath
5 Mounting frame 6 Metal case
7 PG29

Remove the No. 5 mounting frame, No. 1 70A sheath, No. 2 40A sheath, No. 3 empty module and
No. 4 17-pin sheath from the metal case with a screwdriver; remove the wiring harnesses protected by
No.1 70A sheath, No. 2 40A sheath and No. 4 17-pin sheath with a screwdriver or an Allen driver; pull
out the wiring harness of electric brush assembly through No. 7 PG29, and place the removed elements
in a special box. Record the installation sequence of electric brush assembly or record the placing
positions of wiring harnesses in different colors.
b. Dismount the central rotary joint connectors from oil pump, hydraulic tank and multi-way
valve. Cover each oil port with a plug or a place bag once it is dismounted.
Chapter 3 c. Remove washers and bolts, and dismount the central rotary joint from the frame.
● Cover each oil port with a dust plug or a plastic bag once it is exposed;
● Take care to prevent from being injured due to slipping (oil dirt) to fall on the frame;
● Take care not to be scratched during dismounting.
2. Disassembly of the central rotary joint
a. Unscrew all plugs at the bottom of center shaft with a torque spanner, remove the bolts and
washers on the fork with a pneumatic spanner;
b. Place the central rotary joint on a tidy and clean platform with the bore support lug end
upward, and then remove the electric brush assembly with a pneumatic spanner;
c. Put a jack on the center shaft and attach a special wire rope to the bore lifting lug. Separate the
bore from the center shaft by placing cushion blocks under the jack and applying the jack;
d. Dismantle the rotary seal ring in each groove from top to bottom with a plain screwdriver;
e. Clean the dismantled elements with hydraulic oil, and cover each exposed oil port with a dust
plug or plastic bag.
3. Reassembly of the central rotary joint
a. Inspection before reassembly: visually check important parts such as the center shaft and
bore, to make sure that there are no scratches and corrosion. Make sure that there are no sharp corners
and burrs on important positions such as oil grooves, oil passages and thread holes, especially sealing
grooves, and there is no sharp corner at the transition joint between the oil port chamfer or oil groove
chamfer and the bore inner diameter, no hand scraping felt;
b. After inspection, lift the center shaft and bore to put them on a rinsing table by using a single-
beam hoist with a soft rope and magnet equipped;
c. Start the cleaning machine to flush the oil passages, oil grooves and matching surfaces

(including surfaces). Remove burrs. Use soft wire brushes and fur brushes to clean apertures and oil
passages;
d. After cleaning of the center shaft and bore is completed, let them dry by natural airing or
wiping, and then turn them over for next assembly process;
e. Take a plain washer with two hands and put it at the lower portion of the center shaft;
f. Spread a O-ring out gently with both hands and insert it into the last sealing groove;
g. Insert the inner rotary seals into the center shaft sealing grooves in turns from bottom to top
with the help of a screwdriver, and make sure there is no torsion and deformation. Put the outer rotary
sealing rings on the inner rotary seals in turns from bottom to top, and then knock the periphery of each Chapter 3
rotary seal with a rubber hammer to make it fit with sealing groove;
h. Insert a supporting ring into the 2nd sealing groove at each end respectively;
i. Coat a little grease on the external surface of the center shaft and the inner wall of the bore;
j. Use two hands to gently put the bore, with the support lug end upward, on the upper end of
the center shaft. Adjust the bore until the oil return port on the bore aligns with the oil return port at the
lower end of the center shaft, and place them in the center of pressure station;
k. Start the pressure machine and press slider down button. After being adjusted by the pressure
machine, to ensure it is located vertically on the same axis with the center shaft, the bore is slowly
pushed to match with the center shaft. Press return button to return the pressure machine. Turn over
the rotary joint to make the machining hole at the center shaft bottom upward, and transfer it to next
station;
Caution:
Make sure there is no rotary seal damaged. If there are obvious deformation and damage found,
stop pushing the bore and never continue before the damaged seal is replaced.
l. Remove the dust covers, tighten each plug for 2~3 turns according to the requirements in the
drawing, and coat 1545 anaerobic pipe thread sealant evenly onto the thread of each plug, and then
tighten the plugs with a torque spanner;
m. Secure the fork on the bore with bolts and washers.
● Never damage the center shaft when dismantling seals. Never use sharp tools when
reassembling seals.
● Ensure cleanliness as far as possible during assembly and disassembly, to prevent
secondary pollution.

3-7 Winch balance valve
3-7-1 Part function
This valve regulates the rotating speed of the hydraulic motor during lifting and prevents the rotating
speed of the hydraulic motor from exceeding the oil supply.
Chapter 3 Outer
A
chamber
X port X
Figure 3-8 Winch balance valve diagram
When the hydraulic motor is working for lowering a load, the hydraulic oil at the side for lowering
the load flows into the hydraulic motor and controls the pressure on the piston of the balance valve
through the choke.
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 the load, the load is descending at the same time.

3-7-3 Disassembly and assembly
1. Seal ring
In principle, replace with new parts. Coat them with hydraulic oil or grease before reassembly. Take
caution to avoid breakage or damage during assembly.
2. Valve rod, piston and choke
Examine the choke for blockage.
Check the sliding surface, and smoothen minor scratches with fine emery cloth or oil stone.
Before inserting the valve rod and piston into the valve, coat them with hydraulic oil on the sliding
surface. Avoid rotating them.
Chapter 3
After the insertion, check the spool for smooth movement.
3-8 Slewing buffer valve

3-8-1 Part function
The slewing buffer valve manages overflow and energy consumption for the slewing hydraulic
system.
The basic operation of the slewing buffer valve is to regulate the pressure in the hydraulic system to
provide smooth, even braking of the slewing ring.
Figure 3-9 Slewing buffer valve

1. Reverse rotating position

When the slewing pilot control lever in the operator's cab gets pulled outside, the corresponding
proportional solenoid valve on the slewing change valve activates and keeps the slewing change valve in
the left position. The pressure oil flows from the “P” port to the “A” port, and “A” connects with
the slewing motor driving turntable rotating to the left of the crane, which is a counterclockwise rotation.
When the slewing pilot control lever gets pulled inside, the slewing change valve is in the right position.
The pressure oil flows from the “P” port to the “B” port, and “B” connects with the slewing motor
driving turntable rotating to the right of the crane, which is a clockwise rotation.
2. Neutral brake position
Chapter 3 When the slewing pilot control lever is in the neutral position, the slewing change valve is in the
middle and does not change position. The oil circuit channels from pressure oil “P” port to the “A”
port and the “B” port become blocked, and pressure oil returns to the oil tank with low pressure
through the relief valve on the slewing change valve. At this time, no pressure oil exists from the “X1”
oil port to the outer control port on the slewing buffer valve. If the slewing system has no mechanical
brake at this time, the turntable will continue to rotate in the original direction, having inertia impact on
the slewing system. In addition, the pressure at the oil circuit exit will increase rapidly. When the pressure
rises to 3MPa and gets adjusted by the relief valve on the slewing buffer valve, the oil that was exhausted
from the oil circuit exit will overflow from the relief valve and enter the other oil port. The check valve
will fill the vacuum produced from the other oil port, and the motor and relief valve will form a loop for
circulation. The relief valve is an outer-control-style valve with a setting pressure of 3～20MPa. When
the outer control pressure is 0MPa, the setting pressure of the relief valve is 3MPa; when the outer control
pressure is higher than 30bar, the setting pressure of the relief valve is 20MPa.
Inertia energy is created when slewing. This inertia energy will build up and open the relief valve.
This can take longer time to develop than mechanical braking, so it will affect the overall braking
performance if the relief valve is not properly set. The pressure in the hydraulic circuit from motor to
relief valve can be adjusted to change when the relief valve is opened, providing the correct cushioning
effect when braking.
3. Free swing
Keep the wire rope vertical in order to eliminate the angle that sometimes exists between the wire
rope on the hook and loads that have already been lowered to the ground. When the slewing operation
stops, the slewing change valve de-activates, and the relief valve in the slewing buffer valve opens by
spring tension (about 3MPa). The two working oil ports of the slewing motor connect through the check
valve in the slewing buffer valve, causing the pressure in the oil port of the motor to approach 0. At this
time, pull the winch or elevating pilot lever, and the pulling force of the load will rotate the turntable when
the wire rope tightens. In addition, the check valve in the slewing buffer valve from the system oil return
circuit fills the vacuum produced from the oil port of the motor. This action helps the boom straighten
automatically.

3-9 Elevating balance valve
3-9-1 Part function
This valve is used to avoid the runaway of the elevating cylinder's descending speed caused by the
weight of the load lifted (the hydraulic cylinder cannot descend steadily).
When the elevating cylinder is working to lower a load, the proportional valve spool of elevating
Chapter 3
counterbalance valve will be energized to work. At the same time, the pilot oil acts on the piston of
counterbalance 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 the load, the load is descending at the same time.
Figure 3-10 Elevating balance valve diagram

No. Name No. Name No. Name

1 Plug M10×1 2 Combined washer 3 Valve spool 1
4 Sealing ring 5 Bush 1 6 Steel ball
7 Spring 1 8 O-ring 9 Valve spool 2
10 Damper 11 Valve spool 12 Push rod
13 Valve spool 14 O-ring 15 Sealing ring
16 Retaining ring 17 Spring 2 18 Spring 3
19 Valve spool 5 20 Plug 21 O-ring
22 Damper 23 Cover 24 Transition block
Chapter 3
25 Pressure plate 26 Sealing element 27 Mesh filter
28 O-ring 29 Connector 30 Cover
31 Bolt 32 Valve block
1. Sealing ring
Examine the choke for blockage.
Common troubles and causes:
1. No movement when descending
Check the pressure of oil at X port of the elevating balance valve (it should be in the range of 6-19
bar); check whether or not the orifice plug inside the end cover of X port of elevating balance valve is
blocked.

3-10 Combined valve for lifting operation
3-10-1 Part function
The combined valve controls the action of the hydraulic flows during lifting. It also activates the
telescoping system, elevating system, main winch, and auxiliary winch. The combined valve also offers
proportional hydraulic control of direction, flow and pressure while lifting. It proportionally governs the
speed of several actuators simultaneously during lifting.
3-10-2 Working principle and structure Chapter 3
This combined valve consists of quadruple hydraulic control proportional change valve, which
controls telescoping, elevating, main winch and auxiliary winch. a1, a2, a3, a4, b1, b2, b3, b4 receive the
control signal of the pilot control valve to drive the related valve elements to move; pressurized oil from
A1, A2, A3, A4, B1, B2, B3, B4, MT1, MT2 and b2' controls the related hydraulic elements to move, and
is the oil source for winch refilling oil, winch brake and elevating control.
Figure 3-11 Structure diagram of combined valve for lifting operation

1. Valve block
Do not grease the O-rings between blocks.
2. Sealing ring
In principle, replace it with new part.
Install the oil seal into the valve rod from both ends. Never push the oil seal through the recess of the
valve rod.
Chapter 3 3. Valve rod and check valve
Assemble the valve rod in the original valve block after the valve blocks have been disassembled.
3-11 Telescoping balance valve spool
Ensure that the telescoping mechanism of the crane can stop at any height and can handle the effect
of close-down in various situations – with the engine on and off and during long and short periods of time.
Figure 3-12 Structure of telescoping balance valve element


1 Controlled piston 2 Valve sleeve 3 Check valve spring
4 Check valve 5 Check valve spool 6 O-ring
7 Balance valve spool outer spring 8 Rear cover
Working principle:
a. Telescoping cylinder extension
The oil entering from port “B” opens the check valve and flows to port “A”. The oil then flows
to the large chamber of the telescoping cylinder, and the telescoping cylinder extends.
b. Telescoping cylinder retraction Chapter 3
The oil in the large chamber of the telescoping cylinder flows to port “A” and gets blocked by
the check valve. Then, the oil in the small chamber of the telescoping cylinder acts on port “K” of
the control piston and activates the balance valve spool, compressing two main springs to move right
shows with a pressure of 45bar. The flow from port “A” to port “B” initiates the retraction of the
telescoping cylinder.
1. Sealing ring
Check whether the choke is blocked; check the sliding surface, and smoothen minor scratches with
fine emery cloth or oil stone.
When inserting the spools into the body, coat with hydraulic oil and take care to avoid forcing them
in misaligned.

