Mobile Crane - ZTCT (25-80) ZTC Series Truck Crane Maintenance Manual

Zoomlion Heavy Industry Science & Technology Co.,Ltd.
Address: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Changsha, Hunan Province, China Postcode: 410131
Website: http://www.zoomlion.com Email: Sos-service@zoomlion.com
Copyright © 2015 Zoomlion Heavy Industry Science&Technology Co., Ltd. All rights reserved
ZTC Series Truck Crane
Maintenance Manual
Applied for 25t – 80t
Edition 1 March 2020

To Users
Thank you for choosing our “ZOOMLION” truck cranes. Before any maintenance, please read
and fully understand the contents of this manual and strictly abide by its relevant instructions.
Regular inspection, troubleshooting and maintenance should be necessary for your truck crane
to give full play to its good performance, ensure safe and reliable operation and extend the
service life. In order to facilitate your regular inspection, troubleshooting and maintenance, we
provide you this Maintenance Manual.
This Maintenance Manual will detail the rules and instructions about truck crane inspection,
troubleshooting and maintenance, as well as judgment and treatment of the common faults.
In order to make this truck crane work normally and ensure the safety of yourself and others,
please carefully read this Maintenance Manual, Operator’s Manual and other attached
documents before any maintenance, and if anything unclear or doubtful, please contact your
local service engineer. We will provide you with timely and effective technical support. Our
company will take no responsibility for any bad consequence incurred due to any disobedience
to this Manual for maintenance or troubleshooting.
During maintenance of this truck crane, unauthorized personnel shall not remove or adjust the
hydraulic assembly. When the truck crane has its hydraulic assembly or any part suffering from
any faults or damage, please contact your local service engineer.
The data (data, specifications, illustrations) in this manual is for cranes in production at the time
of this manual publication. We reserve the right to make changes to this manual at any time,
without obligation.
The manual has been translated to be best of our knowledge. Zoomlion assumes no liability for
translation errors. The Chinese version of the MAINTENANCE MANUAL is solely applicable for
factual accuracy.
Thank you!
Zoomlion Heavy Industry Science and Technology Co., Ltd.
Copyright
Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any
electronic medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy
Industry Science and Technology Co., Ltd.
Copyright © 20XX, Zoomlion Heavy Industry Science and Technology Co., Ltd.
All rights reserved.
I
Instructions for Safety Information
DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this
manual to show important instructions. In this manual, the labels follow the paragraph or item they
apply to. The markers are as follows:
Refers to a dangerous situation which, if you do not prevent, will cause

DANGER death or injury.
Refers to a possible dangerous situation which, if you do not prevent,

WARNING could cause death or injury.
Refers to a possible dangerous situation which, if you do not prevent, may

CAUTION cause light or moderate injury.
Refers to a situation which, if you do not prevent, may cause property or

NOTICE equipment damage.
II
Contents
To Users ........................................................................................................................................ I
Safety Instructions ....................................................................................................................... II
Chapter 1 Crane Maintenance Instructions
1.1 Instructions to maintenance cycles ............................................................................... 1-1

1.2 User's responsibilities .................................................................................................. 1-1
1.3 Obligations of marketing service networks.................................................................... 1-1
1.4 Disclaimer.................................................................................................................... 1-2
Chapter 2 Maintenance Schedule
2.1 Routine inspection and maintenance............................................................................ 2-1

2.2 Inspection and maintenance during break-in period .................................................... 2-10
2.3 Monthly inspection and maintenance ......................................................................... 2-22
2.4 Quarterly inspection and maintenance ....................................................................... 2-26
2.5 Semi-annually inspection and maintenance................................................................ 2-29
2.6 Inspection and maintenance every 9 months.............................................................. 2-36
2.7 Inspection and maintenance every 12 months ............................................................ 2-37
Chapter 3 Daily Inspect and Maintenance Guidelines
3.1 Inspection of liquid level, pressure and temperature ..................................................... 3-1

3.2 Inspection and maintenance of hydraulic system .......................................................... 3-9
3.3. Inspection and maintenance of oil and water leakage ................................................ 3-12
3.3.1 Inspection and maintenance of hydraulic system leakage ............................... 3-12
3.3.2 Inspection and maintenance of oil and water leakage ..................................... 3-12
3.4 Inspection and maintenance of safety indicators and devices ..................................... 3-14
3.4.1 Superstructure ............................................................................................... 3-14
3.4.2 Chassis .......................................................................................................... 3-16
3.5 Inspection and maintenance of wire rope ................................................................... 3-18
3.6 Inspection and maintenance of steering system ......................................................... 3-19
3.7 Inspection and maintenance of brake system ............................................................. 3-21
3.8 Inspection and maintenance of wheels ....................................................................... 3-23
ZTC Series Truck Crane (25t~80t) III

Chapter 4 Periodical Maintenance Guidelines for Superstructure
4.1 Periodical inspection and maintenance of main vulnerable parts .................................. 4-1
4.1.1 Periodical inspection and replacement of hoses ............................................... 4-1
4.1.2 Periodical inspection and replacement of air conditioning ................................. 4-1
4.2 Periodical inspection and replacement of oil ................................................................. 4-4
4.2.1 Periodical inspection and replacement of gear oil of winch reducer ................... 4-4
4.2.2 Periodical inspection and replacement of gear oil of slewing reducer ................ 4-6
4.2.3 Periodical inspections and replacement of hydraulic oil..................................... 4-8
4.3 Periodical inspection and replacement of key fasteners.............................................. 4-10
4.3.1 Slewing bearing .......................................................................................... 44--10
4.3.2 Installation of reducer ......................................................................................4-11
4.3.3 Boom and derricking cylinder shaft ................................................................. 4-12
4.3.4 Mounting bolt of counterweight ....................................................................... 4-12
4.4 Periodical inspection and maintenance of mechanisms and systems.......................... 4-13
4.4.1 Periodical inspection and maintenance of telescoping system ........................ 4-13
4.4.2 Periodical inspection and maintenance of slewing gear .................................. 4-17
4.4.3 Periodical inspection and maintenance of hoist gear....................................... 4-17
4.4.4 Periodical inspection and maintenance of load moment limiter........................ 4-18
4.4.5 Periodical inspection and maintenance of counterweight handler .................... 4-25
4.4.6 Periodical inspection and maintenance of cable reel ....................................... 4-25
4.4.7 Periodical inspection and maintenance of central collecting ring ..................... 4-28
4.5 Periodical maintenance and replacement of wire rope ................................................ 4-30
4.6 Periodical inspection and maintenance of load-bearing parts...................................... 4-37
4.6.1 Periodical inspection and maintenance of slewing table .................................. 4-37
4.6.2 Periodical inspection and maintenance of boom ............................................. 4-38
4.6.3 Periodical inspection and maintenance of jib .................................................. 4-39
4.6.4 Periodical inspection and maintenance of hook .............................................. 4-41
4.6.5 Periodical inspection and maintenance of counterweight ................................ 4-42
4.7 Maintenance points of superstructure ......................................................................... 4-43
4.7.1 Points of inspection and maintenance ............................................................ 4-43
4.7.2 Lubricating points ........................................................................................... 4-45
IV ZTC Series Truck Crane (25t~80t)

Chapter 5 Periodical Maintenance Guidelines for Chassis
5.1 Periodical inspection and maintenance ........................................................................ 5-1

5.1.1 Periodical inspection and cleaning of fuel filter element .................................... 5-1
5.1.2 Periodical inspection and maintenance of air filter element ............................... 5-3
5.1.3 Periodical inspection and replacement of return oil filter element ...................... 5-6
5.1.4 Periodical inspection and replacement of suction oil filter element .................... 5-7
5.1.5 Periodical inspection and replacement of air dryer ............................................ 5-8
5.1.6 Periodical inspection and replacement of hose ................................................. 5-9
5.1.7 Periodical inspection and replacement of battery ............................................ 5-10
5.1.8 Periodical inspection and maintenance of air-conditioning system .................. 5-12
5.2 Periodical inspection and replacement of oil ............................................................... 5-14
5.2.1 Periodical inspection and replacement of engine coolant ................................ 5-14
5.2.2 Periodical inspection and replacement of engine oil ........................................ 5-16
5.2.3 Periodical inspection and replacement of gear oil of transmission ................... 5-17
5.2.4 Periodical inspection and replacement of gear oil of driven axle...................... 5-18
5.2.5 Periodical inspection and replacement of hydraulic oil .................................... 5-19
5.2.6 Periodical addition of grease .......................................................................... 5-21
5.3 Periodical inspection and tightening of key fasteners .................................................. 5-23
5.4 Periodical inspection and maintenance of mechanisms and systems.......................... 5-26
5.4.1 Periodical inspection and adjustment of outrigger telescoping mechanism ...... 5-26
5.4.2 Periodical inspection and maintenance of engine and its peripheral systems .. 5-29
5.4.3 Periodical inspection and adjustment of transmission control mechanism ....... 5-30
5.4.4 Periodical inspection and adjustment of clutch operating mechanism.............. 5-31
5.4.5 Periodical inspection and adjustment of brake ................................................ 5-33
5.4.6 Periodical inspection and maintenance of suspension system ........................ 5-34
5.4.7 Periodical inspection and maintenance of propeller shaft ................................ 5-35
5.4.8 Periodical inspection and adjustment of wheel alignment ................................ 5-37
5.5 Periodical inspection for load-bearing parts ................................................................ 5-42
5.5.1 Periodical inspection of chassis frame ............................................................ 5-42
5.5.2 Periodical inspection of sliding beam .............................................................. 5-44
5.5.3 Periodical inspection of axle ........................................................................... 5-45
5.5.4 Periodical inspection and exchange of wheels ................................................ 5-47
5.6 Main maintenance points of chassis ........................................................................... 5-50
5.6.1 Points of inspection and adjustment ............................................................... 5-50
5.6.2 Lubrication points ........................................................................................... 5-52
ZTC Series Truck Crane (25t~80t) V

Chapter 6 Oil Medium Selection
Table for oil medium capacities............................................................................................. 6-1

—Table for oil medium capacities for 25 T series truck cranes .............................................. 6-1
—Table for oil medium capacities for 50 T / 55 T series truck cranes..................................... 6-3
Chapter 7 Diagnosis and Troubleshooting for Common Failures
7.1 Electrical system, superstructure.................................................................................. 7-1

7.1.1 Electrical system .............................................................................................. 7-1
7.1.2 Hydraulic pump ................................................................................................ 7-3
7.1.3 Hoist gear ........................................................................................................ 7-4
7.1.4 Derricking gear................................................................................................. 7-5
7.1.5 Telescoping system .......................................................................................... 7-6
7.1.6 Slewing gear .................................................................................................... 7-7
7.1.7 Counterweight handler ..................................................................................... 7-8
7.1.8 Display detection and diagnosis ....................................................................... 7-9
7.1.9 Telescoping mechanism ................................................................................. 7-15
7.2 Chassis ..................................................................................................................... 7-16
7.2.1 Engine system ............................................................................................... 7-16
7.2.2 Transmission.................................................................................................. 7-23
7.2.3 Propeller shaft ................................................................................................ 7-24
7.2.4 Drive axle....................................................................................................... 7-25
7.2.5 Steering system ............................................................................................. 7-26
7.2.6 Brake system ................................................................................................. 7-28
7.2.7 Tire ................................................................................................................ 7-29
7.2.8 Hydraulic system ............................................................................................ 7-31
7.2.9 Electrical system ............................................................................................ 7-32
7.2.10 Outrigger...................................................................................................... 7-35
Chapter 8 Appendix
8.1 Routine inspection and maintenance............................................................................ 8-1

8.2 Inspections and maintenances during break-in period .................................................. 8-7
8.3 Monthly inspection and maintenance ......................................................................... 8-16
8.4 Quarterly inspection and maintenance ....................................................................... 8-19
8.5 Semi-annually inspection and maintenance................................................................ 8-21
VI ZTC Series Truck Crane (25t~80t)

8.6 Inspection and maintenance every 9 months.............................................................. 8-26
ZTC Series Truck Crane (25t~80t) VII

Chapter 1 Crane Maintenance Instructions
Chapter 1
Your correct maintenance shall be an important prerequisite to ensure the value of this truck
crane. Before any maintenance, please carefully read and correctly understand this manual,
and implement daily and regular maintenance of this truck crane in accordance with the
contents and requirements of this manual. At the same time, our nationwide ZOOMLION
marketing service networks will strive to provide you with professional consultation,
maintenance and repair services. This chapter will explain the scope of responsibility for
maintenance of this crane.
1.1 Instructions to maintenance cycles

The daily and weekly maintenance is called as routine maintenance, and the maintenance over
a week is called as regular maintenance. This truck crane must be maintained periodically in
strict accordance with the technical requirements and methods as stated in this manual.
1.2 User's responsibilities

In order to ensure the usability and safety of this product for a long time, please follow the
contents and requirements as stated in this manual to implement routine and regular
maintenance of this crane, and you must fulfill the duties included but not limited to:
a) Correctly operate and use this product in accordance with the Operator’s Manual.
b) Follow the contents and requirements as stated in this manual to implement routine and
regular maintenance of this crane, but professional repair must be carried out at our
designated marketing service networks.
c) Please use ZOOMLION original accessories.
d) Timely and accurately report any fault of the crane to our designated marketing service
networks.
e) When any on-site service is required for our marketing service network personnel, you
should provide appropriate venue, equipment and tools.
f) When your equipment needs to be transferred, you must inform your local marketing
service network.
1.3 Obligations of marketing service networks