3-13 Telescoping cylinder
During lifting operations, the telescoping cylinder changes the boom length with the help of the wire
ropes. The telescoping cylinder also serves as the holding device for the boom length during operations.
3-13-2 Structure of telescoping cylinder
Refer to the Telescoping cylinder in the Parts Catalog for structure details.
Chapter 3
1. When withdrawing the rod assembly from the cylinder, take care not to damage the rod surfaces,
piston or packing.
2. Make sure that the cylinder body aligns with the rod so that the rod and cylinder cover are easy to
turn.
3. Support ring, sealing ring

4. Rod, piston, cylinder
Smoothen the minor scratches on the sliding surfaces with fine oil stone.
When inserting the rod assembly into the cylinder, apply hydraulic oil to them, and take care not to
damage support ring and seal ring.

3-14 Elevating cylinder
During lifting operations, the elevating cylinder changes the boom height. The elevating cylinder
also serves as the holding device for the boom height during operations.
Refer to the Elevating cylinder in the Parts Catalog for structure details.
Chapter 3

3-15 Jack cylinder
The jack cylinder is a hydraulic cylinder that controls the vertical movement of the crane's outrigger
jack. It supports the crane's own weight and vertical pressure during work.
3-15-2 Working principle
The jack cylinder starts the cylinder piston rod telescoping through the action of hydraulic oil and
Chapter 3
produces a pushing/ tension force, causing the parts connected with the cylinder to telescope.
The telescoping principle of the jack cylinder is shown in Figure 3-14a and Figure 3-14b, and the
direction of the arrowhead is the flow direction of the hydraulic oil. In Figure 3-14a, hydraulic oil enters
from port “A” and pushes the piston to move right; the piston rod retracts and the hydraulic oil flows
out from port “B.” In Figure 3-14b, hydraulic oil enters from port “B” and forces the piston to move
left; the piston rod extends and the hydraulic oil flows out from port “A”.
A B A B
Figure 3-14a Cylinder retraction diagram Figure 3-14b Cylinder extension diagram

3-15-3 Jack cylinder
Chapter 3
Figure 3-15 Jack cylinder structure diagram

1 Bolt 2 Supporting ring 3 Seal
4 Seal 5 O-ring 6 Retainer ring
7 Piston 8 Piston rod 9 Cylinder barrel
10 Guide sleeve 11 Supporting ring 12 Stepseal
13 Shaft seal 14 Retainer ring 15 O-ring
16 Retainer ring 17 Oilless bearing 18 Cover
19 O-ring 20 Supporting ring 21 Dust ring
1. When disassembling and reassembling the guide sleeve and piston seal, take caution to prevent the
radial hole of the cylinder from damaging the seal.
Ensure cleanliness when changing the cylinder on-site to avoid contamination.

3-16 Extension cylinder
The extension cylinder is a hydraulic cylinder that controls the horizontal movement of the crane's
outrigger beam. It supports horizontal pressure during work.
3-16-2 Working principle
The working principle of the extension cylinder is the same as that of the jack cylinder.
Chapter 3 3-16-3 Extension cylinder structure
Figure 3-16 Extension cylinder structure

1 Supporting ring 2 Bolt 3 Seal
4 O-ring 5 Piston 6 Cylinder barrel
7 Piston rod 8 Spacer sleeve 9 Guide sleeve
10 Shaft seal 11 Retainer ring 12 O-ring
13 Bolt 14 O-ring 15 Cover
16 Dust ring

3-17 Suspension cylinder
The suspension cylinder is a hydraulic cylinder that connects the frame and axle. It reduces jolts and
vibration during machine travel and is an important part of the suspension hydraulic system.
The working principle of the suspension cylinder is the opposite of the jack cylinder. It controls the
Chapter 3
flow of hydraulic oil in the cylinder through the telescoping of the piston rod. The flow resistance of oil
fluid can reduce the vibration of the suspension cylinder.
The principle of the suspension cylinder is as shown in Figure 3-14a and Figure 3-14b, and the
direction of the arrowhead is the flow direction of the hydraulic oil. In Figure 3-14a, the piston rod moves
right and causes the hydraulic oil to draw inward from port “A,” and then it causes the hydraulic oil to
flow out from port “B.” In Figure 3-14b, the piston rod moves left and causes the hydraulic oil to draw
inward from port “B” and flow out from port “A.”
Figure 3-17 Suspension cylinder structure diagram

1 Knuckle bearing 2 Retainer ring 3 Cylinder barrel
4 Retainer ring 5 O-ring 6 Supporting ring
7 Seal 8 Piston 9 Supporting ring
10 Bolt 11 Piston rod 12 Retainer ring
13 O-ring 14 Guide sleeve 15 Stepseal
16 Seal 17 Hoop 18 O-ring
19 Dust ring 20 Dust cover 21 Hoop
22 Oil cup

Chapter 3
3-18 Engine and accessory system

3-18-1 Engine
Maintain the engine according to the requirements in the H series electric-controlled diesel engine
operation and maintenance instructions.
Contact a Shanghai Diesel engine service center for help with unresolved troubles.
3-18-2 Fuel pipeline maintenance
Fire and Explosion Hazard:
Always use caution when servicing the fuel system. Diesel fuel is flammable and explosive under
certain conditions.
Examine the condition of the fuel pipeline for tightness as well as leakage. In the engine fuel inlet
pipeline, there is a fuel filter/water separator (see Figure 3-18) fitted above the fuel tank and under the
deck.

Chapter 3
Figure 3-18 Fuel filter
1. Water draining method
Water will settle at the bottom of the filter, as water is heavier than oil. The water level sensor is
mounted at the bottom of the filter housing and monitors the density of the surrounding solution. When
there is enough water at the bottom of the filter to replace the surrounding fuel, the sensor will detect a
change in density and the display in the driver's cab will display a fault code of P2269. Turn the drain
valve counterclockwise to drain the water.
2. Filter element replacement
The replacing frequency of filter element depends on the level of impurity in diesel oil. The element
will become clogged with impurities during operation of the engine, and the flow resistance of the
fuel will increase gradually. Eventually the engine power will decrease significantly and/or the engine
will become difficult to start. Replace the element every 500 hours of operation or when engine power
decreases, whichever occurs earlier. Keep a spare element on the crane to maintain machine uptime when
the fuel filter needs replacement.

3. Troubleshooting
The main reason for an engine decreasing in power or becoming difficult to start is that air enters into
the fuel system.
If fuel cannot get pumped or pressure does not build in the system, first examine the drain valve for
tightness, and then examine the filter housing. Thereafter, check all connections to make sure the fuel
lines are not stuck or blocked by impurity. If a problem remains after replacing the element with a new
filter element, contact your dealer or XCMG service.

3-18-3 Radiator maintenance
Examine the coolant level and refill if necessary. If abnormal coolant consumption occurs, find the
source of the problem and address it immediately. Visually check pipelines and hoses for leakage and
damage. Repair or replace the radiator if damage or trouble is found.
Make sure that all pipelines and hoses are not damaged or scratched. Verify pipelines and hoses
are properly installed.
Chapter 3 1. Examine the outside of the radiator and clean when necessary
Clean the radiator after using it in dusty environments for long periods of time. Blow impurities (dust,
dead insects, and other debris) out of the radiator pipeline using compressed air, or remove foreign bodies
on the back of the radiator with water (in the opposite direction of the cooling air). Clean the radiator
with proper pressure to avoid damaging the radiator pipeline. During cleaning, move the water gun
continuously Never directly point at the following items in order to avoid damage to components:
a. electrical components
b. connectors and
c. sealing parts
2. Clean the radiator water line
Add a solution of 5% light alkaline cleaning compound and 95% water into the cooling system.
Preheat the engine with proper speed to approximately 83℃ (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 it with clean water. Start and preheat the engine; drain out the water after 5
minutes. And then repeat the operation again.

3-18-4 Air filter
Always replace the air filter element if there is excessive oil consumption, if there is large
amount of exhaust and smoke, or when reduced power occurs. Otherwise, engine damage may
occur.
Perform maintenance on the air filter every 3 months or 250 working hours or when a red line
appears in the pressure differential indicator. Increase the frequency of maintenance when the machine
operates in dusty environments.
Confirm whether or not the connector between the air filter and the engine is sealed well before

refilling fuel every day; also examine the hose connectors and air filter cover on a daily basis. If a crack
appears, repair it immediately and keep a record of the repair in a maintenance book.
The second-stage filter (called safety element) is mounted in the first-stage filter. Never clean
the second-stage filter. As this will cause damage. Never disassemble the second-stage filter before
replacement.
Take caution when disassembling the first-stage filter to keep dust from entering into the filter
housing. Replace the safety element 1 time for every 3 times the first-stage filter element gets replaced.
If the safety element looks clean and its deadline for replacement has not passed, it is not necessary to
Chapter 3
replace the safety filter element.
When cleaning the filter with the old safety element still in place, remove the dust that falls from
the safety element. Never use compressed air for cleaning. When replacing the safety element, open the
latch on the cover of the filter and remove the element carefully from the housing. Before installing a new
safety element, clean the inner surface of the filter housing with a clean, wet rag (refer to Figure 3-19).
Open the metal snap at the rear of the air filter Remove the rear cover of the air filter
Clean the inner surface of filter housing Remove the filter element for cleaning
with a clean and wet rag or replacing
Figure 3-19 Air filter cleaning

3-18-5 Coupler
The coupler is a mechanical part that is installed on the flywheel of the engine at one end and is
connected with the drive shaft at the other end for transferring torque.
When the vehicle has been operated about 2,000 hours or 1 year (whichever comes first), examine the
appearance of the rubber parts on the coupler promptly for signs of early failures. Refer to the following
for details:
1. Over time, the surface of the elastomer may become hard due to high temperatures or ultraviolet
Chapter 3 rays (ozone), and cracks may appear. NOTE: A hard or cracked elastomer does not reduce the capacity to
transfer torque.
Figure 3-20 Cracked surface of the elastomer

2. The permanent offsetting of lines on the elastomer may occur over time, and the elastomer will not
recover to its original condition even it does not transfer torque. See Figure 3-21 for the offsetting of lines
from “a” to “b”; the offset value is “S.”
Chapter 3
Figure 3-21 Permanent offsetting of lines on the elastomer
3. The longer the coupler works, the deeper the cracks become. “A” shows the depths of the
cracks in Figure 2-22. See Figure 2-22.
Figure 3-22 Cracks become deeper
Immediately replace the elastomer with a new one when “S” approaches 50 mm or depth “A”
is about 2 mm.

3-19 Transmission
Burn Hazard:
Always use caution when handling hot transmission oil and parts. Allow the oil and parts to cool
before servicing. To prevent possible fire, never allow transmission oil to contact hot parts.
Replace the transmission oil when the transmission is warm for complete draining. At the same time,
drain the oil from the cooling circuit. Drain the used oil into a container and dispose it according to the
Chapter 3
environmental protection requirements.
Clean the drain plug and tighten the plug according to specified tightening torque.
Follow the guidelines of the EPA or other governmental agencies for the proper disposal of waste oil.
Replace the transmission oil according to the following procedures:
1. Refilling the oil
Before starting, refill the oil according to the specified oil amount and brand. Maintain cleanliness
and prevent impurities from entering the system.
2. Checking transmission oil level
1) Checking when the transmission oil is cool (30℃-40℃)
After the engine runs at idle for 3 to 5 minutes, and when the oil temperature meets the requirements,
check the transmission oil level from the oil dipstick located at the transmission support at the left side
of the crane. The oil level should be within the cold and hot marks (i.e. the middle mark and min. mark).
Add the oil if it is insufficient. It is not necessary to drain the oil if it is higher than the middle mark.
2) Check the oil level at the working temperature (80℃～90℃)
When the working temperature of the oil is reached, check the level on the dipstick when the engine
runs at idle for 2~3 minutes. The oil level should be between the top two marks (i.e. the max. mark and
middle mark). Add or drain oil accordingly.
Check the transmission oil level in working temperatures weekly. Low oil levels will damage
the transmission.