Our marketing service networks will make great effort to provide you with a full range of
after-sales services. Specifically including:
a) Provide professional product technical support.
b) Provide ZOOMLION original accessories.
c) Provide warranty services in accordance with the warranty agreement.
d) Deal with major abnormal faults and accidents.
e) Provide equipment maintenance services.
ZTC Series Truck Crane（25t~80t） 1-1

1.4 Disclaimer
Chapter 1
ZOOMLION shall bear no responsibility for any direct or indirect losses caused by the following
behaviors:
a) Mis-operation and incorrect use of the equipment.
b) Unauthorized refit and parameter adjustment of the equipment.
c) No use of ZOOMLION original parts and special oil.
d) No maintenance according to the contents and requirements as stated in this manual.
1-2 ZTC Series Truck Crane（25t~80t）

Chapter 2 Maintenance Schedule
2.1 Routine inspection and maintenance

— Superstructure
Interval
Chapter 2
Items Contents Remarks
Daily Weekly
See Section
1. Oil level and 3.1.1 for
Check the hydraulic oil level. ●
temperature maintenance
guidelines.
See Section
2. Return-line Check the filter for blockage and 5.1.3 for
●
filter damage. maintenance
guidelines.
See Section
3.2 for
Check the mounting bolts for tight fit. ●
maintenance
guidelines.
See Section
Hydraulic motor
3.2 for
Check it for leaks. ●
maintenance
guidelines.
See Section
Check the housing for deformation and 3.2 for
●
cracks. maintenance
guidelines.
See Section
Check it for abnormal noise and 3.2 for
●
vibration. maintenance
3. Hydraulic system
guidelines.
See Section
Hydraulic cylinder
3.2 for
maintenance
guidelines.
Check it for functional work. Make sure See Section
3.2 for
it does not retract inadvertently during ●
maintenance
crane operation. guidelines.
See Section
Proportional valve
3.2 for
maintenance
block
guidelines.
See Section
3.2 for
Check the bolts for tight fit. ●
maintenance
guidelines.
See Section
Balance
valve
3.2 for
maintenance
guidelines.

Interval
Daily Weekly
See Section
3.2 for
Check them for leaks. ●
maintenance
guidelines.
See Section
Pipelines and fitting
Chapter 2
3.2 for
Check them for proper seating. ●
maintenance
guidelines.
See Section
Check the pipelines for cracks and 3.2 for
●
damage. maintenance
guidelines.
See Section
Check the pipe clamps for correct 3.2 for
●
seating. maintenance
guidelines.
See Section
Check the hoisting limit switch for 3.4.1 for
●
functional work. maintenance
guidelines.
See Section
Check the lowering limit switch for 3.4.1 for
●
guidelines.
See Section
Check the warning devices for 3.4.1 for
●
4. Safety functional work. maintenance
guidelines.
indicators and See Section
devices Check the emergency stop switch for 3.4.1 for
●
guidelines.
See Section
Check the diameter of level gauge 3.4.1 for
●
bubble and the position of level gauge. maintenance
guidelines.
See Section
Check the angle indicator for functional 3.4.1 for
●
work. maintenance
guidelines.
See Section
5. Load moment 4.4.4 for
Check it for functional work. ●
limiter maintenance
guidelines.
See Section
3.5 for
Check it for damage. ●
maintenance
guidelines.
6. Wire rope See Section
3.5 for
Check it for proper lubrication. ●
maintenance
guidelines.
See Section
7. Boom, Check the boom and derricking ●
4.3.3 for

Interval
Daily Weekly
derricking cylinder shaft for proper lubrication. maintenance
guidelines.
cylinder shaft See Section
4.3.3 for
Check and tighten the chuck plate. ●
maintenance
Chapter 2
guidelines.
See Section
4.4.3 for
maintenance
guidelines.
8. Hoist gear See Section
Check whether the wire rope on the 4.4.3 for
●
drum winds uniformly. maintenance
guidelines.
See Section
4.4.2 for
9. Slewing gear Check it for leaks. ●
maintenance
guidelines.
See Section
10.Counterweight Check the counterweight lifting 4.4.5 for
●
handler cylinders for leaks. maintenance
guidelines.

— Chassis
Interval
Daily Weekly
See Section
3.1.1 for
maintenance
Chapter 2
guidelines.
See Section
3.1.2 for
Check the fuel reserve. ●
maintenance
guidelines.
See Section
3.1.3 for
Check the engine oil pressure. ●
maintenance
guidelines.
See Section
1. Liquid level, 3.1.3 for
Check the engine oil level. ●
pressure and maintenance
temperature guidelines.
See Section
Check the engine coolant 3.1.4 for
●
temperature. maintenance
guidelines.
See Section
Check the liquid level in the expansion 3.1.4 for
●
tank. maintenance
guidelines.
See Section
3.1.5 for
Check the AdBlue level. ●
maintenance
guidelines.
See Section
3.2 for
Check it for tight fit and damage. ●
2. Hydraulic System
maintenance
Hydraulic pump
guidelines.
See Section
3.2 for
maintenance
guidelines.
Check it for abnormal noise and ● See Section

Interval
Daily Weekly
vibration. 3.2 for

maintenance
guidelines.
Chapter 2
See Section
Check whether the neutral position
3.2 for
pressure of the hydraulic pump is in ●
maintenance
normal range.
guidelines.
See Section
Check the pipe fittings for proper 3.2 for
●
seating and leaks. maintenance
guidelines.
See Section
3.2 for
●
Hydraulic cylinder
Check it for leaks.

maintenance
guidelines.
See Section
Examine it for functional work. Make
3.2 for
sure it does not retract inadvertently ●
maintenance
during crane operation.
guidelines.
See Section
Clean off the contamination on the 3.2 for
●
tank. maintenance
guidelines.
Hydraulic oil tank
See Section
2. Hydraulic System
3.2 for
Check it for tight fit. ●
maintenance
guidelines.
See Section
3.2 for
maintenance
guidelines.
See Section
Pipelines and joints
3.2 for
maintenance
guidelines.
See Section
Check them for tight fit. ●
3.2 for

Interval
Daily Weekly
maintenance
guidelines.
See Section
Chapter 2
Check the pipelines for cracks and 3.2 for

●
damage. maintenance
guidelines.
See Section
3.2 for
Check the pipe clamp for tight fit. ●
maintenance
guidelines.
See Section
Check the transmission and axles for 3.3.2 for
●
leaks. maintenance
guidelines.
See Section
3. Oil and water Check the antifreeze and 3.3.2 for
anti-corrosive fluid in the engine ●
leakage cooling system for leaks. maintenance
guidelines.
See Section
Check the pipelines of the fuel supply 3.3.2 for
●
system for leaks. maintenance
guidelines.
See Section
3.4.2 for
Check the engine oil pressure gauge. ●
maintenance
guidelines.
See Section
Check the warning light “charging 3.4.2 for
4. Safety ●
monitoring” and voltmeter. maintenance
indicators and
guidelines.
devices
See Section
3.4.2 for
Check the water thermometer. ●
maintenance
guidelines.
See Section
Check the air pressure gauge. ●
3.4.2 for

Interval
Daily Weekly
maintenance
guidelines.
See Section
Chapter 2
3.4.2 for
Check the service brake. ●
maintenance
guidelines.
See Section
3.4.2 for
Check the parking brake ●
maintenance
guidelines.
See Section
3.4.2 for
Check the engine fault indicator. ●
maintenance
guidelines.
See Section
Check the warning light “Filter 3.4.2 for
●
cartridge blocked”. maintenance
guidelines.
See Section
Check the lights and signal devices 3.4.2 for
●
special for the vehicle during driving. maintenance
guidelines.
See Section
3.6 for
Check the steering mechanism. ●
maintenance
guidelines.
See Section
3.6 for
Check the system for functional work. ●
5. Steering maintenance
system guidelines.
See Section
3.6 for
maintenance
guidelines.
See Section
Check the wheel alignment. ●
3.6 for

Interval
Daily Weekly
maintenance
guidelines.
See Section
Chapter 2
3.7 for
Check the brake pressure. ●
maintenance
guidelines.
See Section
Check the sealing performance of air 3.7 for
●
line. maintenance
guidelines.
6. Brake system
See Section
3.7 for
Check the brake performance. ●
maintenance
guidelines.
See Section
Drain off the accumulated water in the 3.7 for
●
air reservoir. maintenance
guidelines.
See Section
3.8 for
Check the tire pressure. ●
maintenance
guidelines.
See Section
3.8 for
Clean up the tire tread surface. ●
maintenance
guidelines.
See Section
7. Wheels / tires
Clean off the contamination on the 3.8 for
●
wheel rim. maintenance
guidelines.
See Section
3.8 for
Check the wheel rim for cracks. ●
maintenance
guidelines.
See Section
Check the wheel nuts. ●
3.8 for

Interval
Daily Weekly
maintenance
guidelines.
See Section
Chapter 2
5.4.6 for
Check it for proper connections. ●
maintenance
8. Suspension guidelines.
system See Section
5.4.6 for
Check the thrust rod support. ●
maintenance
guidelines.
See Section
Check the transmission ventilation 5.2.3 for
9. Transmission ●
cap. maintenance
guidelines.
See Section
Check the ventilation plug of drive 5.5.3 for
10. Drive axles ●
axles. maintenance
guidelines.
See Section
5.1.7 for
11. Battery Check the voltage. ●
maintenance
guidelines.

2.2 Inspection and maintenance during break-in period
— Superstructure
Interval (whichever
comes first)
Chapter 2
Calendar Service
month hours
See Section
5.1.3 for
Clean the filter element. 200 hours
maintenance
guidelines.
1. Return-line filter
See Section
Check the filter element for 5.1.3 for
200 hours
damage. maintenance
guidelines.
Check whether the work See Section 3.2
pressure of the system is in 200 hours for maintenance
normal range. guidelines.
See Section 3.2
Check the hydraulic pump for
200 hours for maintenance
functional work.
guidelines.
See Section 3.2
Check the valves for leaks. 200 hours for maintenance
guidelines.
2. Hydraulic
Check the pipelines and See Section 3.2
system
fittings for tight fit, leaks, 200 hours for maintenance
deformation and cracks. guidelines.
See Section 3.2
Replace pilot oil filter
250 hours for maintenance
element.
guidelines.
See Section
Replace hydraulic oil filter 5.1.3 for
250 hours
element. maintenance
guidelines.
See Section
Replace the lubricating oil of 4.4.3 for
500 hours
winch reducer. maintenance
guidelines.
3. Hoist gear
See Section
Check the hoist winch for 4.4.3 for
200 hours
leaks. maintenance
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Check whether the wire rope 4.4.3 for
200 hours
Chapter 2
on the drum winds uniformly. maintenance
guidelines.
Check whether the See Section 3.5
4. Wire rope telescoping rope is in good 200 hours for maintenance
state. guidelines.
See Section
Check whether the slewing 4.4.2 for
200 hours
bearing is lubricated properly. maintenance
guidelines.
See Section
Clean the tooth surface of 4.4.2 for
200 hours
slewing bearing. maintenance
guidelines.
See Section
Check the mounting bolts of 4.4.2 for
200 hours
slewing bearing for tight fit. maintenance
guidelines.
5. Slewing gear
See Section
Replace the lubricating oil of 4.4.2 for
500 hours
slewing reducer. maintenance
guidelines.
See Section
Check the slewing gear for 4.4.2 for
200 hours
leaks maintenance
guidelines.
See Section
4.4.2 for
Check the slewing clearance. 200 hours
maintenance
guidelines.
See Section
Check the lock plate bolt at
4.3.3 for
6. Derricking gear the derricking cylinder 200 hours
maintenance
fulcrum pin for tight fit.
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Check the derricking cylinder 4.3.3 for
Chapter 2
200 hours
for leaks. maintenance
guidelines.
See Section
Check the derricking cylinder
4.3.3 for
for abnormal noise and 200 hours
maintenance
vibration.
guidelines.
See Section
Check the welding seams for 4.6.1 for
7. Slewing table 200 hours
cracks. maintenance
guidelines.
See Section
Check the telescoping 4.4.1 for
200 hours
system for functional work. maintenance
guidelines.
Check whether the See Section
telescoping cylinder retracts 4.4.1 for
200 hours
inadvertently during crane maintenance
operation. guidelines.
See Section
8.Telescoping Check the pipelines and 4.4.1 for
200 hours
system fittings for tight fit. maintenance
guidelines.
See Section
Check the hoses for 4.4.1 for
200 hours
deformation and damage. maintenance
guidelines.
See Section
Check the telescoping 4.4.1 for
200 hours
cylinder for leaks. maintenance
guidelines.
See Section
9. Boom 200 hours
cracks. maintenance
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Adjust the clearance of the 4.6.2 for
200 hours
Chapter 2
slide blocks. maintenance
guidelines.
See Section
Check whether the pulley
4.6.2 for
block rotates easily and 200 hours
maintenance
smoothly.
guidelines.
10. Counterweight counterweight lifting cylinders 4.4.5 for
200 hours
handler can extend/retract maintenance
simultaneously. guidelines.
See Section
Examine the 5th outrigger
5.4.1 for
overpressure protection 200 hours
maintenance
device for functional work.
guidelines.
See Section
Check the outriggers for 5.4.1 for
11. Outriggers 200 hours
guidelines.
See Section
Adjust the tightness of 5.4.1 for
200 hours
telescoping rope. maintenance
guidelines.
See Section
Check the hoisting limit 3.4.1 for
200 hours
switch. maintenance
guidelines.
See Section
12. Safety
Check the lowering limit 3.4.1 for
indicators and 200 hours
switch. maintenance
devices
guidelines.
See Section
Check the angle indicator for 3.4.1 for
200 hours
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Check the level gauge for 3.4.1 for
200 hours
Chapter 2

guidelines.
See Section
Check the load moment 4.4.4 for
200 hours
limiter for functional work. maintenance
guidelines.

— Chassis
Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Chapter 2
5.2.3 for
Check the ventilation cap. 3 months 3000 km
maintenance
guidelines.
1. Transmission
See Section
5.2.3 for
Replace the lubricating oil. 3 months 3000 km
maintenance
guidelines.
See Section
Check whether the kingpin of 5.5.3 for
3 months 3000 km
steer axle is lubricated properly. maintenance
guidelines.
See Section
5.5.3 for
Clean the ventilation holes. 3 months 3000 km
maintenance
guidelines.
2. Axles
See Section
Check the connecting bolts and
5.5.3 for
clamps of steering trapezoid for 3 months 3000 km
maintenance
tight fit.
guidelines.
See Section
Adjust clearance of the brake 5.5.3 for
3 months 3000 km
shoe. maintenance
guidelines.
See Section
Check and lubricate the steering 5.2.6 for
3 months 3000 km
column universal joint. maintenance
3. Lubricating guidelines.
grease See Section
Check and lubricate the universal 5.2.6 for
3 months 3000 km
joint bearing of propeller shaft. maintenance
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Check and lubricate the sliding 5.2.6 for
Chapter 2
3 months 3000 km
splines of propeller shaft. maintenance
guidelines.
See Section
Check and lubricate the
5.2.6 for
intermediate bearing of propeller 3 months 3000 km
maintenance
shaft.
guidelines.
See Section
Check and lubricate the angle 5.2.6 for
3 months 3000 km
drive device. maintenance
guidelines.
See Section
Check and lubricate the oil pump 5.2.6 for
3 months 3000 km
guidelines.
See Section
3 months 3000 km
joint of oil pump propeller shaft. maintenance
guidelines.
See Section
Check and lubricate the rocker 5.2.6 for
3 months 3000 km
arm shaft. maintenance
guidelines.
See Section
Check and lubricate other 5.2.6 for
3 months 3000 km
lubricating points. maintenance
guidelines.
See Section
Check and lubricate the kingpin of 5.2.6 for
3 months 3000 km
steer axle. maintenance
guidelines.
See Section
5.3 for
4. Key fasteners Check the wheel nuts for tight fit. 3 months 3000 km
maintenance
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Check the nuts of propeller shaft 5.3 for
Chapter 2
3 months 3000 km
for tight fit. maintenance
guidelines.
See Section
3 months 3000 km
intermediate bearing for tight fit. maintenance
guidelines.
See Section
5.3 for
Check the U-bolt for tight fit. 3 months 3000 km
maintenance
guidelines.
See Section
Check the mounting bolts of 5.3 for
3 months 3000 km
engine for tight fit. maintenance
guidelines.
See Section
4. Key fasteners 3 months 3000 km
transmission for tight fit. maintenance
guidelines.
See Section
Check the thrust rod bolts and 5.3 for
3 months 3000 km
clamp nuts for tight fit. maintenance
guidelines.
See Section
Check the ball joint nuts and
5.3 for
clamp nuts of the steering drag 3 months 3000 km
maintenance
rod for tight fit.
guidelines.
See Section
5.3 for
clamp nuts of the steering booster 3 months 3000 km
maintenance
cylinder for tight fit.
guidelines.
See Section
Check the nuts of brake chamber 5.3 for
3 months 3000 km
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Check the mounting bolts of the oil 5.3 for
Chapter 2
3 months 3000 km
pump for tight fit. maintenance
guidelines.
4. Key fasteners
See Section
Check the mounting bolts of the 5.3 for
3 months 3000 km
driver’s cab for tight fit. maintenance
guidelines.
See Section
Check the system for functional 3.6 for
3 months 3000 km
work. maintenance
guidelines.
See Section
3.6 for
Check and adjust the wheel toe-in. 3 months 3000 km
maintenance
guidelines.
See Section
5. Steering Check the steering hydraulic 3.6 for
3 months 3000 km
system circuit for leaks. maintenance
guidelines.
See Section
Make sure that the work pressure
3.6 for
of the hydraulic system is in 3 months 3000 km
maintenance
normal range.
guidelines.
See Section
Check the pipes and fittings for
3.6 for
tight fit, leaks, deformation and 3 months 3000 km
maintenance
cracks.
guidelines.
See Section
3.7 for
Check the brake pressure. 3 months 3000 km
maintenance
guidelines.
6. Brake system
See Section
Check the sealing performance of 3.7 for
3 months 3000 km
air line. maintenance
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
3.7 for
Chapter 2
Check the brake performance. 3 months 3000 km
maintenance
guidelines.
See Section
5.4.6 for
Check the thrust rod. 3 months 3000 km
maintenance
guidelines.
See Section
Check the balance suspension 5.4.6 for
3 months 3000 km
and the support. maintenance
7. Suspension guidelines.
system See Section
Check the leaf spring and the 5.4.6 for
3 months 3000 km
rubber spring. maintenance
guidelines.
See Section
5.4.6 for
Check the shock absorber. 3 months 3000 km
maintenance
guidelines.
See Section
Check the flanged bolts and nuts 5.4.7 for
3 months 3000 km
of propeller shaft for tight fit. maintenance
guidelines.
Check the propeller shaft. Check
the cross shaft and shaft fork for
tight fit, damages and See Section
8. Propeller deformations. Check the propeller 5.4.7 for
3 months 3000 km
shaft shaft tubes for deformations, maintenance
damages and cracks. Check guidelines.
whether there is balance block fell
off.
See Section
Check the intermediate bearing 5.4.7 for
3 months 3000 km
for damages and proper seating. maintenance
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Check the U-bolts of suspension 5.2.4 for
Chapter 2
3 months 3000 km
for correct connection. maintenance
guidelines.
See Section
Check the bolts of thrust rod for 5.2.4 for
3 months 3000 km
correct connection. maintenance
guidelines.
See Section
5.2.4 for
Check the thrust rod ball cup. 3 months 3000 km
maintenance
guidelines.
See Section
5.2.4 for
Check the steering rod ball end. 3 months 3000 km
maintenance
9. Wheel guidelines.
alignment See Section
(only applied 5.2.4 for
Check the rocker arm bearing. 3 months 3000 km
for all-wheel maintenance
steer guidelines.
products) See Section
5.2.4 for
Check the steering coupling fork. 3 months 3000 km
maintenance
guidelines.
See Section
Check the ball end of trapezoidal 5.2.4 for
3 months 3000 km
mechanism. maintenance
guidelines.
See Section
Adjust the neutral position of the 5.2.4 for
3 months 3000 km
steering wheel. maintenance
guidelines.
See Section
Check the toe-in of each steer 5.2.4 for
3 months 3000 km
axle. maintenance
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
5.2.4 for
Chapter 2
Align the steer axles. 3 months 3000 km
maintenance
guidelines.
See Section
10. Steer drive 5.2.4 for
Replace gear oil. 3 months 3000 km
axle maintenance
guidelines.
See Section
11.Drive axle 5.2.4 for
(Non-steer) maintenance
guidelines.
See Section
12. Return-line Replace the hydraulic oil filter 5.1.3 for
3 months 3000 km
filter element. maintenance
guidelines.

2.3 Monthly inspection and maintenance
— Superstructure
Interval (whichever
comes first)
Chapter 2
Calendar Service
month hours
See Section
Check the level and quality of the 4.4.2 for
1 month 100 hours
gear oil in slewing reducer. maintenance
guidelines.
See Section
1.Slewing Check whether the slewing bearing is 4.4.2 for
1 month 100 hours
gear lubricated properly. maintenance
guidelines.
See Section
Clean the tooth surface of slewing 4.4.2 for
1 month 100 hours
bearing. maintenance
guidelines.
See Section
Check the level and quality of gear oil
4.4.3 for
2. Hoist gear in the reducers of main 1 month 100 hours
maintenance
(auxiliary).winch
guidelines.
See Section
Check the lubricating grease in cable 4.4.6 for
3. Cable reel 1 month 100 hours
reel pulley, and add it if necessary. maintenance
guidelines.

— Chassis
Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Chapter 2
4.4.2 for
Check the oil level in transmission. 1 month 1000 km
maintenance
guidelines.
1. Oil level
See Section
Check the gear oil level in drive 4.4.2 for
1 month 1000 km
axle. maintenance
guidelines.
See Section
1 month 1000 km
joint of steering column. maintenance
guidelines.
See Section
1 month 1000 km
joint bearing of propeller shaft. maintenance
guidelines.
See Section
Check and lubricate the sliding 5.2.6 for
1 month 1000 km
splines of propeller shaft. maintenance
2. Lubricating guidelines.
grease See Section
5.2.6 for
intermediate bearing of propeller 1 month 1000 km
maintenance
shaft.
guidelines.
See Section
Check and lubricate the angle drive 5.2.6 for
1 month 1000 km
device. maintenance
guidelines.
See Section
Check and lubricate the oil pump 5.2.6 for
1 month 1000 km
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Chapter 2
1 month 1000 km
joint of oil pump propeller shaft. maintenance
guidelines.
See Section
Check and lubricate the rocker arm 5.2.6 for
1 month 1000 km
shaft. maintenance
guidelines.
See Section
Check and lubricate the kingpin of 5.2.6 for
1 month 1000 km
guidelines.
See Section
5.3 for
Check the wheel nuts for tight fit. 1 month 1000 km
maintenance
guidelines.
See Section
Check the nuts of propeller shaft for 5.3 for
1 month 1000 km
tight fit. maintenance
guidelines.
See Section
1 month 1000 km
intermediate bearing for tight fit. maintenance
3. Key guidelines.
fasteners See Section
5.3 for
Check the U-bolt for tight fit. 1 month 1000 km
maintenance
guidelines.
See Section
Check the bolts and clamp nuts of 5.3 for
1 month 1000 km
thrust rod for tight fit. maintenance
guidelines.
See Section
Check the ball joint nuts and clamp
5.3 for
nuts of the steering drag rod for tight 1 month 1000 km
maintenance
fit.
guidelines.

Interval (whichever
comes first)
Calendar
Mileages
month
See Section
Check the ball joint nuts and clamp
5.3 for
Chapter 2
nuts of the steering booster cylinder 1 month 1000 km
maintenance
for tight fit.
guidelines.
See Section
Check the nuts of brake chamber 5.3 for
1 month 1000 km
guidelines.
See Section
Check the mounting bolts of the oil 5.3 for
1 month 1000 km
pump for tight fit. maintenance
guidelines.

2.4 Quarterly inspection and maintenance
— Superstructure
Interval (whichever
comes first)
Chapter 2
Calendar Service
month hours
See Section
Check the quality of the 5.2.5 for
1. Hydraulic oil 3 months 250 hours
hydraulic oil. maintenance
guidelines.
See Section
Check the wire rope for good 3.5 for
3 months 250 hours
state. maintenance
guidelines.
2. Wire rope
See Section
3.5 for
Check the lubrication state. 3 months 250 hours
maintenance
guidelines.
See Section
Check the gear oil, and add it 4.2.1 for
3. Winch reducer 3 months 250 hours
if necessary. maintenance
guidelines.
See Section
Check the gear oil, and add it 4.2.2 for
4. Slewing reducer 3 months 250 hours
if necessary. maintenance
guidelines.
5. Counterweight counterweight lifting cylinders 4.4.5 for
3 months 250 hours
handler can extend/retract maintenance
simultaneously. guidelines.
See Section
Check the filter element and 5.1.3 for
3 months 250 hours
drain the sediment. maintenance
guidelines.
See Section
Check the filter element for 5.1.3 for
3 months 250 hours
damage. maintenance
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Check and clean the
7. Central collecting 4.4.7 for
electrical brush and the 3 months 250 hours
Chapter 2
ring maintenance
electrical ring.
guidelines.