3-20 Axle

Both the front and rear axles of the crane are steering and driving axles. Wheels sit on both ends of each
axle. The axle increases the torque passed from the drive shaft, distributes the torque to the left and right driving
wheels, and enables differential function, which is required in mechanical traveling motions. The axle also
supports the longitudinal, lateral and vertical force and movement between the frame and wheels.
3-20-2 Structure
The axle consists of the main reducer, differential, rim reducer, half shaft, brake, axle housing, and
Chapter 3
other components.
Figure 3-23a Main reducer (Meritor axle)

1 Input flange 2 Main reducer input shaft 3 Main reducer housing
4 Differential 5 Main reducer bevel gear 6 Sliding sleeve

Chapter 3
Figure 3-23b Rim reducer (Meritor axle)

1 Rim reducer 2 Half shaft II 3 Hub
4 Brake 5 Kingpin 6 Half shaft I
7 Axle housing
3-20-3 Maintenance
The authorized service station or authorized personnel at the axle factory should perform axle
maintenance.

3-21 Pumps
3-21-1 Variable pump
3-21-1-1 Part function
The variable pump enables telescoping, elevating and hoisting during lifting operations.
3-21-1-2 Working principle and structure
The variable pump is the device that changes mechanical energy into hydraulic energy. Its output
Chapter 3
flow is in proportion to the rotating speed of the driveshaft. The input rotational moment increases
with the rise of the pressure difference between the high pressure side and the low pressure side. When
the engine drives the main shaft of the rotating pump, the connecting rod, plunger and cylinder rotate
together, and the cylinder rotates on the valve plate. Because there is an intersecting angle between
the main shaft and the cylinder axial line, the plunger gets an oil suction stroke when it moves from
the bottom dead center to the top dead center and draws oil into the cylinder by the oil suction port
and valve plate waist type hole. When the plunger moves from the top dead center to the bottom dead
center, it gets an oil extrusion stroke and squeezes the oil that fully filled in the cylinder to the output
port in order to drive the executive elements. The variable pump works by changing the incline angle
between the main shaft and the cylinder axial line through the variable mechanism. Changing the
incline angle can change the oil suction volume of the variable pump. The torque of the variable pump
depends on its working volume, output pressure, and flow. When output torque is constant, the bigger
the working volume and the bigger the pressure of the variable pump. When output rotation speed is
constant, the larger the working volume and the higher the variable pump flow.

Chapter 3
Figure 3-24 Piston pump

1 Main shaft 2 Connecting rod 3 Plunger
4 Top dead center 5 Cylinder 6 Bottom dead center
7 Valve plate
2-21-1-3 Disassembly and reassembly
Never disassemble individual parts of the oil pump. If trouble occurs, replace the whole unit
instead of replacing individual parts.

3-21-2 Gear pump
3-21-2-1 Part function

1. The gear pump supplies pressure oil for the outrigger hydraulic system and ensures the
extension and retraction of the outrigger beams and outrigger jacks.
2. During lifting operations, the gear pump supplies pressure oil for the slewing system.
3. The gear pump supplies pressure oil for lifting and elevating operations.
4. When the vehicle steers or the pivot steers, the gear pump supplies pressure oil for the steering
cylinder to boost it. This action reduces the force on the steering wheel.
3-21-2-2 Working principle and structure
Chapter 3
The concept of the gear pump is simple. Two gears of the same size mesh with each other and rotate
in a tightly fitted housing. The interior structure of the housing is similar to the shape of the number “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 the hydraulic oil tank enters the middle of the two gears from the suction port,
permeates this space, moves with the rotation of the gear along the housing, and discharges when the two
gears mesh.
The gear pump is also called the oil discharge unit, which is similar to a piston in a cylinder. When
one tooth enters the liquid space of another, the liquid will get extruded mechanically. Because liquid
is incompressible and it cannot occupy the same space with the tooth at the same time. Therefore, the
liquid gets extruded as the teeth mesh continuously. Therefore, the liquid gets extruded as the teeth mesh
continuously. As a result, a continuous discharge volume forms at the exit of the pump, and the discharge
volume of each rotation of the pump remains the same. With the uninterrupted rotation of the driving
shaft, oil discharges from the pump continuously.
Figure 3-25 is the working principle diagram of the external meshing gear pump. Note that a pair of
external meshing gears are mounted in the housing of this kind of pump. As the gap formed by the gear
end face and the housing end cover is very small, and the gap formed by the tooth top of the gear and
inner surface of the housing is also small, the gear pump housing is divided into a left and right sealed
chamber. When the gear rotates as shown in the figure below, the gear on the right side disengages from
the mesh gradually, and the intertooth space appears. Consequently, the volume of the sealed chamber on
this side increases, forming a partial vacuum. Oil under the action of the atmospheric pressure enters this
chamber through the oil suction port. With the rotation of the gear, the oil in every intertooth flows from
the right to the left. In the left sealed chamber, the gear teeth mesh gradually, decreasing the volume of
this left sealed chamber and extruding the oil in the intertooth from the output port. This chamber is called
the exhaust chamber. When the gear pump rotates continuously, the oil suction port and the output port
draw and extrude oil accordingly, activating the process of delivering oil to the hydraulic system. In the
gear pump, the oil suction area and the oil discharge area get divided by the meshing gear teeth and the
pump. Therefore, no independent oil distribution mechanism exists.
2-21-2-3 Disassembly and reassembly
Never disassemble individual parts of the oil pump. If trouble occurs, replace the whole unit instead
of replacing individual parts.

Chapter 3
Figure 3-25 Working principle diagram of gear pump
A B
B-B A-A
A B
Figure 3-26 Structure diagram of gear pump

1 Gear, rolling bearing 2 Side panel 3 Housing
4 Front end cover 5 Shaft head seal, external bearing 6 Secondary sealing ring
7 Oil suction side 8 Pressure side 9 Drive gear
10 Driven gear 11 “3” type sealing 12 Rear end cover

3-22 Outrigger
The outrigger increases the support base of the crane, compensates for the incline and unevenness of
the ground on the working site, and increases the stability of the crane and the hoisting capacity.
This crane has four outriggers (arranged as “H”) with two hydraulic cylinders for each – a
Chapter 3
horizontal hydraulic cylinder and a vertical hydraulic cylinder – which activate the outrigger's telescoping
and lifting movements. In a working state, the outriggers extend to the ground and lift the crane off the
ground, supporting the whole weight of the crane. When traveling, the outriggers retract to reduce the
outline dimension and decrease its width.
Refer to the outrigger assembly in the Parts Catalog for structure details.
1. Disassembly of outrigger
The procedures are as follows:

Hydraulic
oil port
Outrigger shielding plate
Chapter 3 (1) Remove the outrigger shielding plate (2) Disassemble the hydraulic pipeline; take
protective methods on pipeline port to ensure its
cleanliness.
Adjusting block assembly

Outrigger lock pin
(3) Remove outrigger adjusting block assembly. (4) Pull out outrigger lock pin.
Cylinder fixing pin

(5) Remove cylinder fixed pin. (6) Choose appropriate equipment, and pull out
outrigger horizontally and steadily.
Figure 3-27 Outrigger disassembly
2. Reassembly of outrigger
The procedures for reassembly are the opposite of the procedures for disassembly, and the methods
are the same.

3-23 Electric system maintenance
3-23-1 Maintenance of electric system for lifting operation
The crane's electric system for lifting operations consists of the power supply circuit, starting circuit,
pilot control circuit, unloading circuit, lowering limiter circuit, instrument indicating circuit, lighting
circuit, moment limiter system, auxiliary circuit, and other parts.
This manual provides detailed explanations of the causes and solutions of some common electric
troubles involving the crane.

Chapter 3
1. No electricity during crane lifting operations
Circuit composition:
Fuse→superstructure starter switch→power supply relay→superstructure electric load→ground
cable
Based on the electric principle schematics, the power supply circuit is composed of the battery,
fuse F101, starter switch, power supply relay, fuse F6, generator, and connecting cables (see Electrical
Principle Schematics for Driving). Any problem in one of the parts will affect all parts and cause a lack of
current during lifting.
Causes and solutions:
No. Trouble Solution
1 Fuse F101 blown Replace

2 Starter switch out of order Repair (take terminal Acc instead of terminal B) or replace
3 Power supply relay broken Replace
4 Lead disconnected or virtual connected Reconnect wire or lay cables
5 Bad ground Reground
2. Trouble in lamp circuit
Power supply→ fuse →switch → lamp → ground cable
No. Trouble Solution:

1 Bulb burned out Replace
2 Fuse blown Replace
3 Grounding faulty Repair
4 Lead disconnected Repair
5 Switch inoperative Repair or replace

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 grounding faulty Repair
Chapter 3 6 Moment limiter faulty Contact a service center
4. Wiper inoperative
Power supply→fuse→switch→wiper motor

1 Fuse blown Replace
2 Switch inoperative Replace
3 Motor damaged Replace
4 Grounding faulty Repair
5. Lowering limiter inoperative
Figure 3-28 Lowering limiter

Power supply → fuse → bridging switch → lowering limiter switch (main winch), (auxiliary winch)
→ controller
Causes:
1. The lowering limiter switch has not been set in place or is inoperative.
2. Fault exists in the circuitry.
Solutions:
a. Open the rear cover of the lowering limiter and readjust the position of the wire rope to connect it
with the switch contact or repair and replace it.
b. Check the circuitry and repair. Chapter 3
6. The lifting operation does not work
1) Faults in the pilot control switch or circuit
Power supply → fuse → pilot button → load moment limiter
Cause:
A malfunction involving the fuse, control switch, or circuit.
Solution:
Examine and repair the circuit and replace the fuse or toggle switch.
2) Faults in the control lever
Power supply → > fuse → control lever
Cause:
The power supply circuit of the lever control is disconnected, virtual connected, or the lever is
damaged.
Solution:
Repair the circuit and replace the lever.
3) A fault in LMI
Enter the “CANBUS state inquiry” screen to examine whether or not there is a communication
fault of the extension mainframe.
Enter “input/output terminal state inquiry” screen of H-1 and H-2 from the “I/O” screen.
Observe whether or not there is a change in the corresponding input/output terminal state parameter
supplied by the current movement controller when handling the left and right levers. Try to determine
whether or not the input and output of the extension mainframe functions properly.