— Chassis
Interval (whichever comes first)

Items Contents Calendar Mileages / Remarks
month Service hours
See Section
Chapter 2
3000 km / 5.2.2 for

Replace the engine oil. 3 months
250 hours maintenance
guidelines.
See Section
Replace the engine oil filter 3000 km / 5.2.2 for
3 months
1. Engine element. 250 hours maintenance
and its guidelines.
peripheral See Section
systems Replace the fuel coarse filter 3000 km / 5.1.1 for
3 months
element. 250 hours maintenance
guidelines.
See Section
3000 km / 5.1.2 for
Clean the air filter element. 3 months
250 hours maintenance
guidelines.
See Section
3 months 3000 km
engine for tight fit. maintenance
guidelines.
See Section
2. Key Check the mounting bolts of 5.3 for
3 months 3000 km
fasteners transmission for tight fit. maintenance
guidelines.
See Section
3 months 3000 km
the driver’s cab for tight fit. maintenance
guidelines.
See Section
3. Wheels / 5.5.4 for
Check the tires for abrasion. 3 months 3000 km
tires maintenance
guidelines.

2.5 Semi-annually inspection and maintenance
— Superstructure
Interval (whichever
comes first)
Chapter 2
Calendar Service
month hours
See Section
1. Return-line Replace the hydraulic oil filter 5.1.3 for
6 months 500 hours
guidelines.
See Section
4.2.2 for
Tighten the mounting bolts. 6 months 500 hours
maintenance
2. Slewing guidelines.
reducer See Section
4.2.2 for
Replace the gear oil. 6 months 500 hours
maintenance
guidelines.
See Section
4.2.1 for
Tighten the mounting bolts. 6 months 500 hours
maintenance
3. Winch guidelines.
reducer See Section
Replace the gear oil of main and 4.2.1 for
6 months 500 hours
auxiliary winches. maintenance
guidelines.
See Section
Check the pipe and cable of A/C 4.1.2 for
6 months 500 hours
for proper connections. maintenance
4. Air guidelines.
conditioning See Section
Check the heating and cooling 4.1.2 for
6 months 500 hours
effect. maintenance
guidelines.
See Section
Check the counterweight lifting
4.4.5 for
5.Counterweight cylinders and its main body for 6 months 500 hours
maintenance
cracks
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
Chapter 2
6 months 500 hours

cracks. maintenance
guidelines.
6. Slewing table
See Section
Check the slewing table for 4.6.1 for
6 months 500 hours
deformation and cracks. maintenance
guidelines.
See Section
6 months 500 hours
cracks. maintenance
guidelines.
See Section
4.6.2 for
Check the boom for deformation. 6 months 500 hours
maintenance
guidelines.
7. Boom
See Section
Check the pulleys and rollers for 4.6.2 for
6 months 500 hours
damage. maintenance
guidelines.
See Section
Lubricate the slide blocks and 4.6.2 for
6 months 500 hours
adjust their clearance. maintenance
guidelines.
See Section
6 months 500 hours
cracks. maintenance
guidelines.
See Section
Check the boom for cracks and 4.6.3 for
8. Jib 6 months 500 hours
deformation. maintenance
guidelines.
See Section
4.6.3 for
Check the pulleys for damage. 6 months 500 hours
maintenance
guidelines.

Interval (whichever
comes first)
Calendar Service
month hours
See Section
4.6.4 for
Check the pulley for damage. 6 months 500 hours
Chapter 2
maintenance
guidelines.
See Section
4.6.4 for
9. Hook Check the bearing for damage. 6 months 500 hours
maintenance
guidelines.
See Section
4.6.4 for
Check the hook for damage. 6 months 500 hours
maintenance
guidelines.
See Section
4.4.6 for
10.Cable reel Adjust the length detection value. 6 months 500 hours
maintenance
guidelines.

— Chassis
Interval
(whichever comes first)
Items Contents Mileages / Remarks
Calendar
Service
month
hours
Chapter 2
See Section
Check the hydraulic oil 5.2.5 for
6 months 5000 km
quality. maintenance
guidelines.
See Section
Check the gear oil quality of 5.2.3 for
1. Oil quality 6 months 5000 km
transmission. maintenance
guidelines.
See Section
Check the gear oil quality of 5.2.4 for
6 months 5000 km
axles. maintenance
guidelines.
See Section
engine
Diesel
5.4.2 for
Check it for proper seating. 6 months 5000 km
maintenance
guidelines.
Check the water tank for
See Section
proper seating, and check
5.4.2 for
the water pipe for tight fit, 6 months 5000 km
Cooling system
maintenance
aging, damage and
guidelines.
deformation.
2. Engine
See Section
and its
Clean the surface of water 5.4.2 for
peripheral 6 months 5000 km
tank radiator. maintenance
control
guidelines.
system
Check the intercooler for
See Section
proper seating, and check
5.4.2 for
Intercooling system
the intercooling pipe for 6 months 5000 km

maintenance
tight fit, aging, damage and
guidelines.
deformation.
See Section
Clean the surface of 5.4.2 for
6 months 5000 km
intercooler radiator. maintenance
guidelines.

Interval
Calendar
Service
month
hours
See Section
Chapter 2
5.4.2 for
Fuel supply system

maintenance
guidelines.
See Section
Drain off and clean the fuel 5.4.2 for
6 months 5000 km
coarse filter. maintenance
guidelines.
See Section
Air intake
system
Replace the air filter 5.1.2 for

6 months 5000 km
guidelines.
See Section
Exhaust
system
5.1.2 for
maintenance
guidelines.
See Section
Replace the air dryer 5.1.5 for
3. Brake system 6 months 5000 km
guidelines.
See Section
Check the U-bolts of
5.4.8 for
suspension for correct 6 months 5000 km
maintenance
connection.
guidelines.
See Section
Check the bolts of thrust rod 5.4.8 for
6 months 5000 km
for correct connection. maintenance
4. Wheel alignment
(only applied for guidelines.
all-wheel steer See Section
products)
Check the thrust rod ball 5.4.8 for
6 months 5000 km
cup. maintenance
guidelines.
See Section
Check the steering rod ball 5.4.8 for
6 months 5000 km
end. maintenance
guidelines.

Interval
Calendar
Service
month
hours
See Section
Chapter 2
Check the rocker arm 5.4.8 for

6 months 5000 km
guidelines.
See Section
Check the steering coupling 5.4.8 for
6 months 5000 km
fork. maintenance
guidelines.
See Section
Check the ball end of 5.4.8 for
6 months 5000 km
trapezoidal mechanism. maintenance
guidelines.
See Section
5.4.8 for
Check the steering wheel. 6 months 5000 km
maintenance
guidelines.
See Section
Check the toe-in of each 5.4.8 for
6 months 5000 km
guidelines.
See Section
5.4.8 for
maintenance
guidelines.
See Section
5.5.3 for
Clean the ventilation holes. 6 months 5000 km
maintenance
guidelines.
5. Axles
See Section
Check the welding seam of 5.5.3 for
6 months 5000 km
axle housing. maintenance
guidelines.
See Section
5.5.4 for
6. Wheels Transpose the wheels. 6 months 5000 km
maintenance
guidelines.

Interval
Calendar
Service
month
hours
See Section
Chapter 2
5.5.4 for
Check the valve mouth. 6 months 5000 km
maintenance
guidelines.
See Section
Check the key welding 5.5.1 for
7. Chassis frame 6 months 5000 km
seams. maintenance
guidelines.
See Section
Check the pulley assy. for 5.4.1 for
6 months 5000 km
wear. maintenance
guidelines.
See Section
Check fixing bolts of
5.4.1 for
8. Outrigger horizontal cylinders for tight 6 months 5000 km
maintenance
fit.
guidelines.
See Section
Check the wire rope for 5.4.1 for
6 months 5000 km
tightening. maintenance
guidelines.
See Section
Replace the hydraulic oil 5.1.3 for
9.Return-line filter 6 months 500 hours
guidelines.

2.6 Inspection and maintenance every 9 months
— Superstructure
Interval
Chapter 2
Calendar Service
month hours
See Section
Telescoping Check and lubricate the slide 4.4.1 for
9 months 750 hours
system blocks. maintenance
guidelines.
— Chassis
Interval
Calendar
Mileages
month
See Section
Check the connecting cable for 5.1.7 for
9 months 7500 km
good connection. maintenance
guidelines.
Battery
See Section
Check the terminal post for rust 5.1.7 for
9 months 7500 km
and corrosion. maintenance
guidelines.

— Chassis
Interval
Chapter 2
Calendar
Mileages
month
See Section
5.2.1 for
1. Engine Replace the engine coolant. 12 months 10000 km
maintenance
guidelines.
See Section
5.2.3 for
2. Transmission Replace the gear oil. 12 months 10000 km
maintenance
guidelines.
See Section
Replace the lubricating oil of
5.5.3 for
hub reducer and central 12 months 10000 km
maintenance
reducer.
guidelines.
3. Axles
See Section
Lubricate the drive axle hub 5.5.3 for
12 months 10000 km
guidelines.
See Section
4. High Replace the
5.1.6 for
temperature high-temperature hose at the 12 months 10000 km
maintenance
hose air pump outlet.
guidelines.
See Section
Replace the coarse fuel filter 5.1.1 for
12 months 10000 km
guidelines.
See Section
5. Fuel supply Replace the fine fuel filter 5.1.1 for
12 months 10000 km
system element. maintenance
guidelines.
See Section
5.1.1 for
Clean the fuel tank. 12 months 10000 km
maintenance
guidelines.

Interval
Calendar
Mileages
month
See Section
5.2.1 for
Chapter 2

maintenance
6. Cooling guidelines.
system See Section
5.2.1 for
Check and clean the radiator. 12 months 10000 km
maintenance
guidelines.
See Section
7. Steering 3.6 for
Replace the hydraulic oil. 12 months 10000 km
system maintenance
guidelines.
See Section
8. Clutch control Replace the clutch brake 5.4.4 for
12 months 10000 km
mechanism fluid. maintenance
guidelines.
See Section
9. Steer drive 5.2.4 for
Replace the gear oil. 12 months 10000 km
axle maintenance
guidelines.
See Section
10. Drive axle 5.2.4 for
(non-steer) maintenance
guidelines.

— Superstructure
Interval
Chapter 2
Calendar Service
month hours
See Section
Hydraulic 4.2.3 for
Replace the hydraulic oil. 18 months 1500 hours
system maintenance
guidelines.
— Chassis
Interval
Calendar Service
month hours
See Section
Outrigger Check whether the outrigger
5.4.1 for
telescoping spreads L and W satisfy the 18 months 1500 hours
maintenance
system requirements.
guidelines.

— Superstructure
Interval
Calendar Service
Chapter 2
month hours
See Section
1. Hydraulic 4.1.1 for
Replace the hydraulic hose. 24 months 2000 hours
hose maintenance
guidelines.
See Section
2. Slewing 4.4.2 for
Check the slewing clearance. 24 months 2000 hours
gear maintenance
guidelines.

— Chassis
Interval
Calendar
Mileages
month
Chapter 2
See Section
3.7 for
Replace the brake hose. 24 months 20000 km
maintenance
guidelines.
See Section
5.4.2 for
Replace the fuel hose. 24 months 20000 km
maintenance
guidelines.
See Section
Replace the water hose of 5.4.2 for
24 months 20000 km
engine. maintenance
guidelines.
See Section
Hoses and Replace the intercooler hose of 5.4.2 for
24 months 20000 km
shock pads engine. maintenance
guidelines.
See Section
Replace the air intake hose of 5.4.2 for
24 months 20000 km
engine. maintenance
guidelines.
See Section
Replace the shock pad of. 5.4.2 for
24 months 20000 km
engine maintenance
guidelines.
See Section
Replace the shock pad of 5.4.2 for
24 months 20000 km
radiator maintenance
guidelines.

Chapter 3 Daily Inspect and Maintenance Guidelines
3.1 Inspection of liquid level, pressure and temperature

3.1.1 Inspection of hydraulic oil level and temperature
[Prerequisites]
a) Check them when necessary.
b) Check them according to the schedule.
[Working requirements]
Free of dust and rain.
The vehicle is in driving state, and the engine is shut off.
Chapter 3
[Preparation of tools]
Clean rag and lighting equipment
[Check items and standards]
a) Check the oil level.
The hydraulic oil level should be between the Min. and Max. marks.
b) Check the oil temperature.
When the crane is in operation, the oil temperature cannot be more than 80°C.
[Inspection procedures and methods]
a) Check the oil level.
1) Check the hydraulic oil level through the liquid level gauge to ensure it is between the
Max. and Min. marks, as shown in Figure 3-1. When the oil level is below the Min.
mark, add hydraulic oil till it is between the Max. and Min. marks.
Max. mark
Min. mark
Figure 3-1 Hydraulic oil level of hydraulic oil tank
2) Check the oil level in steering oil tank through the oil dipstick, as shown in Figure 3-2.
When the oil level is below the Min. mark, add hydraulic oil till it is between the Max.
and Min. marks.

Max. mark
Min. mark
Chapter 3
Figure 3-2 Hydraulic oil level in steering oil tank
CAUTION
(1) If the oil level is below the Min. mark, add specified hydraulic oil according to
the Table for Oil and Medium Capacities till it is between the Max. and Min.
marks. Do not make the oil exceed the Max. mark.
(2) When adding the hydraulic oil, you should use a fine filter to keep the oil clean
and prevent contamination.
b) Check the oil temperature.