Chapter 3
Figure 3-29 CANBUS state inquiry screen

4) A fault in the circuit between the main unit of LMI and its corresponding solenoid valve and
also the solenoid valve itself
Load moment limiter → control solenoid valve
Causes:
Problems in plug-in, connecting cables, or the solenoid valve itself
Solution:
Examine and repair cables and replace the plug-in or solenoid valve.
Chapter 3

3-23-2 Maintenance of electric system for driving operations
Plug-in is small component which is the most applied in electric system. It is easy to have
trouble. The problem is mainly bad contact or reed cracked or deformation. When any one of
problems occurs, replace the component.
Chapter 3 1. No current in crane and carrier electric systems
Analysis:
The power supply circuit consists of the battery, fuse F101, starter switch, power supply relay coil
(control circuit) and main contact (main circuit), generator, and connecting cables. So any problem in one
of them will cause no current in the crane and chassis electric systems.
Trouble Cause Remedy
No current in battery or connecting cable disconnected Charge the battery or reconnect cable
No electric
Fuse F101 tripping Examine and reset
current in
Starter switch faulty Repair or replace
crane and
Fuse F101 blown Replace
carrier electric
Cables of components disconnected, plug-in comes off Reconnect cables, re-plug in components
systems
Bad ground Reground
2. Starter failure
Analysis:
Most starting circuit troubles arise from the starter switch; troubles also arise from the starting circuit
and the neutral and starting coil.
a. Regularly examine:
First, put the transmission shift lever in the “N” position. “N” will appear on the display of
the transmission state; never permit starting until the “N” appears. If other information appears on the
display, address the transmission trouble according to the transmission instructions.
If the transmission is normal, perform the following procedures. First, check the absorbing coil. If
sound emits from the coil while the coil gets held, the coil is normal. If no sound emits from the absorbing
coil, the absorbing coil is broken and needs repair or replacement. Second, examine the battery and the
main electric circuit. If no problems exist in the battery and main circuit, there is a problem in the starting
motor, and the starting motor needs to be repaired or replaced.

b. Address trouble in the controller area network (CAN)-bus:
Become familiar with the working conditions of every communication node in the “Chassis
trouble diagnosis” screen as shown in Figure 3-30 and observe whether P1 bus communication
functions normally or not. If “P1 fault” appears, measure whether or not the resistance between the
two controller area network (CAN) cables (X104:2, X104:6) at the P1 controller with the AVO meter is
60 Ω or not. If the value measured is in the range of 56~62 Ω, it is considered normal.
If not， examine the CAN-bus resistors and plugs. If “Engine or Transmission fault” appears,
observe whether or not a fault exists between the engine and transmission. Use the repair method
Chapter 3
previously described. If the system cannot be started after repairs, examine the K205 neutral relay
and the connection. If all of the previously mentioned items appear normal, the problem is the starter.
Repair or replace the starter motor.
Figure 3-30 Chassis trouble diagnosis screen

3. Generator does not generate electricity
Solution: Examine the generator for a mechanical or electrical problem. Mechanical problem:
The belt or screw is loose; the generator bearing is faulty. Repair or replace the affected parts. Electric
problem: check with an AVO meter. In general, the voltage from the generator should be more than 27V.
If the voltage is lower than 27V, and no change after increasing accelerator, that means there is problem in
the generator. Repair or replace the generator.
4. Starter motor failure
Cause and solution:

Chapter 3
a. If the starter motor is not parallel with the center of the flywheel gear ring, re-install the starter
motor.
b. If the starting cable and power cable are causing a short circuit, examine the circuit and make
repairs.
c. Faulty starter motor.
5. Faulty instrument
Signals on the instrument in the driving state are read from the controller area network (CAN)-
bus in SAE J1939 format. If no indication appears on the engine tachometer, water temperature and oil
pressure gauge, check the CAN-bus communication through the display system and P1 power supply.
During normal communication, instruments indicate actual values. If communication is not normal, all
instruments do not indicate actual values. Examine the connections of the communication circuit. If
communication is normal, but one of instruments does not work normally, trouble exists in the engine.
Figure 3-31 Driving screen

6. The lamp does not illuminate
Solution:
a. Examine the lamp circuit: First, examine whether or not the power supply of the P1 controller is
normal, and then check the switch and bulb. After that, check ground cable, plug-in and cables. Repair or
replace parts.
b. Examine communication controller area network (CAN)-bus: If the starter does not work, follow
the previously mentioned instructions in the item b under Starter Failure.
Chapter 3
If a problem occurs in the lamp circuit, be sure to check the condition of the plug-in.
Bad contact or cracked/deformed connector may be the problem. If so, replace the plug-in.
7. Faulty fuses F201 and F206
If no electricity after turning ignition key, it means that fuse F201 and F206 are blown. It is necessary
to measure the fuse’s output load. If a short circuit exists, make repairs promptly. Replace fuse only after
the main switch of vehicle power source is turned off.
8. Outrigger failure
a. Observe whether or not there is a fault through the “chassis trouble diagnosis” screen.
The P1 controller controls the outrigger valve, illumination, axle disconnected valve, suspension
valve, and other parts. If an error exists in the P1 controller CAN-bus, pressure will not build in the
hydraulic system and the outriggers will not work.
b. Enter P1 to verify whether or not input or output exists on the corresponding terminal.
If there is input or output on the corresponding terminal during operation, a green color will appear
on the terminal state column.

Chapter 3
Figure 3-32 P1 controller state screen
If there is input or output on the corresponding terminal during operation, a green color will appear
on the terminal state column.

9. Steering system fault
If there is a fault in the steering system, the fault code 90300240 will appear in the “steering
system fault”column in Figure 3-33.
Chapter 3
Figure 3-33 Steering system monitoring screen

Solution:
Click “fault parameter”as shown on the screen in Figure 3-33 to enter corresponding screen
and find the corresponding fault description. Make repairs if necessary. For example, when the code
9030024 appears, the corresponding fault description is “steering solenoid valve Y261 faulty.”
Check and make repairs according to the following:
1. Check to see if plug Y261 is in place. If it is in place, measure the current in the P1 controller
plug XM101:15 with the AVO meter.
2. Once repairs have been made, turn off the key switch, and then turn it on again, and observe to
Chapter 3
see whether or not a fault exists.
3. Immediately after each repair, turn the key switch off and turn it on again to verify that the fault
has been addressed. At the same time, check for other faults. Keep checking according to the process
shown in Figure 3-34 until “steering system normal” appears on the “system state.”
Figure 3-34 Fault solution process
10. Standard fault information
Refer to the “Fault information code table” in the H series electric-controlled diesel engine
operation and maintenance instructions for standard fault information.

Chapter 3

Chapter 3
3-56
Chapter 4 Oil
Check, replace and refill oil (including grease) according to the requirements specified in the
manual. Use the oil in terms of type and quantity according to the requirements in the manual.
Otherwise, deterioration of product performance or reduction in service life of related parts or
damage to parts may be caused, even accidents.
Chapter 4
If operating the crane in a severe environment, such as high temperature, high humidity,
extreme cold, dusty conditions, etc, oil changes and lubrication may need to be done more frequently
to maintain the performance and safe operation of the crane.
4-1 Hydraulic oil

1. Filtration and replacement schedule
Before replacing hydraulic oil or maintaining hydraulic oil tank, place the shut-off valve in the
closed state. Reset the shut-off valve to the open state after the replacement of hydraulic oil or completion
of maintenance.
● Whenever oil becomes excessively contaminated, filter or replace it even before the scheduled
filtration or replacement time.
● Replace hydraulic oil according to ISO/DIS 4406. Always use suitable oil depending on the
ambient temperature.
● When the shut-off valve is in the closed state, the hydraulic oil pump may get damaged if the
engine is started.
Oil 4-1
2. Hydraulic oil temperature With the

crane in travel
The oil temperature should never exceed configuration, the
hydraulic oil level
80℃. cannot be below
the mark.
3. Quantity of hydraulic oil
Refer to Table 4-2 for the required quantity
of hydraulic oil.
Checking the hydraulic oil level with
outriggers retracted and boom retracted and
lowered. The sight glass shows the oil level and
the hydraulic oil temperature. When checking the Figure 4-1 Sight glass with thermometer
oil level, make sure that the oil level is between
the max. and min. marks. If the oil level is lower

Chapter 4
than the min. mark, add hydraulic oil.
Filling method: wipe off and remove any dust and debris on the hydraulic oil tank, remove the oil
filler cap at the top of the oil tank, and then add hydraulic oil.
Filler
Drain port
Figure 4-2 Hydraulic oil tank
Take caution when adding hydraulic oil. Never allow dust and small particles of dirt to enter
the oil tank. Ensure cleanliness. Otherwise, damage to the oil pump and valves will occur.
4-2 Oil
Draining method: Wipe off and remove any dust and debris from the exterior of the oil tank, and then
remove the oil filler cap at the top of the oil tank. Use the pumping unit to draw the hydraulic oil from the
oil tank into a specified container; drain the remaining hydraulic oil that cannot be drawn by the pumping
unit through the oil drain at the bottom of the hydraulic oil tank.
waste oil.
4-2 Gear oil

1. Replacement schedule
Chapter 4
● Whenever gear oil becomes excessively contaminated, replace the oil before scheduled
maintenance.
● Frequently check the oil level, and refill if it is lower than the specified level.
2. Winch system
Filling amount: refer to Table 4-2.
Filling method: Remove the plug at the bottom of the drum. Refill with oil.
3. Slewing system
Filling method: Remove the plug and refill with enough oil according to the slewing system
indicating plate.
Oil 4-3
4. Main reducer for drive axle
Draining method: Remove the oil drain plug at the bottom of the main reducer body, and then drain
the oil into a specified container. Clean the oil drain plug and the oil drain, and tighten the oil drain plug
according to the specified torque.
Filling method: Remove any dust or debris from the main reducer for the drive axle. Remove the oil
filler plug; add oil until the oil level is the same as the level of the oil filler's lower edge.Clean the oil filler
plug and oil filler, and tighten the oil filler plug according to the specified torque.
Chapter 4
Oil filler
Oil drain
Figure 4-3 Oil drain at the bottom of main reducer (Meritor axle)
Follow the guidelines of the EPA or other governmental agencies for the proper disposal of waste oil.
4-4 Oil
5. Rim reducer for drive axle
Filling amount: refer to Table 4-2. Oil filler

Draining method: Turn the wheel to position
the oil drain plug on the rim reducer body at
the lowest level possible, and then remove any
dust and debris near the oil drain. Remove the
oil drain plug to drain the oil into a specified
container, and then wipe off the oil drain plug
and the oil drain. Tighten the oil drain plug
Filling method: Turn the wheel to position

Oil drain
the oil drain plug on the rim reducer body at the
Chapter 4
Figure 4-4 Rim reducer (Meritor axle)
lowest level possible, and then remove any dust
and debris near the oil filler. Remove the oil filler
plug to add oil until the oil level is the same as
the level of the oil filler's lower edge. Clean the
oil filler plug and oil filler, and tighten the oil
filler plug according to the specified torque.
Oil 4-5
4-3 Engine oil

Replacement schedule
Every 500 hours or six months, whichever expires earlier.
Burn Hazard:
Always use caution when handling hot engine oil and parts. Allow the oil and parts to cool before
servicing.
Refer to Table 4-2 for the required quantity and brand of engine oil.
Oil level check method:

Chapter 4 After turning the turntable about 45° clockwise, open the upper cover plate of the engine hood.
Remove the engine oil dipstick to examine whether or not the engine oil level meets requirements. Refer
to the H series electric-controlled diesel engine operation and maintenance instructions for details.
Dipstick
Figure 4-5 Engine oil dipstick
Draining method: remove the oil drain plug on the engine oil sump and drain the oil through the
oil drain at the bottom of the frame. Clean the oil drain plug and oil drain, and tighten the oil drain plug
Filling method: after turning the turntable about 45° clockwise or counterclockwise, open the upper
cover plate of the engine hood, and add engine oil to the oil filler port on the engine cylinder head.
4-6 Oil
4-4 Transmission oil
Replace transmission oil after 100～250 working hours. Afterwards, replace at least one time every
12 months or 1,000 hours, whichever expires earlier.
Burn Hazard:
Always use caution when handling hot transmission oil and parts. Allow the oil and parts to cool
before servicing. To prevent possible fire, never allow transmission oil to contact hot parts.
Chapter 4
Refer to Table 4-2 for the required quantity and brand of transmission oil.
Checking oil level:
There is an oil dipstick for checking the level of transmission oil, it is located at the transmission
support at the left side of the crane as shown in Figure 4-6. See section 3-19 in this manual for checking
method.
Refilling oil:
Counter clockwise turn the T-type handle as shown in Figure 4-7, to remove the plug for refilling oil.
After refilling is completed, insert the plug and clockwise tighten the T-type handle.
Oil dipstick
Filler
Figure 4-6 Transmission oil dipstick Figure 4-7 Filler
Oil 4-7
Draining method:
Remove the transmission oil drain plug, shown in Figure 4-8, and drain the oil into a specified
container. Clean the oil drain plug and oil drain, and then tighten the oil drain plug according to the
specified torque.
waste oil.
Always replace oil filter whenever oil is replaced.
Chapter 4
Oil drain
Figure 4-8 Transmission oil drain
4-8 Oil
4-5 Engine coolant
Every 2000 hours or one year, whichever expires earlier.
Burn hazard:
Always use caution when handling hot coolant and parts. Allow the coolant and parts to cool
before servicing.
Refer to Table 4-2 for the required quantity and brand of coolant.
Inspection methods: rotate the turntable clockwise about 45°, and remove the filler cap of the
Chapter 4
expansion water tank on the engine cover. Coolant level should be parallel to the lower end of the filler
neck. If the coolant level is too low, add coolant.
Sight hole
Figure 4-9 Expansion water tank sight hole
Oil 4-9
Filling method:
After slewing the turntable about 45° counterclockwise, remove the filler cap of the expansion
water tank from the opening at the upper side of the engine hood. Add the specified coolant slowly from
the filler until the coolant level is up to the lower edge of filler neck.
Oil filler
Chapter 4
Figure 4-10 Filler of expansion water tank
4-10 Oil
4-6 Grease
1. Grease points
N
G
F
L
k
I
Chapter 4
J
H
EB
A
D
C
Figure 4-11 Grease points for lifting operation
Oil 4-11
Grease zerk for pin shaft of rear axle (O)
Grease zerk for pin shaft of rear axle (O)
Grease zerk for two ends of steering cylinder (Q)

Chapter 4 Grease zerk for universal joint of transmission shaft (P)
(b) Grease points for the pin shaft of steering cylinder

(a) Grease points for the pin shaft of rear axle and
universal joint
Grease zerk for two ends of steering kingpin (S)
Grease zerk for two ends of rear axle suspension cylinder (R)
(c) Grease points for two ends of suspension cylinder and steering kingpin
Figure 4-12 Grease points for driving operation
4-12 Oil
2. Refer to Table 4-1 for grease points.

Table 4-1
No. Greasing points Interval Oil Method

Main hook trunnion Weekly or before use Lithium base grease ZL45-2 Grease pump
A
Auxiliary hook trunnion Weekly or before use Lithium base grease ZL45-2 Grease pump
Self-lubricating
B Main hook pulley —— —— bearing
Self-lubricating
C Sheaves at boom head —— —— bearing
Molybdenum disulfide
D Boom head sliders Weekly Coat
grease
E Gliding surfaces for the sliders Molybdenum disulfide
Weekly Coat
of 2nd ~ 4th boom sections grease
F Boom tail sliders Weekly Grease pump
grease
G Boom rear pivot Weekly Grease pump
grease
Chapter 4
Self-lubricating
H Jib pulley —— —— bearing
IJib guide roller Before use 2# Lithium base grease Grease pump
Upper and lower pivots of
J elevating Weekly 2# Lithium base grease Grease pump
cylinder
K Slewing ring 100 hours ZG-3 calcium base grease Grease pump
L Pinion tooth surface of slewing Weekly 2# Lithium base grease Coat

reducer
Wire rope Weekly 2# Lithium base grease Coat
M
Wire rope (for telescoping boom) Weekly 2# Lithium base grease Coat
N Bearing seat of main/auxiliary Weekly 2# Lithium base grease Grease pump

winch
O The pin shaft of rear axle Weekly 2# Lithium base grease Grease pump
P Propeller shaft universal joint Weekly 2# Lithium base grease Grease pump
Q The pin shaft of steering cylinder Weekly 2# Lithium base grease Grease pump
R The pin shaft of rear axle Weekly 2# Lithium base grease Grease pump
suspension cylinder
S Steering main pin Weekly 2# Lithium base grease Grease pump
T Upper and lower surface of Weekly 2# Lithium base grease Coat

outrigger beam
● Prior to refilling grease, clean the oil cup and other surface to be coated.
● The gliding surfaces, which are not indicated in Table 4-1 also require periodic greasing.
● Apply a thin coat of grease monthly to the exposed portion of the elevating cylinder piston
rod with the boom placed on the boom rest.
Oil 4-13
4-7 Brand and capacity of fuel and lubricant, etc.

1. See Table 4-2 for the brand and capacity of fuel and lubricant, etc.
Table 4-2 Brand and capacity of fuel and lubricant
Name Brand Volume/L
Engine oil 22
CH-4 15W-40 (above -15℃)
CH-4 0W-30 (-40℃～-15℃)
Transmission lubrication oil 45
0# light diesel (in summer)

Engine fuel 450
-10# light diesel (in winter)
Engine coolant FD-2B (-40) coolant 32
GL-5 80W/90 (above -25℃)
Drive axle lubrication oil 66
Chapter 4 GL-5 75W/90 (below -25℃)
AE46 anti-wear hydraulic oil (-20°C~50°C)
Hydraulic oil tank 750
XA130 hydraulic oil (-40°C~50°C)
Main/auxiliary winch reducer L-CKD220 gear oil (above -16℃) 1.5 respectively
Slewing reducer L-CKT220 gear oil (below -16℃) 2.4
Superstructure parts such as

boom, slewing ring and pulley;
chassis parts such as the pin
L-XBCHA2 Lithium base grease 30 kg
shaft of rear axle, the pin
shaft of steering cylinder and
steering link.
Note:
The filling capacity shown in the table is theoretical value; for actual capacities, refer to the readings
at dipstick, inspection aperture and sight glass.
4-14 Oil
Table 4-3 Comparison between oil brands abroad and domestic
Engine, Winch reducer, Slewing

Category Steering system Axles Hydraulic system
Transmission reducer
Medium Heavy duty
Diesel engine duty
Name Hydraulic oil vehicle gear Industrial gear oil Hydraulic oil
oil vehicle
gear oil oil
Sinopec AE46 —— AE46 ——
CH-4 GL-4 GL-5 L-CKD220, L-CKD320
PetroChina —— XA130 —— XA130
DTE10 Mobilube Mobilube DTE10

MOBIL Delvac super DTE25 Mobilger630, Mobilger632 DTE25
Excel 32　 GX HD Excel 32　
Tellus Tellus Tellus

SHELL Rimula D SPIRAX G Spirax A Omala220, Omala320 Tellus S4VX32
S2MX46 S4VX32 S2MX46
RANDO HDZ Thuban Thuban RANDO HDZ

CALTEX EDLA500 RANDO HD 46 Meropa220, Meropa320 RANDO HD 46
LT32 GL-4 GL-5EP LT32
15W/40 HYSPIN Multitrax Alpha Max220, Alpha

CASTROL HYSPIN HLP 46 SMX 80W/90 HYSPIN HLP 46 HYSPIN AWV 32
RX Super AWV 32 85W/140 Max320
Carter
Transmission
TOTAL Rubia XT AZOLLA AW46 equis XV32 BOLD ORBV EP220, Carter AZOLLA AW46 equis XV32
TM80W/90
EP320
HYSPIN Energol GR-XF220,

BP Venellus C3 Extra HYSPIN HLP 46 Energol EP Hypogear EP HYSPIN HLP 46 HYSPIN AWV 32
AWV 32 Energol GR-XF320
Notes: 0#, 10#, -10#, -20#, -35# light diesel fuel should be selected.
Apply EP Lithium base grease to the lubrication points of bearing, slider, slewing ring, rope, boom pivot and elevating cylinder pivot, etc.
Oil 4-15
Chapter 4
● The oil and coolant are important and will affect the operational and service life of all parts
in the vehicle. Refill them according to recommendations.
● Contact Shanhai Diesel and Hangzhou Advance service centers for more information.
4-8 Disposal of oil and antifreeze fluid
Chapter 4
hazardous materials such as engine oil, diesel fuel, and engine coolant. Consult the local authorities
or reclamation facility.
Various lubricants, greases, fuels, and antifreeze fluids used in cranes will cause direct or indirect
pollution in the environment. Antifreeze fluid and hydraulic oil are toxic. If they can't be used, dispose
them according to the laws of the respective country. Recover used antifreeze fluid and hydraulic oil with
permissible disposal equipment (including disposal equipment in service stations and equipment supplied
by automobile service stations). Contact local environmental protection agencies for assistance if needed.
4-16 Oil
Chapter 4
4-17
Chapter 4
4-18
Chapter 5 System principle schematics
5-1 Electric principle schematics of XCR40

5-1-1 Electric principle schematics for lifting operations
Chapter 5
Figure 5-1 Electric principle schematic for lifting operations (1 of 22)
System principle schematics 5-1

Chapter 5
5-2 System principle schematics

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5

5-1-2 Electric principle schematics for driving operations
Chapter 5
Figure 5-2 Electric principle schematic for driving operations (1 of 11) (Off-road EU Stage IIIA)

Chapter 5

Chapter 5

Chapter 5

Chapter 5

Chapter 5
5-28
Start locking relay
Accelerator pedal
System principle schematics

ECU main power supply
Engine fuse
Intake heat relay
Oil/water separating
liquid level switch
Engine with harness and connector
Engine key power
Technical requirements
The wire diameter without indication is 0.75mm2
Engine belt
Chapter 5

Chapter 5

Chapter 5

Chapter 5
5-32
Off-pump
detection switch Op-amp
conversion circuit
Fuel sensor
System principle schematics

Driving
controller Fan 1 power supply Fan 2 power supply
Fan 1 relay Fan 2 relay
Engine other
key power Cooling fan Cooling fan
Remote flameout Remote control
Low water level relay
Engine low
water level alarm
Technical requirements
The wire diameter without indication is 1mm2
Chapter 5

Figure 5-3 Electric principle schematic for driving operations (1 of 14) (Off-road Stage IV)
5-34
5-35
5-36
5-37
5-38
5-39
5-40
5-41
5-42
5-43
5-44
5-45
5-46
5-47
5-2 Hydraulic principle schematics
Chapter 5
Figure 5-4 Hydraulic principle schematic (1/4)

Chapter 5

Chapter 5

Chapter 5

Chapter 5
Braking refilling valve
Figure 5-5 Steering hydraulic principle schematic

Chapter 5
Figure 5-6 Braking hydraulic principle schematic

Chapter 5
5-54
Chapter 6 Troubleshooting
6-1 Common troubles and troubleshooting
Section Trouble Cause Remedy
Visually check whether or not there is air

in the fuel pipeline. If necessary, tighten
1. Air in fuel suction pipeline
and replace the fuel pipe connector, fuel
pipe, and fuel filter.
Engine 2. Battery voltage is too low Check the generator or replace the battery.
Engine cannot be
started 3. Oil level in oil tank is too low Check the oil level and add oil.
Contact a Shanghai Diesel service center
5. Engine inner fault
for repair.
6. Transient suppression diode damaged Replace the transient suppression diode
1. Vehicle cannot be moved after releasing

Check the wire harness.
hand brake
Machine cannot
be moved 2. Signal cables between engine and
Check the wire harness.
transmission are not connected well
Drive line 1. Oil cooler system pipeline is clogged Check and clean the pipeline
2. Incorrect oil level Check the oil level, and refill or drain oil
Excessive oil
3. Deteriorated oil Replace with new oil
temperature in
transmission 4. Fan of transmission oil cooler is inoperative Check and repair.
Chapter 6
Add lubricant according to
5. Insufficient lubricant
recommendations.
Check each connection. If the plug-ins are
1. Faulty signal transmission not loose, contact a professional service
Speed-jump, station for repair.
irregular speed
Contact a Advance service station for
2. Transmission inner fault
repair.
High vehicle 1. Loose connection of drive shaft Check and tighten.

vibration 2. Rubber support of engine is damaged Check and replace.
Refer to the H series electric-controlled diesel engine operation and maintenance
Other troubles
instructions for details.
1. Lubricant level is too low full of lubricant.
Abnormal noise
in the drive line 2. Improper clearance of gear in drive axle Contact a professional service station for repair
3. Parts in axles are worn or damaged Contact a professional service station for repair
Axle and 1. Oil seal is worn, loose or damaged Replace the oil seal
suspension
Lubricant 2. Drain plug is loose or lining damaged Tighten the plug or replace the lining
leakage 3. Breather is clogged or damaged Clean or replace the breather
4. Axle case is deformed due to overload Rectify or replace the axle case
Common troubles and troubleshooting 6-1


Check the circuit and all
1. Insufficient pressure for braking accumulators.
Contact a professional service station for
2. Braking disc and braking caliper faulty
Insufficient brake repair
force 3. Improper clearance between brake disc and Check and adjust
brake caliper
4. Rear adjusting screw of brake pedal is Adjust the screw
Axle and adjusted to be too long
suspension
1. Brake time is too long or braking is too frequent Stop and cool off
Adjust the brake clearance according

2. Insufficient brake clearance to recommendations.
High brake
temperature 3. Back pressure of braking oil return circuit is Check the smoothness of the braking
too high oil return circuit
4. The connecting rod between brake pedal Adjust the rod length
and brake valve is too long
Steering on one Have an expert repair the steering

1. Leakage in one side of steering gear
side is heavy gear
1. Friction caused by deformed steering drive

shaft or misalignment between steering drive Rectify or replace
shaft and connected spline
Steering is 2. Improper pressure in steering hydraulic system Adjust the pressure

difficult
3. Leakage in steering gear Repair the steering gear
4. Insufficient oil pressure or flow in oil pump Repair or replace the oil pump
5. Boost cylinder inner leakage or damage Repair or replace the cylinder
Engine functions 1. Priority valve is stuck Replace or repair the priority valve.
Chapter 6 normally,
but steering
movements do not 2. Switching valve is stuck Replace the switching valve.
Steering function
system 1. Loose bolt for fixing steering gear and its
Play in steering Tighten any loose parts
support
wheel
2. Improper adjustment of steering gear Adjust or repair the steering gear
1. Damaged hydraulic steering gear Repair the steering gear
Noise from
steering gear or 2. Oil level in oil tank is too low Refill according to recommendations
oil pump during
steering Investigate for air leak. Repair and
3. Air in oil circuit evacuate air
Avoid driving at high speeds for a long
1. Excessive oil flow in pump time
Overheating of
steering gear 2. Oil flow is impeded due to damaged, Arrange the hoses or replace the oil
(65℃ exceeding creased, or blocked oil hose or internal hoses
atmospheric blockage
temperature)
Steering limit time should not exceed
3. Steering to relief position is held too long 5 seconds


1. Check for clogs in the oil return
During normal
traveling, brake disc 1. There is oil pressure in the brake pipeline.
cylinders for each axle 2. Check oil inlet pipeline for
is overheating leakage.
Braking Rear axle fails to Adjust inspection switch of rear axle
system automatically align 2. Rear axle inspection switch fault aligning mechanism
Adjust the brake clearance of
Bad parking brake 3. Parking brake disc is not adjusted the parking brake according to
performance properly recommendations.
Check the relief valve for normal
1. Faulty relief valve operation.
Outriggers do not 2. The pressure of relief valve is insufficient Adjust the pressure of the relief valve
extend out/retract
in, or movement is 3. Faulty solenoid valve Check the valve
sluggish 4. Oil cylinder piston sealing is damaged Replace the sealing
Clean or replace double-way
5. Faulty double-way hydraulic valve hydraulic valve
Jack retracts or
extends automatically Internal leakage in oil cylinder Replace the sealing or cylinder.
Outrigger 1. Faulty relief valve pressure setting in

system Adjust
carrier multi-way valve
Inoperative 2. Relief valve element blockage Disassemble and clean
3. Faulty control valve Repair
Movement is 1. Faulty inner part of control valve Repair

sluggish 2. Relief valve pressure setting is too low Adjust
Clean or replace double-way
Jack automatically 1. Faulty double-way hydraulic valve hydraulic valve Chapter 6
retracts or extends
during operation or 2. Internal leakage in cylinder Replace the sealing or cylinder.
road travel.
3. External leakage in cylinder Repair
1. Brake lining is worn or oil is on brake lining Repair or replace
Brake is ineffective 2. Air in brake oil circuit Bleed the air
3. Faulty brake cylinder Repair
1. Slewing buffer valve in main valve
pressure settings is too low or valve spool Repair and adjust
is stuck
Slewing
system 2. Slewing buffer valve is inoperative Repair
3. Faulty slewing motor Repair or replace
Boom will not swing
4. Slewing reducer faulty Repair or replace
5. Faulty pilot valve Repair
6. Faulty relief valve in pilot oil circuit Repair
7. Pilot oil circuit is blocked Repair and adjust


1. No pressure in hydraulic system
or pressure is too low: if the pressure
Repair or replace
of relief valve in swing valve reaches
specified value.
Sluggish 2. Hydraulic motor leakage Repair or replace
slewing
3. Insufficient pressure in control
Check and repair
circuit or faulty pilot valve
4. Internal leakage in main valve or
Check , replace
faulty change
1. Faulty pilot valve Check and repair
Big starting
shock 2. Too much air charged in
Adjust
accumulator
Slewing Unsteady 1. Faulty slewing brake Check and repair
slewing brake 2. Faulty main slewing valve Check and repair
system
1. Solenoid valve stuck or faulty
Free-sliding of Check and repair
solenoid valve electric circuit
slewing system
inoperative 2. Brake pressure of inlet circuit is too Adjust the pressure relief valve and
and free/lock low the relief valve of the pilot oil circuit
change system
inoperative 3. Pressure of free-sliding relief valve
Adjust
is too high
1. Check whether the bolt on valve
rod of swing valve is loose or if the Tighten, adjust
Slewing to only valve rod cannot reach one direction
Chapter 6 one direction 2. Damaged valve plate in one
direction on the slewing motor and ——
high leakage
1. Relief valve pressure setting is too

Adjust
low in superstructure multi-way valve
2. Internal leakage in superstructure

Elevating Boom elevation multi-way valve, control pressure is Check and repair
cylinder will not too low
system extend
3. Internal leakage in cylinder Check and repair
4. Master pump pressure is too low Check and repair

1. Same as items 5 and 6 in the previous

Check and repair
section
2. Faulty counterbalance valve Check and repair
Boom elevation 3. Back pressure of main return oil circuit is

Check and repair
cylinder will not too high
retract
4. Too low pressure due to internal leakage in
Check and repair
oil cylinder
5. Excessive low pressure setting of secondary

Adjust
relief valve for elevating operation
Elevating pressure 1. Seized control piston in elevating balance Repair

is normal, but valve cannot push the slide valve
boom cannot be
lowered 2. Blocked throttle bore on control piston of
Clean
elevating balance valve
1. Internal leakage in cylinder Repair or replace
Cylinder retracts 2. Faulty counterbalance valve Repair or replace
during operation
3. Balance valve opens because of high
Check and repair
pressure in control system
Elevating Check pump and safety valve in
system the superstructure multi-way valve
1. No pressure or insufficient pressure in
elevating system (check it at the same time with the
telescoping system).
2. Internal leakage caused by damaged
No pressure elevating valve in superstructure multi-way Check and repair
or insufficient
pressure for valve
Chapter 6
elevating 3. Damper of confluence valve in
Check and repair
superstructure multi-way valvecoming off
4. Internal leakage in elevating cylinder Check and repair
5. Faulty confluent valve in superstructure
Check and repair
multi-way valve
1. Shaking with sound occurs during boom

up and down, especially when oil temperature
or ambient temperature is too high: Too tight
Check and repair
elevating cylinder Guide sleeve of elevating
cylinder or nylon supporting ring thermal
Shaking occurs expansion
during elevating
operation
2. Shaking occurs during boom down: Too
high opening pressure of elevation balance
valve Too large orifice on the piston of Check and repair
balance valve; Too high pressure setting of
secondary relief valve for elevating operation


1. Pressure setting of relief valve in
telescoping control valve in superstructure Adjust
multi-way valve is too low
Boom will not extend
2. Same as items 2, 3, 4, 5 and 6 in
"Boom elevation cylinder will not Repair and adjust
extend"
1. Too low pressure setting of relief Adjust
valve in superstructure multi-valve
Boom will not retract 2. Faulty counterbalance valve Check and repair or replace
3. Same as items 2, 4, 5 and 6 in
"Boom elevation cylinder will not Repair and adjust
extend"
1. Faulty counterbalance valve Repair
Elevating 2. Internal leakage in cylinder Repair
system Boom retracts during 3. External leakage in cylinder, valve Repair
operation or piping joints
4. Balance valve opens because of Check and repair
high pressure in control system
1. The guide sleeve in the telescoping
cylinder or nylon supporting ring
on the piston is influenced by the Adjust or replace
Vibrated boom telescoping environmental temperature and
expands
2. Too tight boom slider or poor slider Adjust
lubrication
No extension and 1. Valve spool is stuck or control Check and repair
retraction of 2nd, 3rd and circuit is broken
4th boom sections and 2. Main valve spool is stuck in open
Chapter 6 there is high pressure Check and repair
position
1. Too low pressure setting of relief Adjust
valve in superstructure multi-valve
2. Faulty hydraulic motor Check and repair
3. Internal leakage in superstructure Check and repair
Winch Winch will not hoist up multi-valve
system load
4. Master pump pressure is too low Check and repair
5. No pressure in pilot oil circuit Check and repair
7. Faulty winch brake Check and repair


2. Control oil circuit of hoisting balance Check and repair
valve is blocked
3. Faulty winch brake Check and repair the brake
Winch will not 1. Check the change valve.
let out rope in 2. Check the pressure
power hoist- 4. No pressure in brake inlet circuit reduction valve and relief
down mode valve.
5. No pressure in pilot oil circuit Check and repair
6. Faulty pilot valve Repair or replace
7. Leakage in winch motor Repair
1. Oil on brake friction disc Clean
Brake 2. Friction disc is worn Adjust or replace

inoperative 3. Air in brake oil circuit Bleed the air
4. Faulty braking cylinder Repair
1. Low volumetric efficiency in pump Check and repair
2. Flow divider valve in superstructure multi- Adjust
valve is not closed
3. Inoperative confluent valve in
Hoist speed is Check and repair
Winch not reaching superstructure multi-way valve
system intended
4. Faulty superstructure multi-way valve Check and repair
requirements
with no load 5. High internal leakage in main safety valve Adjust
6. High internal leakage in hydraulic motor Adjust
Chapter 6
7. If the motor is variable motor, check
whether or not the displacement is in the Check
specified minimum value
1. Brake is not fully opened Check and repair
2. Faulty superstructure multi-way valve Check and repair
3. Hydraulic motor faulty Repair or replace
Shaking is found 4. Faulty counterbalance valve Repair or replace
in winch
5. Excessive high pressure setting of
secondary relief valve in superstructure Adjust
multi-way valve for hoisting operation
6. Unsteady winch system Adjust
1. High internal leakage in main safety valve Adjust
Rotation speed 2. High internal leakage in hydraulic motor Adjust
decreasing when 3. Low oil displacement in hydraulic pump Check and repair
winch is in
operation 4. Faulty superstructure multi-way valve Repair or replace
5. Overload Adjust