Check the oil temperature through the liquid level gauge installed on the hydraulic oil tank.
When the crane is in operation, the hydraulic oil temperature cannot more than 80°C.
Otherwise, you should immediately stop to check it.
3.1.2 Inspection of oil level in fuel tank

[Prerequisites]
a) Check when necessary.
b) Check according to the schedule.
None
CAUTION
Make sure that the fuel you use in the crane has the correct viscosity. Make your
selection on the lowest temperature you operate in.
Make sure that the fuel tank is full. Condensation, rust and sediment can freeze and
cause a blockage in the flow of fuel. The engine cannot start if the fuel does not flow or
flows too slowly.

Check the fuel gauge or fuel indicating bar. The numerical value should be between 0 - 1. “0”
indicates the fuel tank is empty while “1” indicates that the fuel tank is full.
CAUTION
If the pointer of fuel gauge is pointing to the red zone, it shows that you should check
the fuel tank and add more fuel oil.

Switch on the power supply of the complete vehicle, but do not start the engine. Examine the
fuel reserve via the instrument in driver’s cab as well as fuel gauge or combination display in
Chapter 3
the operator’s cab. If it is insufficient, add the appropriate fuel in accordance with the Table for
Oil and Medium Capacities.
a) Check the fuel reserve via the fuel gauge, as shown in Figure 3-3.
Figure 3-3 Oil level indicated in fuel gauge
b) Check the fuel reserve via the combination display, as shown in Figure 3-4.
Figure 3-4 Oil level indicated in combination display
3.1.3 Inspection of engine oil level and pressure

[Prerequisites]
a) Check the oil level: Stop the vehicle on a level load-bearing surface, shut down the engine
and apply the parking brake.
b) Check the oil pressure: Start the engine and drive the vehicle.

Clean rag and lighting equipment.
a) Check to see whether the engine oil level is between the Max. and Min. marks on the oil
dipstick.
b) Check to see whether the engine oil pressure is between 0.2 MPa and 0.55 MPa.
a) Check the engine oil level.
Pull out the oil dipstick and observe whether the level is between the Max. and Min. marks.
If the oil level approaches the Min. mark, add engine oil immediately.
Chapter 3
CAUTION
(1) After observing the level, the oil dipstick should be reset to prevent oil leakage.
(2) Add suitable engine oil according to the Table for Oil and Medium Capacities.
(3) Carefully check the oil dipstick, turbocharger and air compressor for oil
leakage.
b) Check the engine oil pressure.

Check the engine oil pressure after the engine started. Do not drive the vehicle or carry out
superstructure movements until the engine oil is in normal value.
Check the engine oil pressure via the engine oil pressure gauge or the combination
display.
1) Check the engine oil pressure via the engine oil pressure gauge, as shown in Figure
3-5.
Figure 3-5 Engine oil pressure gauge
2)

Check the engine oil pressure via the combination display, as shown in Figure 3-6.
After the engine is started, the engine oil pressure will be instantly displayed.
Figure 3-6 Engine oil pressure indicated in combination display
When the engine is idling, the engine oil pressure cannot be less than 0.1 MPa. With
normal engine RPM, the engine oil pressure must be between 0.2 MPa and 0.55
MPa.
WARNING
Chapter 3
If the engine oil pressure is too high or too low, immediate maintenance or
repair should be carried out.
CAUTION
If the warning light “Engine oil pressure too low” illuminates, the oil pressure is
too low or the oil filter is blocked. Stop the vehicle immediately and rectify it.
Otherwise, the engine may be severely damaged due to excessively low oil
pressure.
3.1.4 Inspection of engine coolant level and temperature

[Prerequisites]
a) The coolant level in the expansion water tank is not within the specified range or the
warning light “Engine coolant level too low” illuminates.
b) The warning light “Engine coolant temperature too high” illuminates.
c) Check according to the schedule.
a) Free of dust and rain.
b) Check the liquid level: Stop the vehicle on a level load-bearing surface, shut down the
engine and apply the parking brake.
c) Check the liquid temperature: Start the engine and drive the vehicle.
Clean rag and lighting equipment.

a) Check the liquid level.
If the warning light “Engine coolant temperature too high” or the warning light “Engine
coolant level too low” in the driver's cab illuminates, check whether the coolant level is
between the Max. and Min. marks.
Chapter 3
Figure 3-7-a Warning light – Engine Figure 3-7-b Warning light – Engine
coolant temperature too high coolant level too low
b) Check the coolant temperature.

The engine coolant temperature shall not be higher than 96°C.
CAUTION
Add the engine coolant of the same brand according to the Table for Oil and
Medium Capacities.
a) Check the engine coolant level.
Observe to ensure that the liquid level is between Min. and Max. marks on the liquid level
gauge, as shown in Figure 3-8. If it is insufficient, unscrew the filler cap to fill coolant.
Filler cap
Liquid level
gauge
Max
Min
Figure 3-8 Liquid level in expansion water tank

b) Check the engine coolant temperature.
Check the coolant temperature via the water thermometer or the combination display.
1) Check the engine coolant temperature via the water thermometer, as shown in Figure
3-9.
Chapter 3
Figure 3-9 Engine coolant temperature indicated in water thermometer
2) Check the engine coolant temperature via the combination display, as shown in
Figure 3-10.
Figure 3-10 Engine coolant temperature indicated in combination display
Check the engine coolant temperature after the engine started. Ensure the
temperature is within the normal range.
WARNING
While driving the vehicle, always check the water thermometer to ensure that
the temperature is between 70°C and 96°C.
3.1.5 Inspection of AdBlue level

[Prerequisites]
None
CAUTION
Use AdBlue complied with the ISO22241 Standard. Otherwise, the warning light will
illuminate and other faults will occur because of exceeding the emission standard.

Check the liquid level indicating bar. The numerical value should be between 0% - 100%. “0%”
indicates the AdBlue tank is empty while “100%” indicates that the AdBlue tank is full.
If the AdBlue liquid level warning light illuminates (lower than 10%), it shows that you should
check the AdBlue tank and add more AdBlue.
Switch on the power supply of the complete vehicle, but do not start the engine. Examine the
AdBlue reserve via the instrument in driver’s cab. If it is insufficient, add the appropriate
AdBlue.
Check the AdBlue reserve via the combination display, as shown in Figure 3-11.
Chapter 3
Figure 3-11 AdBlue level indicated in combination display

3.2 Inspection and maintenance of hydraulic system
[Prerequisites]
a) Check it when necessary.
b) Check it according to the schedule.
Shut down the engine and apply the parking brake.
The vehicle is leveled and stops on level load-bearing surface.
Wrench, clean rag and lighting equipment
Chapter 3
a) Hydraulic pump
The hydraulic pump shall be free of oil leakage, abnormal vibration and noise.
b) Hydraulic motor
The hydraulic motor shall be free of oil leakage, abnormal vibration and noise.
c) Hydraulic cylinder
The hydraulic cylinder is working normally, with good sealing performance and free of oil
leakage.
d) Hydraulic oil tank
The hydraulic oil tank is reliably connected, free of cracks and oil leakage.
e) Control valves and directional control valves
They are reliably connected, free of looseness and oil leakage.
f) Balance valves
There are reliably connected, free of looseness and oil leakage.
g) Pipelines
The pipelines are reliably connected, free of damage, looseness, deformation and oil
leakage.
a) Hydraulic pump
1) Check the contact surfaces of hydraulic pump for oil leakage. If necessary, contact
professional service personnel for repair.
2) Check the hydraulic pump for abnormal vibration or noise during operation. If
necessary, contact professional service personnel for repair.

3) In winter, the hydraulic oil features a higher viscosity, and the pump should be inched
and gradually enabled to operate continuously according to the mode as follows:
Start the engine by inching without load (let it run for 3 S) stop it (repeatedly
for 3 or 4 times) start it by inching (let it run for 5 S) stop it
(repeatedly for 3 or 4 times) start it by inching (let it run for 10 S)
stop it (repeatedly for 2 or 3 times) and let it run continuously without load for
10 – 20 min.
4) Check the pipe fittings of hydraulic pump for tight fit and oil leaks.
b) Hydraulic motor
1) Check the hydraulic motor for tight fit and cracks.
2) Check the contact surfaces of hydraulic motor for oil leakage. If necessary, contact
Chapter 3
professional service personnel for repair.

3) Check the hydraulic motor for abnormal vibration or noise during operation. If
4) Check the pipe fittings of hydraulic motor for tight fit and oil leaks.
c) Hydraulic cylinder
1) After lifting operation, check the piston rod of hydraulic cylinder for oil leakage. If
2) During lifting operation, check whether the hydraulic cylinder is retracted accidently. If
d) Hydraulic oil tank
1) Check the connecting bolts of hydraulic oil tank for tight fit. Tighten the bolts if
necessary.
2) Check whether there is any oil leakage at the bottom and side of the hydraulic oil tank.
Replace the hydraulic oil tank if necessary.
3) Check the hydraulic oil tank for cracks. Replace the hydraulic oil tank if necessary.
4) Check the hydraulic oil temperature and level as stated in Section 3.1.1.
5) Regularly replace the hydraulic oil as stated in Section 4.2.3.
6) Frequently wipe off the dust and oil stains on the hydraulic oil tank with clean rag.
e) Control valves and directional control valves
1) Check the mounting bolts of control valves and directional control valves for proper
seating. Tighten the bolts if necessary.
2) Check the contact surfaces of the control valves and directional control valves for oil
leaks. Contact professional service personnel for repair if necessary.
3) Check the pipe fittings of the control valves and directional control valves for tight fit
and oil leaks. Tighten or replace the pipe fittings if necessary.

f) Balance valves
1) Check the sealing surface of balance valves for oil leaks. Contact professional service
personnel for repair if necessary.
2) Check the pipe fittings of balance valves for tight fit and oil leaks. Tighten or replace
the pipe fittings if necessary.
g) Pipelines and fittings
1) Check the pipe fittings of the pumps and valves for tight fit. Tighten the pipe fittings if
necessary.
2) Check the pipe fittings for oil leaks and damages. Tighten or replace the fittings if
necessary.
3) Check the pipe clamps for tight fit and cracks. Tighten or replace the clamps if
Chapter 3
necessary.
4) Check the hoses for aging, distortion and damages. Replace the hoses immediately if
necessary.

3.3. Inspection and maintenance of oil and water leakage
3.3.1 Inspection and maintenance of hydraulic system leakage
[Prerequisites]
Stop the vehicle on a level load-bearing surface.
Chapter 3
The hydraulic elements and pipelines have no leakage.
[Maintenance procedures and methods]
Set up the outriggers and run the engine without load. Under this condition, check the hydraulic
elements and pipelines for oil leakage. If the pipe fittings have oil leakage, tighten them. If any
hydraulic element leaks, please contact professional service personnel for repair.
3.3.2 Inspection and maintenance of oil and water leakage

[Prerequisites]
a) When any part is replaced.
b) When any part is removed and re-assembled.
c) When necessary.
d) Check and maintain them according to the schedule.
a) The water tank and pipelines of the engine cooling system are free of water leakage.
b) The transmission and axles have no oil leakage.
c) The fuel tank and pipelines of the fuel supply system have no oil leakage.
a) Engine cooling system
Check the engine cooling system to see whether its water tank and pipelines have leakage.
And if any, tighten or replace relevant components.

b) Transmission and axle
1) Check whether the joint surface of the transmission oil filler and drain plugs have any
oil leakage. And if any, tighten or replace the seal ring.
2) Check the main reducer and wheel reducer of drive axle to see whether the joint
surface of their oil filler and drain plugs has any oil leakage. And if any, tighten or
replace the seal ring.
3) Check whether the transmission and axle breather cap have any oil leakage due to
blockage. And if any, remove and clean it.
4) If any moving part has oil leakage, the bearing or sealing element may be damaged.
Replace the damaged one. The bearing or sealing element should be replaced by
manufacturer’s professional service personnel.
Chapter 3
c) Fuel supply system
Check whether the fuel tank and pipelines of fuel supply system suffer from leakage. And if
any, tighten relevant components.
WARNING
Any operation shall not be carried out until the oil and water temperature has
dropped below 40°C. Otherwise, it may easily lead to personal injury!