1. High counter-pressure in return circuit Adjust
Hook
automatically 2. Inoperative brake Check and repair
lowers when 3. High leakage in hydraulic motor Adjust
load gets lifted
1. Damaged hydraulic motor Repair or replace
2. Damaged speed reducer Repair or replace
3. Balance valve faulty Repair or replace
4. Thick oil viscosity Replace
Abnormal
noise in winch 5. Air entered Adjust
operation
6. Influence of outside vibration Adjust
7. Contaminated oil Replace
8. Too high pressure setting of secondary relief Adjust

valve for hoisting operation
1. Low volumetric efficiency in pump Check and repair

2. Flow divider valve in superstructure multi- Check and repair
valve is not closed
Winch
system Hoist speed is
not reaching 3. Inoperative confluent valve in superstructure Check and repair
designed multi-way valve
requirements
with a heavy 4. Faulty superstructure multi-way valve Repair or replace
load 5. High internal leakage in main safety valve Adjust
Chapter 6 6. High internal leakage in hydraulic motor Adjust

7. If the motor is variable motor, check the Check
displacement of the motor
1. Faulty main safety valve Check and repair
No winch 2. High internal leakage in hydraulic motor Adjust
rotation because
of low pressure 3. High internal leakage in hydraulic pump Adjust
4. Faulty superstructure multi-way valve Repair or replace
1. Overload Adjust
2. Inoperative brake, brake friction plate
No winch seriously worn, contaminated brake friction Check and repair
rotation when plate, air in the brake piping, leakage of brake
pressure is liquid or defect in brake piping
normal
3. Hydraulic motor faulty Check and repair
4. Faulty speed reducer Check and repair or replace
Inching control, 1. Pressure in control oil circuit is too low Adjust
Functional controllable and
proportional 2. Faulty pilot pressure relief valve Check and repair
parts function
insensitive 3. Faulty superstructure multi-way valve Check and repair


Work lamps do not 1. Bulb is burned out Replace
illuminate
2. Fuse blown Replace
Boom lamp does not
illuminate 3. Earthing faulty Repair
Interior lighting does
4. Wire broken Repair
not illuminate
5. Faulty switch Repair or replace
1. Blown fuse Replace
2. Faulty switch Replace
Wipers inoperative 3. Motor faulty Replace
4. Earthing faulty Repair
1. Faulty grounding Repair
2. Faulty switch Replace
3. Faulty relay Replace
Buzzer will not sound
5. Faulty buzzer Repair or replace
6. Faulty LMI Contact with our service center
Starter could not be 1. Main fuse is blown or loose Repair or replace
Electrical operated from crane 2. Wire is broken, faulty switch Repair or replace
operator's cab
system
2.Relay inoperative Replace
Chapter 6
Faulty LMI 3. Solenoid valve faulty Repair or replace
4. Solenoid valve earthing faulty Repair
5. Others Contact a service station
2. Cord reel faulty Repair or replace
4. Limit 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. Limit switch earthing faulty Repair
9. Faulty LMI Contact a service station
1. Bulb burned out Replace
Chassis front headlight 2. Conducting wire short circuit,
Repair or replace
does not illuminate switch inoperative
3. Poor communications Repair


1. Blown F15 fuse Replace
Radio is 2. Burned transformer or broken
Repair or replace
inoperative circuit
3. Horn burned or broken circuit Repair or replace
Electrical 1. Starting key is inoperative Repair or replace
Engine cannot
system
be started 2. Blown fuse Replace
1. Dome light switch is inoperative Replace
Dome light does
not illuminate
3. Bulb burned out Replace
1. Insufficient oil Add oil
2. Air is entering through suction line Repair and bleed air.
3. Mounting bolt is loose Tighten the bolt
Noise in
4. Contaminated hydraulic oil Replace the oil or filter it
hydraulic pump
5. Drive shaft vibration Repair
6. Universal joint is worn Replace
7. Faulty hydraulic pump Repair or replace
1. High internal leakage in main pump Check and repair
Hydraulic 2. Faulty relief valve in multi-way
system Check and repair
valve
Overheating
hydraulic oil, 3. High opening pressure of
Check and repair
low speed of counterbalance valve
functional parts 4. High internal leakage in winch
Check and repair
Chapter 6 motor
5. Low pressure setting of relief valve
Check and repair
in main pump
System pressure 1. Low pressure setting of relief valve Adjust the pressure setting
is lower than the
designed value 2. High internal leakage in oil pump Replace the oil pump

6-2 Replacing wire ropes
6-2-1 Wire rope replacement standard
Wire ropes get fatigued with use, and continuing to use them without paying attention to fatigue
leads to extreme danger. Examine and replace wire ropes according to ISO 4309: 2010. Replace any wire
ropes that fall into one or more of the categories below.
a. Wire ropes in which 10% or more of all the wires (excluding filler wires) are broken in one rope
lay
b. Reduction in diameter exceeds 7% of the nominal diameter.
c. Twisted
d. Excessively deformed (indented strand, protrusion of wires, or bird-caging) or corroded wire ropes
e. Wire ropes with an abnormal rope end.
6-2-2 Requirements of replacing wire rope
In general, replace wire rope with the same type and size as the original rope. If the rope is not the
same type, the rope should perform at the same level as the original rope. Fit grooves on the drum and
sheaves.
If the rope must get cut from a longer rope, securely seize the rope ends before cutting. Chapter 6

6-2-3 Wire rope replacement
For example, replace the main winch rope as noted in the following instructions.
Set up the crane on firm, level ground. Fully retract the boom, and then replace the wire rope
according to the following images and procedures.
No. Procedure Note Tools
Place the main hook block on the

ground.
Avoid disorderly rope winding

1
on the drum.
Disconnect the
rope socket from
the boom head or Keep the parts carefully so as not
2 main hook block. to lose them. Wrench
Chapter 6
Remove the
rope from the Bar,
Keep the parts carefully so as not
rope socket. Hammer,
3 to lose them.
Wrench


Let out the rope by turning the
winch under power.
4 Pull the rope.
Remove the rope end from the

winch drum. Keep the wedge.
Bar,
5
Hammer
Reeve the new rope over all the

sheaves.
Chapter 6
Through the correct route. Wire or
6 Bind the rope end with a wire or vinyl tape
vinyl tape.
Install the rope end to the winch 1. Put the wedge in the
drum. correct orientation.
2.The rope end must
not protrude from the Hammer
7
external periphery of
the drum.

Wind the rope on the drum. 1. Avoid disorderly rope winding

on the drum.
2. Bind the rope end with a wire
Wire or vinyl
or vinyl tape.
8 tape
Reeve the rope over the sheaves at

the boom head and the hook block.
Exercise care to route the rope

9 correctly.
Attach the rope socket and rope

clamp to the rope.
Chapter 6
Put the wedge in the correct Hammer,
orientation. Wrench
10
Attach the rope

socket to the
boom head or
the hook block
11 Wrench
depending on the
number of parts
of line.

Raise and extend the boom, then D o n ' t l o w e r t h e h o o k b l o c k

lower the hook block until no turn excessively. Otherwise the rope Bar,
12
of the rope remains on the winch may be damaged. Hammer
drum.
Hoist up a weight which applies Do not exceed the total rated

approx. 30% of the "maximum load. Maximum permissible load Hammer,
13 permissible load for one single spanner
for single winch rope is 2800kg.
winch rope" to the rope and then
wind the rope on the drum
Remove the load from main hook

14
block.
Chapter 6

6-3 Return filter
6-3-1 Notes on operation
a. Stow the boom.
b. Stop the hydraulic pump.
Replace the filter element at the intervals shown below:
Delivery Replace Replace

3 months Every six months
date element element
6-3-2 Replacement method
Remove the cover
Chapter 6
—— Wrench
1
Remove the filter assembly.
Keep the parts carefully so as

2 not to lose them. ——

Remove the snap

pin, loosen the nut
and remove the
filter element.
Wrench
3
Replace the filter

element and
assemble the filter. Ti g h t e n t h e n u t g r a d u a l l y.
After the sealing surface makes Wrench
4 contact with the element evenly,
further tighten the nut within
one turn and insert the snap pin.
Install the filter assembly
Chapter 6
—— ——
5
Install the cover
6 —— Wrench

6-4 Line filters (replacing filter element)
Precautions for operation
a. Stow the boom;
b. Stop the hydraulic pump.
Replace the filter element at the intervals shown below:
Delivery Replace
Every 12 months
date element
6-5 Tire maintenance and replacement
6-5-1 Basic parameters for tire
Basic parameters for tires of XCR40 Rough Terrain Crane
Tire specification: 20.5R25 tubeless
Tire maximum speed: 40 km/h, the vehicle cannot travel continuously exceeding 2 hours.
Chapter 6 Standard inflation pressure: 0.65~0.7 MPa
The inflation pressure here means the cold tire pressure that is measured before the vehicle travels or
3 hours after the vehicle stops. If measuring the tire pressure when tires are hot (has been recently used),
the pressure will be higher by 5% or 10% than the pressure measured when tires are cool (has not been
recently used). The loading capacity of the tire is closely connected to the vehicle speed and inflation
pressure.
Table 6-3 Single tire loading capacity at different vehicle speed

Tire pressure: (0.65～0.70) MPa
Vehicle speed (km/h) 0 3 40
Loading capacity (kg) 31000 24000 14000

6-5-2 Visual check for tires
The tread depth of the tire crown should not be less than 5 mm;
There should not be crack and cut on tire tread face and side wall.
When mounting tires, be sure the type and tread of the tires on an axle are the same.
Never install used tires.
6-5-3 Tire pressure check
Regularly check the tires for damage, depth of tread and foreign particles, If the pressure decreases
too quickly, check the reason for the air leakage (for instance, check whether or not the tire has a puncture,
a laceration or a leak in the valve mouth).
6-5-4 Control of vehicle speed
There is a limit on the maximum speed permissible for tires, so never exceed the limit while driving
the vehicle. Driving at speeds above the recommended limit for a long period of time will result in the
tires overheating, and the tire's service life will shorten. During driving, the driver should pay close
attention to avoid obstacles. If there is an obstacle in the front of the vehicle (for example, a pit), the
driver should respond in advance to avoid the obstacle. If the driver cannot avoid the obstacle, the driver
should decrease the vehicle speed to the lowest speed possible.

Chapter 6

6-5-5 Storage of tires
Store tires vertically. Store them in a shady, dry room; never store tires in an open-air environment.
Sun exposure over a long period of time will cause premature aging of the rubber before the tire's official
expiration date. Tires are made of rubber, so when driving and stopping the vehicle or when storing tires,
never let tires contact chemicals such as oil, acid, hydrocarbon or other chemicals. Contact could cause
corrosion, deformation and softening of tires. While storing, transporting and mounting tires, avoid
damaging the bead toe. Otherwise, air tightness will diminish and the tire will not function.
6-5-6 Rim inspection
The rim is an important part of the vehicle's traveling system. When changing the wheels, check for
the following:
1. Rim rustiness;
2. Rim deflection and deformation;
3. Rim cracks;
4. Opening of the rim flange, mounting hole, and rim bolts and nuts.
After checking the rim, repair or replace the damaged or deformed parts at once. If paint is stripped,
repaint after rust is removed.
Chapter 6
Never weld connections of the rim bolt. Never repair deformed rim bolts. Always replace old
parts with new parts.

6-5-7 Tire rotation
1. After 10000 km of traveling, rotate the tires. Refer to Figure 6-1.
Forward direction
Figure 6-1 Tire rotation diagram
2. Never scratch the bolt thread when replacing the wheels. Never allow paint, grease or dirt on the
touching surface between the brake drum and rim.
3. Keep the faces of the wheel nuts clean.
4. Coat threads of the wheel bolts and nuts with a little grease, oil, or other anti-seizing agent.
5. Threads of all wheel nuts are right-handed. With the tires mounted and the wheels suspended,
tighten the nuts in the order of the diagonal rotation. Lower the wheels on the ground, and tighten the Chapter 6
wheel nuts with a tightening torque of 700～800 N.m.
6. After tires get remounted, retighten wheel nuts once every 50 km of traveling according to
recommendations.
7. When replacing tires, use tires that conform to proper loading capacity, speed, and working mode.

Chapter 6
6-22
Chapter 7 Inspection of steel structures
Load carrying steel structures, such as boom, turntable, frame and outriggers, should be checked at
least once per year. Pay more attention to the welding beams on these steel structures, even if they are not
located at high stress areas.
When the crane was subjected to excessive operating loads; e.g., due to an unusual impact, the crane
structure, especially the steel structures must be inspected immediately!
If paint damage with corrosion (rust) is found on load carrying parts of the crane structure, especially
on telescopic booms, lattice jibs, pull rods etc., then the rust must be removed, the part must be primed
and painted.
If any damage (such as cracks or suspicion of cracks) are apparent on any part of the steel structure,
the total extent of the damage must be determined by qualified specialists using appropriate material
testing methods, such as magnetic crack detection, ultrasound or x-rays. Thereafter, the qualified
personnel must determine whether or not the damaged area can be repaired by welding or by other means.
● The crane structures, particularly steel constructions have to be checked by an expert or
authorized inspector at least once a year. The crane inspector has the inescapable responsibility for the
inspection.
● The following diagrams are provided to assist the inspector. The diagrams are only examples
and are not necessarily 100 % complete!
Chapter 7
● Check the crane structures completely.
● Shorten the inspection intervals when the crane is subjected to above-average load spectrums,
for example when handling large material quantities or frequently erecting long boom systems.
Inspection of steel structures 7-1

If defects such as cracks or permanent deformation are detected on load-bearing steel components,
they should be immediately reported to XCMG Customer service center. Furthermore, the defect must be
appraised by an authorized inspector in accordance with standard welding practice rules. The inspector
must ascertain whether or not the crane can continue to be safely operated until the time of the repair.
● If abnormal condition appears in operation, stop operation and check at once.
● It is forbidden to operate the crane with defects! Serious equipment damage and casualties
may be caused!
The following diagrams are samples of the load-bearing weld designs. The inspections required for
the welding joints or seams or steel structural zones may be present more than once and in various forms.
The joints or zones must be inspected all around at the locations identified by arrows.
Chapter 7
7-2 Inspection of steel structures

Chapter 7
Figure 7-1 Example 1 for frame

Chapter 7
FigureFigure
6-3 Example
7-2 Example
for front
2 for
outrigger
frame box

Chapter 7
Figure
Figure
6-4 Example
7-3 Example
for front
1 foroutrigger
turntablebeam

Chapter 7
Figure 7-4 Example 2 for turntable

Chapter 7
Figure 7-5 Example for outrigger beam

Chapter 7
Figure 7-6 Example for base boom

Chapter 7
Figure 7-7 Example for medium boom section

Chapter 7
Figure 7-8 Example for end boom section

Chapter 7
Figure 7-9 Example for jib

Chapter 7
7-12
Chapter 8 Appendix
8-1 Main parts
Table 8-1 Main parts list
Certification
No. Name Manufacturer Remark
mark
Xuzhou Rothe Erde Slewing Bearing Co., Ltd.
1 Slewing ring
MAANSHAN FY SLEWING RING
Main/auxiliary winch
2 Xuzhou Sunbun Machinery Co., Ltd.
reducer
Qingdao Hailida Gear Case Co., Ltd.
3 Slewing reducer
Main/auxiliary winch
4 Zhonghang Liyuan Hydraulic Co., Ltd.
motor
5 Transmission Hangzhou Advance Gearbox Group Co., Ltd.
6 Engine Shanghai Diesel Engine Co., Ltd.
7 Axle Xuzhou Meritor
Zhonghang Liyuan Hydraulic Co., Ltd.
8 Oil pump
PERMCO (Tianjin) Hydraulic INC., LTD
9 Elevating cylinder
Xuzhou Hydraulic Parts Co., Ltd. XCMG
CHENGDU CHENGGANG HYDRAULIC
10 Telescoping cylinder
EQUIPMENT MANUFACTURING CO.,
11 Extension cylinder LTD.
12 Jack cylinder
13 LMI WIKA Mobile Control
Chapter 8
Appendix 8-1
8-2 Tightening torque of main bolts and nuts

Table 8-2 Tightening torque of main bolts
No. Assembled position Qty Tools Tightening torque (N.m)

1 Slewing ring and frame 48 Torque wrench 800～900
2 Slewing ring and turntable 48 Torque wrench 800～900
3 Slewing reducer fixture 24 Torque wrench 110～130
Bearing seat fixture of main and auxiliary
4 24 Torque wrench 78～104
winch reducers
5 Fixture of main and auxiliary winch motors 8 Torque wrench 193～257
6 Fixture of main and auxiliary winch reducers 32 Torque wrench 376～502
7 Wheel nuts 12 Torque wrench 700～800
8 Bolts and nuts for installing front axle 8 Torque wrench 900～950
Bolt connection of propeller shaft and
9 4 Torque wrench 110～130
transmission
Notes about the tightening torque of bolts and nuts:
1. According to the requirements of Appendix A in JB/T5945-1991 General Technical Specifications
for Construction Machinery Installation, the corresponding value of 8.8 class should be adopted for the
tightening torque of bolts and nuts that are not specified in Table 6-1. The corresponding value of 5.6 class
should be adopted for the tightening torque of bolts that are less important connecting parts such as hose
clip, etc.
2. For the bolts connecting suspensions, and other bolts and nuts having no special connection
requirements, after repairing, their threads need to be coated with thread sealant before remounting.
(Tianshan-branded 1242 or 1262 thread sealant is recommended.)
8-3 Maintenance and check record form

1. Routine inspection record, regular check record and report, and special check report are required.
Chapter 8
See Table 8-3 for record form.
8-2 Appendix
Table 8-3 Maintenance and check record
No. Item Content maintained Signature Date Remark

1
2
3
...
2. The regular check report and special check report should at least include:
a. The name and address of employer who asks for regular check or special check;
d. The basis for the regular check or special check;
e. Identification items of crane, including crane type, manufacturer information, manufacture date,
and so on;
f. The date of previous regular check or special check;
g. The safe working load of the crane or the safe working load related to the previous regular check
or special check;
h. The first regular check after assembly or reassembly at a new job site or new environment:
1) Crane's erection and operation;
2) Check results.
i. Regular check of lifting appliances:
1) Check interval;
2) Identification and description of the defects;
3) Repaired, replaced or modified items for removing the defects;
4) Defects, which do not pose danger for the time being but potentially pose danger to personnel:
——The time that danger comes due to the defects;
—— Repaired, replaced or modified items for removing the defects;
—— The date for next regular check.
j. Special check
Chapter 8
1) The problems found and conclusion;
2) Repaired items;
3) Suggestions about overhaul;
4) The date for next regular check.
k. Items of regular check or special check;
l. The signature and address of check and approval personnel, check date and report date.
Appendix 8-3
Chapter 8
8-4
Ａｄｄ：　Ｎｏ．　６８，　Ｇａｏｘｉｎ　Ｒｏａｄ，　Ｅｃｏｎｏｍｉｃ　ａｎｄ　Ｓｅｒｖｉｃｅ　ｈｏｔｌｉｎｅ
400-110-9999
Ｔｅｃｈｎｏｌｏｇｉｃａｌ　Ｄｅｖｅｌｏｐｍｅｎｔ　Ｚｏｎｅ，　Ｘｕｚｈｏｕ，　
Ｊｉａｎｇｓｕ，　Ｃｈｉｎａ
Ｐｏｓｔ　Ｃｏｄｅ：　２２１００４
Ｓａｌｅｓ　Ｔｅｌ：　＋８６－５１６－８３４６２３５０　　８３４６２２４２ 400-001-5678
Ｓｐａｒｅ　Ｐａｒｔｓ　Ｔｅｌ：　＋８６－５１６－８３４６１５４２
Ｑｕａｌｉｔｙ　Ｉｎｑｕｉｒｙ　Ｔｅｌ：　＋８６－５１６－８７８８８２６８
Ｗｅｂｓｉｔｅ：　ｗｗｗ．ｘｃｍｇ．ｃｏｍ／ｑｉｚｈｏｎｇｊｉ
Ａｌｌ　ｒｉｇｈｔｓ　ｒｅｓｅｒｖｅｄＦｉｒｓｔ　ｅｄｉｔｉｏｎ，　Ｍａｒｃｈ　２０２１

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XCR40 Rough Terrain Crane

Maintenance and Service Manual

Xuzhou Heavy Machinery Co., Ltd. XCMG

XCR40 Rough Terrain Crane

Date Year Month

Please read the manual carefully before operating the crane.

This equipment is designed and manufactured in accordance with

This machine has obtained Chinese Special Equipment Production Permit.

parts should be used.

before putting it to work.

ALL RIGHTS RESERVED

-without the written permission of XCMG.

Chapter1 General safe operation ................................................................................................................ 1-1

1-1 General safety precautions ............................................................................................................ 1-1

Chapter 2 Maintenance and service introduction....................................................................................... 2-1

2-1 Systems that need to be maintained and serviced ......................................................................... 2-1

2-2 Maintenance and service items ..................................................................................................... 2-3

2-2-1 Daily maintenance and service items ..................................................................................... 2-5

2-2-2 Regular maintenance and service items ................................................................................. 2-8

2-2-3 Special inspections ............................................................................................................... 2-16

Chapter 3 Maintenance and service ........................................................................................................... 3-1

3-1 Boom and telescoping system....................................................................................................... 3-1

3-1-1 Part function ........................................................................................................................... 3-1

3-1-2 Working principle and structure ............................................................................................. 3-1

3-1-3 Use and maintenance ............................................................................................................. 3-2

3-2 Winch system ................................................................................................................................ 3-5

3-2-1 Part function ........................................................................................................................... 3-5

3-2-2 Working principle and structure ............................................................................................. 3-5

3-3 Slewing ring .................................................................................................................................. 3-6

3-3-1 Part function ........................................................................................................................... 3-6

3-3-2 Working principle and structure ............................................................................................. 3-7

3-4 Slewing system ............................................................................................................................. 3-8

3-4-1 Part function ........................................................................................................................... 3-8

3-4-2 Working principle and structure ............................................................................................. 3-8

3-4-3 Use and maintenance ............................................................................................................. 3-9

3-5 Winch hydraulic motor ............................................................................................................... 3-10

3-5-1 Part function ......................................................................................................................... 3-10

3-5-2 Working principle and structure ........................................................................................... 3-10

2-5-3 Common troubles and troubleshooting ................................................................................ 3-10

3-6 Central rotary joint ...................................................................................................................... 3-11

3-6-1 Part function ......................................................................................................................... 3-11

3-6-2 Working principle and structure ........................................................................................... 3-11

3-6-3 Disassembly and reassembly ............................................................................................... 3-11

3-7 Winch balance valve ................................................................................................................... 3-14

3-7-1 Part function ......................................................................................................................... 3-14

3-7-2 Working principle and structure ........................................................................................... 3-14

3-7-3 Disassembly and assembly................................................................................................... 3-15

3-8 Slewing buffer valve ................................................................................................................... 3-15

3-8-1 Part function ......................................................................................................................... 3-15

3-8-2 Working principle and structure ........................................................................................... 3-15

3-9 Elevating balance valve .............................................................................................................. 3-17

3-9-1 Part function ......................................................................................................................... 3-17

3-9-2 Working principle and structure ........................................................................................... 3-17

3-9-3 Disassembly and assembly................................................................................................... 3-18

3-10 Combined valve for lifting operation........................................................................................ 3-19

3-10-1 Part function ....................................................................................................................... 3-19

3-10-2 Working principle and structure ......................................................................................... 3-19

3-10-3 Disassembly and assembly................................................................................................. 3-20