3.4 Inspection and maintenance of safety indicators and devices
3.4.1 Superstructure
[Prerequisites]
The crane is in its load-free state.
Wrench, screwdriver, clean rag and lighting equipment
Chapter 3
WARNING
Do not check and maintain the crane with a suspended load.

a) Check the hoisting limit switch for functional work. If it is triggered, it should cut off the
“Spool up winch” movement with warning light illuminating and buzzer activating.
b) Check the lowering limit switch. If there are only three wraps left on the drum, it will cut off
the “reel off winch” movement with warning light illuminating and buzzer activating.
c) Check the angle indicator to ensure its pointer is able to swing smoothly.
d) Check the balance valves and the two-way hydraulic locks for proper seating, leaks and
functional work.
e) Check the load moment limiter for functional work. For details, please refer to Section
4.4.4.
f) If the emergency stop switch is pressed, the engine should stop working.
g) Check the level gauge.
1) The bubble diameter of the level gauge should be about 0.7 cm.
2) The level gauge is parallel to the chassis frame plane.
a) Hoisting limit switch
1) Set up the outriggers and level the crane.
2) Operate the control lever to lift the hook slowly.
3) Check whether the hook continues its upward movement when it touches the hoisting
limit switch. If the upward movement is not cut off, and the corresponding warning
light and buzzer are not activated, it means that the hoisting limit switch has failed.
Please contact professional service personnel.
CAUTION
Check the hoisting limit switches of the main and auxiliary hooks accordingly.

b) Lowering limit switch
2) Choose the right boom length and reeving number. Operate the winch to reel off the
wire rope.
3) Observe the status of the winch rope. When only three wraps are left on the drum,
check whether the switch can stop the winch reeling off automatically. And if the winch
keeps reeling off, the corresponding warning light does not illuminate and its buzzer
does not send out alarm, it indicates the lowering limit switch has failed. Please
contact professional service personnel for repair.
c) Angle indicator
During derricking movement, the pointer of angle indicator should swing smoothly and
Chapter 3
point to the correct angle. If the pointer is not flexible or is stuck, lubricate the moving parts.
If the pointer still works abnormally after full lubrication, please replace the indicator.
d) Check the balance valves and the two-way hydraulic locks.
1) Check the connecting bolts of balance valves and two-way hydraulic locks for tight fit.
Tighten such bolts if necessary.
2) Set up the outriggers and run the engine without load. Under this condition, check the
balance valves and two-way hydraulic locks for oil leaks and functional work. Contact
professionals for troubleshooting if necessary.
WARNING
(1) Do not maintain the hydraulic system or replace any components when the
hydraulic pump is working.
(2) Only professional personnel are permitted to dismantle the balance valves and
the two-way hydraulic locks.
e) Check the load moment limiter for functional work. For details, please refer to Section
4.4.4.
f) Emergency stop button
1) Press the emergency stop button during the engine running, and the engine should
stop working.
2) When the emergency stop button is pressed, you cannot start the engine.
g) Level gauge
1) Check and ensure the bubble diameter in the level gauge is about 0.7 cm. Otherwise,
please replace the level gauge.
2) Check whether the level gauge is parallel to the chassis frame plane. Regulate the
adjusting screw below the level gauge if necessary.

CAUTION
(1) The safety devices should be the important guarantee for safe operation.
Ensure that all the safety devices are in normal working condition at any time.
(2) While you check the safety devices for functional work, switch off the bypass
key switch.
3.4.2 Chassis
[Prerequisites]
a) Check and maintain when instruments or warning lights send out alarm.
b) Check and maintain according to the schedule.
Chapter 3
a) Engine oil pressure gauge
In normal operation after the engine starts, the engine oil pressure gauge should work
normally. When the engine is running at idle speed, the engine oil pressure gauge should
indicate 0.1 MPa.
b) Warning light “Charging monitoring”
Before the system is powered on and the engine starts, the warning light will light up. After
the engine has been working normally, the warning light should extinguish.
c) Voltmeter
The voltmeter should work normally. When the engine stops, the voltage indication should
be about 24 V. The voltage indication should be about 28 V during the engine running.
d) Water thermometer
The water thermometer should work normally. If the engine is working normally, the water
thermometer should indicate the engine coolant temperature within the range of 70°C -
96°C.
e) Barometer
The barometer should work normally. The barometer should indicate the brake pressure
within 0.8 MPa.
f) Service brake
Apply the service brake pedal to ensure it works normally.
g) Parking brake
When the start-up pressure is reached, release the parking brake and the vehicle can
normally start.

h) Warning light “Engine error code displayed”
When the complete vehicle is powered on, the engine will start its self-test process. If there
is no fault, the warning light will light up and then extinguish. If the engine has defects, the
warning light will be on all the time.
Figure 3-12 Engine error code display
Chapter 3
Note: When the engine has failed, please refer to Section 7.2.4 for troubleshooting.
i) Oil filter soiled indicator

After the engine has started to work normally and when the hydraulic oil temperature is
higher than 40°C, check whether the oil filter soiled indicator is on. And if it is on, please
timely clean and replace the hydraulic oil filter element.
j) The external lighting and signals used during vehicle driving
External lighting and signals work normally.
Note: The external lighting and signals used during vehicle driving refer to the low /
high beam, turn signal, license plate lamp, rear fog lamps, brake lamps, corner
marker lights, side marking lights and reflectors on the chassis.

After the superstructure and chassis have return to their initial state and the engine starts,
check all instruments and warning / control lights in the driver's cab for functional work. Please
contact professional service personnel for troubleshooting when necessary.
CAUTION
If the external lighting and signals cannot work normally, promptly clean or replace the
defective parts.

3.5 Inspection and maintenance of wire rope
[Prerequisites]
a) Check and maintain it when necessary.
b) Check and maintain it according to the schedule.
Wrench, brush and clean rag
WARNING
Chapter 3
Do not check and maintain the crane with a suspended load.

a) The wire rope should be free of deformation or damage.
b) The wire rope should be properly lubricated.
NOTICE
It is only applicable for the inspection and maintenance of the hoist rope.

a) Set up the outriggers and level the crane.
b) Choose the proper boom length and reeving number. Operate the control lever to unwind
the wire rope.
c) Remove the contamination stuck on the wire rope.
d) Lubricate the wire rope according to its state in a regular interval.
CAUTION
(1) If the wire rope is damaged, please maintain or replace the wire rope as stated in
Section 4.5.
(2) The wire rope should be properly lubricated, with the surface kept clean.

3.6 Inspection and maintenance of steering system
[Prerequisites]
a) When the steering is abnormal.
b) Check and maintain when necessary.
c) Check and maintain according to the schedule.
Chapter 3
Wrench, pipe vice and clean rag
a) Steering system
1) Check all drag rod clamps, rocker arm tightening bolts and other elements for tight fit.
2) Check each steering drag rod ball joint for tight fit.
3) Check each steering drag rod for distortion.
b) Steering function
1) Steer in situ and each wheel is steering normally.
2) The steering wheel is operated comfortably and smoothly when the vehicle is at low
speed.
c) Steering hydraulic system leakage
Check all hydraulic elements, pipelines and fittings for oil leaks.
d) Wheel alignment
The wheel alignment state is normal.

a) Steering system
1) Check all drag rod clamps, rocker arm tightening bolts and other elements for tight fit.
Tighten the loose elements when necessary.
2) Shake by hand to check the steering drag rod ball joints for tight fit. Replace the loose
ball joint when necessary.
3) Check each steering drag rod for distortion. Contact professional service personnel
for troubleshooting when necessary.
b) Steering function
1) Steer in situ to observe whether each wheel steers normally. If not, maintain the
wheels as the procedures stated in Section 7.2.
2) If the steering wheel is operated not smoothly when the crane is at low speed, check
the steering hydraulic system and adjust it when necessary.

c) Steering hydraulic system leakage
Check all hydraulic elements, pipelines and fittings for oil leaks. Tighten or replace relevant
parts when necessary.
d) Wheel alignment adjustment

When the vehicle is traveling straight forward, see whether the steer wheels deviate or
misalign. Adjust the wheels when necessary. For details, please refer to Section 5.4.8.
Chapter 3

3.7 Inspection and maintenance of brake system
[Prerequisites]
a) Check and maintain when the brake is abnormal.
b) Check and maintain when necessary.
Chapter 3
Wrench, feeler and clean rag
a) The service brake and parking brake is functional.
b) The air brake pipelines feature good seal performance.
c) The work pressure of the brake system has reached 0.55 MPa - 0.8 MPa.
d) Drain off the accumulated water in the air reservoir.
a) Check the service brake and parking brake for functional work.
1) Pressurize the system up to 0.8 MPa. Depress the service brake pedal gradually to
check the travel and force of the pedal. If the pedal travel is too small, you can adjust
the adjusting screw. When the pedal force is rather small, replace the release spring
of the master brake valve.
2) Apply the service brake repeatedly to check whether the brake chamber of each axle
can work and be released effectively.
3) Apply the parking brake repeatedly to check whether the brake chambers of the
intermediate and rear axles can work and be released effectively.
b) Check the air pipelines for good seal performance.
1) Pressurize the system up to 0.6 MPa and shut down the engine. Check the system
pipelines for leaks. 3 minutes later, the system pressure shall be decreased by no
more than 0.01 MPa.
2) Pressurize the system up to 0.8 MPa, and depress the service brake pedal
completely for five times. Then check to ensure the pressure is not lower than the
start-up pressure.
c) Check the work pressure of the brake system.
Before starting the vehicle, check the barometer in the driver's cab and ensure both the
two pointers indicate the pressure greater than 0.55 MPa. Only at this time, the vehicle can
be allowed to start. Before starting the vehicle, you’d better charge the system pressure up
to 0.8 MPa to ensure safety during driving.

d) Drain off the accumulated water in the air reservoir.
Open the manual drain valve at the lower part of the air reservoir until there is no water
drained out.
Chapter 3

3.8 Inspection and maintenance of wheels
[Prerequisites]
a) Check and maintain when necessary.
Pressure gauge, inflating equipment and clean rag
Chapter 3
a) Check the tire pressure.
Table 3-1 Tire pressure
Tire size Tire type Tire pressure (Mpa)
11.00R20 (Ply Rating 18) Radial-ply tire 0.93 - 0.98
11.00-20 (Ply Rating 18) Bias-ply tire 0.91 - 0.96
12.00-20 (Ply Rating 18) Bias-ply tire 0.81 - 0.86
12R22.5 (Ply Rating 18) Radial-ply tire 0.93 - 0.98
385/65R22.5 (Ply Rating 18) Radial-ply tire 0.91 - 0.96
385/95R25 (Made in China) Radial-ply tire 1.00 - 1.05
385/95R25 (Imported) Radial-ply tire 0.9 - 0.95
b) The tire tread has no foreign material or be damaged.

c) The rim is free of deformation and cracks.
d) No nut is loose.
DANGER
Do not drive the vehicle if any tire is suffering from serious damages!

a) Tire pressure
1) Connect the pressure gauge to the valve mouth and measure the tire pressure.
2) According to the pressure level, select an appropriate device to inflate / deflate the tire
to an appropriate value. However, do not inflate the tire beyond the specified pressure
and then deflate it to the specified pressure.
b) Tire tread
1) Promptly replace the tire when it is worn to the limit position.
2) Clean the sundries in the tire tread pattern.
c) Rim
Promptly replace the rim if there is any crack or obvious deformation.
Chapter 3
d) Wheel nuts:
The nuts (if loose) should be timely tightened, 25 T – 55 T truck cranes with the tightening
torque up to 550 Nm – 600 Nm and 70 T – 80 T truck cranes with the tightening torque up
to 820 Nm – 870 Nm as required.

Chapter 4 Periodical Maintenance Guidelines
for Superstructure
4.1 Periodical inspection and maintenance of main vulnerable

parts
4.1.1 Periodical inspection and replacement of hoses
[Prerequisites]
a) Check and replace them when necessary.
b) Check and replace them according to the schedule.
Chapter 4
Wrench, oil container and clean rag
a) Check the surfaces of hoses for cracks and damage.
b) Check the fittings of hoses for leaks.
WARNING
Do not tighten or replace any hydraulic hoses during crane operation.
[Replacement procedures and methods]

a) When you replace the suction hoses, do the items that follow:
1) Turn off the shut-off gate valve and place the oil container beneath the hose to be
replaced.
2) Replace the hose with a new one, and wipe oil stain off the new hose.
3) Turn on the shut-off gate valve.
b) When you replace any other hoses, do the items that follow:
1) Place a container.
2) Loosen its fastener.
3) Replace the hose with a new one and wipe oil stain off the new hose.
4.1.2 Periodical inspection and replacement of air conditioning

[Prerequisites]
a) Check and replace it when the A/C fails to function for cooling or heating.
b) Check and replace it according to the schedule.

Normal environment
Wrench.
a) Check the pipe fittings and compressor securing bracket for tight fit.
b) Check the hoses of refrigerating system for wear.
c) Check the insulation layer of electrical circuit for damage and aging.
d) Check all connectors for tight fit.
e) Check the A/C and cab heater for functional work.
The composition of A/C is shown in Figure 4-1.
Evaporator
Chapter 4
Fluid reservoir
Condenser Hydraulic motor
Belt
Air compressor
Figure 4-1 Air conditioning system

a) Inspection of air-conditioning pipelines
Check all pipelines as shown in Figure 4-1 for looseness. Tighten the loose pipelines
and fittings if necessary.
b) Inspection of condenser assembly
Check the radiating ribs of condenser for collapsing or clogging. Immediately remove
the clogging if necessary.
c) Inspection of refrigerant
Please contact the professional service personnel for inspection and maintenance.
Chapter 4

4.2 Periodical inspection and replacement of oil
4.2.1 Periodical inspection and replacement of gear oil of winch reducer
[Prerequisites]
a) Check and replace it when necessary.
a) Check to ensure that the oil level is 15 mm – 20 mm below the middle scale.
Chapter 4
Air hole
Oil filler and

sight glass
Oil drain hole
Figure 4-2 Oil filler of winch reducer
b) Check the gear oil for abnormal color, emulsification, obvious particles, impurities, and oil
sludge.
WARNING
(1) Change the gear oil if it is polluted seriously even though it has not reached the oil
change intervals.
(2) Monitor the oil level regularly and add oil if it is below the Min. mark.
(3) You cannot mix gear oil of different brands (specifications) or types.

(4) Always use the recommended gear oil according to the ambient temperature. If you
use the unqualified gear oil or gear oil with improper type or viscosity in the reducer,
you can damage it.
[Maintenance procedures and methods 1]

a) When you fill the oil, do the items that follow:
1) Remove the oil filler plug and air hole plug when the hoist winch is stationary.
2) Add gear oil via the oil filler.
3) Wait for 2 minutes and observe the oil level.
4) If the oil level is still lower than the required level, repeat steps 2) and 3) until the oil
reaches the required level.
b) When you replace the oil, do the items that follow:
1) Remove the oil filler plug and air hole plug. Clean the sealing surfaces.
2) Remove the oil drain plug. Clean the sealing surfaces.
3) Drain the used oil and tighten the oil drain plug.
4) Add gear oil (about 1.5 L) according to the oil filling steps.
Chapter 4
[Maintenance procedures and methods 2]
1) Unwind the wire rope till the dust cap on the drum of reducer is revealed and upright
to the drum of reducer when the hoist winch is stationary.
2) Remove the dust cap and the oil filler (oil drain) plug. Refer to Figure 4-3.
5) If the oil level is still lower than the required level, repeat steps 3) and 4) until the oil
1) Unwind the wire rope till the dust cap on the drum of reducer is revealed and below
the drum of reducer when the hoist winch is stationary.
2) Remove the dust cap and the oil filler (oil drain) plug.
3) Drain the used oil. Refer to Figure 4-3.
4) Slowly rotate the winch reducer till the oil filler (oil drain) plug is above the drum.

Dust cap
Oil filler (oil drain) plug
Figure 4-3 Oil filler of winch reducer

Chapter 4
CAUTION
The hoist winch is an important component of the crane. Be sure that the gear oil is both
clean and sufficient. Otherwise damage could be caused to the hoist winch.
4.2.2 Periodical inspection and replacement of gear oil of slewing reducer

[Prerequisites]
a) Check the gear oil for abnormal color, emulsification, obvious particles, impurities, and oil
sludge.
b) The oil level is above 2/3 of the full scale.

Air hole
Oil filler
Oil drain hole
Figure 4-4 Oil filler and oil drain hole of slewing reducer
WARNING
Chapter 4
(1) Change the gear oil if it is polluted seriously even though it has not reached the oil
change intervals.
(2) Monitor the oil level regularly and add oil if it is below the Min. mark.
(3) You cannot mix gear oil of different brands (specifications) or types.
(4) Always use the recommended gear oil according to the ambient temperature. If you
use the unqualified gear oil or gear oil with improper type or viscosity in the reducer
mechanism, you can damage it.

4) If the oil level is still lower than the required level, repeat steps 2 and 3 until the oil
2) Remove the oil drain plug. Clean the sealing surfaces.
3) Drain the used oil and tighten the oil drain plug.
CAUTION
The slewing reducer is an important component of the crane. Be sure that the gear oil is
both clean and sufficient. Otherwise damage could be caused to the reducer.

4.2.3 Periodical inspections and replacement of hydraulic oil
[Prerequisites]
a) Check the hydraulic oil and replace it when it is deteriorated.
b) Check and replace it when necessary.
c) Check and replace it according to the schedule.
Check the hydraulic oil for abnormal color, emulsification, obvious particles, impurities, and oil
sludge.
Chapter 4
CAUTION
(1) The quality, viscosity and cleanliness of the hydraulic oil are the most key factors
for normal operation of the crane. Ignorance to change the hydraulic oil can cause
various parts defects and greatly shorten the service life of the crane.
(2) Filter or change the hydraulic oil if it is polluted seriously even though it has not
reached the oil change intervals.
(3) Always use the proper hydraulic oil according to the ambient temperature. You
cannot mix hydraulic oil of different brands (specifications) or types.
(4) You must change the hydraulic oil every 18 months. After 18 months, you cannot
use the hydraulic oil even though it is filtered.
(5) It is recommended to use the ZOOMLION special hydraulic oil.
[Steps for oil replacement]

a) Replace the hydraulic oil in the hydraulic oil tank as follows:
1) Drain the used oil in the hydraulic oil tank.
2) Remove the master oil return pipe.
3) Carefully clean the oil tank and filter.
4) After the tank is dry, clean the tank with new hydraulic oil.
5) Drain the oil used to clean the tank.
6) Fill the tank with new hydraulic oil.
b) Flush the used oil out of the system as follows:
1) Start the engine and operate it at a low speed.
2) Start the hydraulic system pump.
3) Operate all the hydraulically controlled functions.

– Make sure that you fully move the items through the full travel of operation.
– Make sure that you add new oil into the tank as the used oil flows out.
– Do not let the used oil go back into the oil tank.
– Do not stop the system pump until the new oil flows out of the master oil return
pipe.
c) Connect master oil return pipe to the hydraulic oil tank. Move all the hydraulically
controlled functions through the full travel and monitor the oil level in the tank. If necessary,
add oil.
d) Before starting the engine for the first time after oil replacement, add oil into the motors
and pumps via their oil drain holes, and deaerate them. Failure to do so could cause
abnormality of the crane even damage to its components.
CAUTION
(1) It is forbidden to remove the balance valves and two-way hydraulic locks during oil
replacement.
Chapter 4
(2) Be sure to collect the used hydraulic oil to prevent pollution.
(3) Before inspecting oil level and adding oil, retract all cylinders completely. The oil
level may not exceed the maximum scale of liquid level gauge.

4.3 Periodical inspection and replacement of key fasteners
4.3.1 Slewing bearing
[Prerequisites]
Wrench, thread sealant, grease pump and clean rag
a) Check the tooth surface for foreign substance and rust. A proper amount of grease shall be
found on tooth surface.
b) Check the bolts of slewing bearing for tight fit and deformation. See the table below for
their tightening torques.
Chapter 4
Table 4-1 Tightening torques of bolts
Ser. No. Bolt (grade 10.9) Tightening torque value Standards
1 M24 900 N·m GB/T 1228
2 M27 1350 N·m GB/T 1228
3 M30 1800 N·m GB/T 1228
c) Check the sealing strips for rupture.

a) Remove foreign substance and rust from the tooth surface.
b) Inspect the tightening torque of bolt.
Check the mounting bolts one by one with torque wrench. If necessary, tighten the
mounting bolts.
NOTICE
Inspection and tightening of the bolts and replacement of the sealing strip should be
carried out by professional service technicians.
CAUTION
The mounting bolts shall be tightened symmetrically and continuously in the
direction of 180°. Tighten the bolts for the last time to ensure that all the bolts on the
circle are tightened to the proper torque.

WARNING
(1) To prevent damage to tooth surface, it is strictly prohibited to clean the tooth
surface with any sharp tools.
(2) It is strictly prohibited to directly flush the slewing bearing by water. Otherwise the
water may enter the rollway.
(3) In case of environment of tropic climate, high humidity, excessive dust or dramatic
temperature change, or in case of continuous operation, the slewing bearing shall
be lubricated once a week.
4.3.2 Installation of reducer

[Prerequisites]
Chapter 4
Wrench and clean rag
a) Check the mounting bolts of hoist winch and slewing gear for tight fit.
b) If any bolt gets loose, tighten it with the required torque.
As for the tightening torques of the bolts, see the table below,
Table 4-2 Tightening torques of bolts
Strength grade 8.8, tightening Strength grade 10.9, tightening

Bolt diameter
torque value (N.m) torque value (N.m)
M10 44 62
M12 77.5 110
M14 120 170
M16 190 265
M18 260 365
M20 370 520
M22 500 700
M24 640 900
M27 950 1350
M30 1300 1800

4.3.3 Boom and derricking cylinder shaft
[Prerequisites]
Wrench and grease pump
a) Check that the pin is properly lubricated.
b) Check the chuck plate for proper seating and deformation.
c) Check the pin for deformation. Check whether there is abnormal noise during derricking
operation.
a) Lubrication
Chapter 4
1) Align the grease pump with the oil cup to add grease.
2) Stop filling grease when the grease pump undergoes great resistance.
3) Operate the superstructure to move derricking cylinder and boom. Then repeat steps
1) and 2).
b) Chuck plate and pin
1) Check the chuck plate and pin for proper seating and deformation.
2) Tighten the loose chuck plate. And replace the deformed chuck plate and pin.
4.3.4 Mounting bolt of counterweight

[Prerequisites]
Wrench
Be sure that the mounting bolt of counterweight fits tight and no deformation occurs. Tighten
the load moment according to Table 4-2.
Note: For the inspection and tightening of the load moment, please contact to the special
service personnel.

4.4 Periodical inspection and maintenance of mechanisms and
systems
4.4.1 Periodical inspection and maintenance of telescoping system
[Prerequisites]
The following is applicable to truck cranes whose telescoping mechanism is of a single cylinder
pinning type:
c) No movement of the cylinder pin or boom pin, or no signal detected;
d) The boom pins cannot be pulled off during automatic telescoping process;
e) Check according to the schedule.
The boom is in the position which the service technicians can get in touch with it.
Chapter 4
Adjustable wrench, socket head wrench, and pliers
a) Check the movement of telescoping cylinder for pulse and noise.
b) Check the movement sequence of telescoping cylinder.
c) Check the telescoping cylinder for oil leaks.
d) Check the function of balance valve.
e) Check whether the fitting of oil pipe is loose. Timely tighten it if necessary.
f) Check whether the hose is aged, deformed or damage. Timely replace it if necessary.
g) Check the wire rope and lubricate it when necessary.
h) During initial crane operation (200 operating hours or 2 months later), you must adjust the
telescoping system. Subsequently, adjust the telescoping system every 600 operating
hours or half a year. And timely grease it according to Operator’s Manual.
pinning type:
a) Check movements of the cylinder pin and boom pins, as well as signal detection: if they
can move and can be inserted/pulled off normally;
b) Boom pin pulling-off movements: the boom pins can be pulled off to position during boom
telescoping process.
When the boom is fully retracted, the telescopic section 3 or 4 is still slightly extended and
unable to fully retract. It may result from the improper adjustment of boom extension / retraction
rope.
Timely adjust the boom extension / retraction rope, if one of the items that follow occurs:

a) Telescoping cylinder cannot extend/retract synchronously.
b) Telescoping cylinder trembles during retraction.
Otherwise, damage could be caused to the telescoping system.
Do the items that follow:
a) Adjust the boom retraction rope in top boom section as follows:
1) Remove the cover shell at the head of telescopic section 4. And the nut at the head of
boom retraction rope is exposed. Refer to Figure 4-5.
2) Unscrew a locknut with a socket wrench.
3) Screw an adjusting nut till the boom extension rope II is properly tight.
Chapter 4

Top boom
Adjusting nut section
Locknut
Chapter 4
Figure 4-5 Adjustment of boom retraction rope in top boom section
b) Adjust the boom retraction rope in telescopic section 3.

The tail of boom retraction rope is symmetrically located at the both sides of head of
telescopic section 3.
1) Unscrew a locknut.
2) Screw an adjusting nut till the boom extension rope I is properly tight.
Adjusting nut
Locknut
Basic boom
Telescopic section 1
Boom retraction rope
Figure 4-6 Adjustment of boom retraction rope in telescopic section 3

pinning type:
a) Check the cylinder pin and boom pins in following steps：
1) Release electrical interlocking;
2) Telescope in the boom to retract the cylinder from the boom head (no coding signal);
3) Operate the pinning mechanism to insert and pull off the cylinder pin and boom pins;
4) The cylinder pin or boom pins do not move (LML indicates no in-position signal of the
boom pins);
5) Check the two-position two-way solenoid valve of the control cylinder and boom pins
on the telescoping mechanism;
6) If the solenoid valve is electrified and not stuck, check if the indication on the LML
screen correspond to actual movements;
7) It is possible that the mechanism is in position while the LML screen fails to indicate
so;
Chapter 4
8) In such a case, it can be confirmed that the in-position detection switch or its
connector is faulty;
9) Tighten or replace the switch timely.
b) If boom pins cannot be pulled off during the automatic telescoping process:
1) Switch over to manual operation;
2) Telescope the cylinder in and out by 15-25 mm and manually operate the boom pin
pulling-off movement again;

3) If the boom pins cannot be pulled off, this indicates that the value between the pin and
the pin hole is insufficient or excessive, or the pins are easily stuck;
4) Repeat the step 2 manually for several times. If the boom pins remain unpinned, then
a preliminary conclusion can be drawn that the boom pins are easily stuck;
5) Contact professional personnel to deal with such case.

CAUTION
(1) Support the crane on a level and solid ground.
(2) Do not adjust the boom extension rope.
(3) Do not screw the adjusting nut too tight. Otherwise, the wire rope may be
excessively tightened. Remember to screw the locknut again after adjustment.
(4) Do not rotate the threaded rod when adjusting the locknut of wire rope.
4.4.2 Periodical inspection and maintenance of slewing gear

[Prerequisites]
Chapter 4
a) Check the slewing gear for oil leaks.
b) Check the side clearance of slewing gear.
1) As for 25 T – 40 T truck crane: 0.23 mm – 0.36 mm
2) As for 50 T – 80 T truck crane: 0.23 mm – 0.36 mm
a) Check for oil leaks as follows:
3) Check the slewing reducer, slewing motor, pipelines and fittings for oil leaks.
4) In case of oil leakage, find out the cause. Tighten relevant fasteners or replace
relevant sealing elements according to the actual conditions.
5) Inspect the oil level. Refer to Section 4.2.2.
b) Inspect the side clearance of slewing gear.
As for side clearance adjustment, please contact the after-sales service personnel of
Zoomlion.
4.4.3 Periodical inspection and maintenance of hoist gear

[Prerequisites]

a) Check the hoist gear for oil leaks.
b) Check whether the wire rope on the drum winds uniformly.
a) Check for oil leaks as follows:
1) Check the winch reducer, winch motor, pipelines and fittings for oil leaks.
2) In case of oil leakage, find out the cause. Tighten relevant fasteners or replace
relevant sealing elements according to the actual conditions.
3) Inspect the oil level. Refer to Section 4.2.1.
b) Check whether the wire rope on the drum winds uniformly.
2) Visually inspect whether the wire rope on the drum winds uniformly without tangle and
looseness.
3) In case of disorderly rope, reel off the rope and re-wind it.
4.4.4 Periodical inspection and maintenance of load moment limiter

Chapter 4
[Prerequisites]
Free of dust.
Shut down the engine.
Clean rag and lighting equipment
a) Check the settings of OM on load moment limiter. The setting must comply with the actual
OM, including the OMs of main boom, jib, and rooster sheave, the setting of rope reevings,
and the setting of movable counterweight.
b) Check the display of load moment limiter. The displayed settings must comply with the
actual OM, including the working areas, boom length, boom angle, and rated lifting
capacity.
c) Check the various sensors (i.e. length sensor, angle sensor and pressure sensor) and
their connectors and wiring harnesses.

pinning type:
c) Check if there is a CAN bus alarm caused by LML component and malfunction alarm in the
LML screen;
Early warning, CAN bus

LML alarm code overloading
alarm
d) Check if the screen is clean and intact;

e) Check if the LML is secured and without water ingress.
1) Check if the electrical connections of the LML computer, upper and lower chamber oil
pressure sensor, angle-tension force sensor, cable reel (cable drum) are secured
without loosening, and there is no water ingress into their bodies and connectors;
Chapter 4
2) Check if the cables are intact without breakage.
f) Check if there is no oil leakage from the upper and lower pressure chamber sensor;
g) Check if the cable reel is secured and the rope holder can move freely.
WARNING
(1) Correctly set the OMs on load moment limiter before crane operation. Otherwise
accidents such as crane toppling over could be caused.
(2) Check the displays of load moment limiter before crane operation, including the
working areas, boom length, boom angle, and rated lifting capacity. If any displayed
parameter is abnormal, immediately stop the crane operation for inspection and
repair.

The main interface of load moment limiter is shown in Figure 4-7.

Date/Time Rated weight Actual weight
Ratio of rated weight

to actual weight
Note of outrigger operating conditions

0/2 indicates outriggers are fully retracted
1/2 indicates outrigger are half extended
2/2 indicates outrigger are fully extended
Length
Note of reeving number:

X12 indicates the reeving number is 12
Height
Anemometer indication
Angle Operating conditions of the fifth outrigger

Operation direction
indication:
Radius Over front
Over side
and over rear
Rapid Background Buzz alarm Language

Main menu
observation light control control (Chinese/English)
Figure 4-7 Main interface of load moment limiter

Chapter 4
Figure 4-8 Main interface of the LML for truck cranes of single cylinder pinning type
a) Set the crane lifting mode according to the Operating Instructions for Load Moment Limiter.
Ensure that the setting complies with the actual one.
b) The front and rear working areas of crane are shown in Figure 4-9. When the crane slews
to the front area, the load moment limiter must be able to correctly display the crane
position.

Over front Over sides and rear
Chapter 4
Figure 4-9 Working areas
c) When the boom is fully retracted and fully extended, the displayed boom lengths should
correspond to the minimum and the maximum values of boom length respectively (see the
lifting capacity table). If not, immediately adjust the length sensor according to the
Operating Instructions for Load Moment Limiter. At this time, it is impermissible to operate
the crane.
d) Check the various sensors (i.e. length sensor, angle sensor and pressure sensor) and
their connectors and wiring harnesses for rupture, breakage, and water ingress. Timely
replace the faulty part if necessary. Otherwise the displaying accuracy of load moment
limiter could be reduced.

pinning type:
e) Check if there is an error alarm in the LML’s screen;
Check if there is a warning light indicating a CAN bus malfunction or other malfunctions
illuminates in the LML’s screen. If there is, conduct checks in following steps:
1) Press in the main interface to enter the navigation interface;
2) Press “Fault Query – LML error code query” in the navigation interface to enter the
fault query interface;
3) Troubleshoot the crane according to description of the error code;
4) Press “Communication Monitoring” in the navigation interface to enter the CAN bus
communication status query interface. Check if status indications of the LML, display,
PLC, remote controller and GPS are in red. For those that are, check their CAN bus
wiring and connectors, and then cut off and reconnect their power supply.
Chapter 4
5) If the malfunction cannot be resolved after the above steps, contact professional
personnel to deal with it.
f) Check if the screen is clean and intact;
As a truck crane is normally working in a harsh environment with considerable amount of
dust, check if the screen is clean and wipe it with a soft cloth if it is not, so as to ensure its
cleaning reading; check if the screen is damaged, and change it if so.
g) Check if the LML’s electrical connections are secure and without water ingress.
1） Check if electrical connectors of the following items are loosened, and then cut off
and reconnect their power supply if there is; check the body of the following items and
their connectors for water ingress. If there is, disconnect them for drying and
reconnect them:
- The LML computer;
- The upper and lower chamber oil pressure sensor;
- Angle/tension force sensor;
- Cable reel (cable drum).
2） Check if there is any damaged cable; change the damaged one and secure it.
h) Check if there is any oil leakage from the upper and lower chamber oil pressure sensor;
Check if there is any oil leakage; if there is, re-fasten or change the sensor.
i) Check if the cable reel is loosened and the wire holders can move freely;
1) Check if the cable reel is secured; if not, fasten it again.
2) Check if the wire holder can move freely; if not, clean or change it;

Change the cable reel in following steps:
1） Retract the boom and lay it down onto the boom bracket;
2） Remove the cables secured onto the boom head and wind them slowly onto the
cable reel’s groove;
3） Pre-tighten three circles of cables onto the cable reel (tensional force ≥30N).
Rotate the cable reel in the reeling off direction, and ensure that the length
measurement cable should rotate together with the cable reel;
4） Pull out the length measurement cable and secure it onto the front end of the
boom in its original way;

5） Check if the line connecting the center in width direction of the cable reel (cable
drum) and the cable fastening point on the boom head is parallel to the axial line of
the boom; adjust the center if it is not;
6） Check if all cable holders are installed in the same straight line and at the same
Chapter 4
height, and if their installation positions are centered to align with the center of the
cable reel in width direction. If not, readjust their positions;

7） Check if the boom length is accurately displayed in the LML screen; if not, open
the cover of the cable reel, rotate the middle shaft of the length potentiometer slowly
using a straight screw driver, as shown in Figure 4-10 (rotate clockwise to increase
the displayed value, and anticlockwise to decrease the value), until consistency
between the actual and displayed boom lengths is reached.
Figure 4-10 Length potentiometer middle shaft adjustment
8） As the angle sensor and length sensor are installed in the same shell, the former
needs to be adjusted as well. Adjust boom angle and measure it using an angle
gauge. Check if the angles indicated in the LML screen corresponds to the physically

measured ones. Check the boom’s working radius in the same way using a meter.
If there is a discrepancy in any one parameter, loosen the three mounting bolts as
shown in Figure 4-11. Rotate the whole angle sensor slightly until the displayed angle
or working radius is consistent with physically measured ones. Re-fasten the three
mounting bolts.
Chapter 4
Figure 4-11 Angle sensor bolt adjustment

4.4.5 Periodical inspection and maintenance of counterweight handler
[Prerequisites]
Wrench, screwdriver and clean rag
a) Check that the two counterweight lifting cylinders are extended and retracted
simultaneously.
b) Check that the counterweight lifting cylinders do not retract accidently during the lifting or
after the lifting is completed.
c) Check the piston rods of counterweight lifting cylinders for deformation and collision.
Chapter 4
WARNING
Do not check and maintain the crane with load.

a) Check whether the cylinders movements are simultaneously during counterweight
handling.
Adjust the throttle valve that controls the counterweight lifting movement.
b) Check whether the counterweight lifting cylinders are retracted accidently.
1) Lift the full counterweight.
2) Shut off the oil line of hydraulic lock.
3) If the cylinder is retracted, it indicates the counterweight lifting cylinders have inner oil
leakage.
4) If the cylinder is not retracted, it indicates the hydraulic lock is invalid.
c) Check the counterweight lifting cylinders for damage.
1) Extend the counterweight cylinders completely.
2) Visually check the piston rods of counterweight lifting cylinders for deformation and
collision.
CAUTION
If the counterweight lifting cylinder is damaged, contact the service personnel of
Zoomlion to solve the problem.
4.4.6 Periodical inspection and maintenance of cable reel

[Prerequisites]

The cable reel is in the position which the service technicians can get in touch with it.
Wrench, Screwdriver and clean rag
Chapter 4

a) Check the cable guide pulley for oil sludge.
b) Check whether the cable guide pulley can slide leftward and rightward or rotate flexibly.
c) Check whether the length data are right.
WARNING
Do not check and maintain the cable reel when the crane is with a suspended load.
j) Lubricate the cable guide pulley
1) Remove the oil sludge off the cable guide pulley and the pulley shaft with clean rag.
2) Evenly grease a lay of lubricant on the pulley shaft. And slide and rotate the cable
guide pulley.
3) Remove the redundant lubricant with clean rag.
Chapter 4
Cable guide
pulley and
pulley shaft
Figure 4-12 Cable guide pulley
CAUTION
Please use the ZL-2 lithium-based grease.
k) Adjust the display boom length as follows:

1) Remove the housing of cable reel.
2) Adjust the rotation shaft of potentiometer with a straight screwdriver to make the
display boom length equal to the Min. boom length. While extending the boom,
observe whether the length display boom length varies with the actual boom length. If
not, readjust the rotation shaft of potentiometer till the display boom length is equal to
the actual boom length.

Adjust the
rotation shaft of
potentiometer
with a straight
screwdriver.
Figure 4-13 Adjust the display boom length of potentiometer

Chapter 4
CAUTION
(1) Do not unscrew other screws in the cable reel when adjusting the potentiometer.
(2) Turn the rotation shaft of potentiometer clockwise, the display boom length
increases. And turn it anti-clockwise, the display boom length decreases.
l) Adjust the bracing wire as follows:
Visually inspect whether the bracing wire on the drum winds orderly.If not, release some of
the bracing wire till it winds orderly.
4.4.7 Periodical inspection and maintenance of central collecting ring

[Prerequisites]
Switch off the electric source of complete vehicle.
Screwdriver, brush, detergent remover for carburetor and silicon grease
a) Check whether the electric brush and the electric ring contact well.
b) There is no power and dust inside.

a) Remove the housing of central collecting ring.
b) Take the electric brush outwards. Remove the power and dirt on the electric brush and the
electric ring with a brush.
c) Clean the power and dirt on the electric brush and the electric ring with detergent remover
for carburetor.
d) In this way, clean all of the electric brushes and the electric rings downwards.
e) Smear a little of silicon grease on each electric ring with a brush.
f) Align the electric brush to the center of electric ring. And slowly push the electric brush
inwards till it secures the fixing post.
g) Assemble the electric brush in turn.
h) Install the housing and tighten the set screw.
CAUTION
The above-mentioned maintenance procedures and methods are not suitable for a
Chapter 4
maintenance-free central collecting ring.

4.5 Periodical maintenance and replacement of wire rope
[Prerequisites]
Wrench, brush, steel bar, hammer and fine wire
a) Number of broken wires
If any broken wire is detected, make a mark on each side of the broken wire over a length
equal to 30×d (d is the nominal diameter of the rope). Count the broken wires between the
two marks.
Compare the number of broken wires with the value in the table. If the number of broken
Chapter 4
wires is less than the value, make a mark on each side of the broken wire over a length
equal to 6×d (d is the nominal diameter of the rope). Then count the broken wires between
the two new marks. Compare the number of broken wires with the value in the table. If the
number of broken wires is less than the value, it is unnecessary to replace the wire rope.
Table 4-1 Wire rope replacement standard
If the number of broken wires exceeds the following value, the wire rope must be replaced.
6×nominal diameter of wire rope 30×nominal diameter of wire rope
2 4
b) Tangle of broken wires

If broken wires come so near as to form tangle, must replace the wire rope. If broken wires
over a length less than 6d are often observed, or at the same strand, it is recommended to
replace the wire rope even if the number of broken wires is less than the value in the table.
c) Broken wire growth rate
If broken wires are detected for the first time, the number of broken wires increases rapidly
within a short time. Under this condition, you shall pay close attention to it. If necessary,
replace the wire rope.
d) Broken strand
Replace the rope with broken strand.
e) Reduction to wire rope diameter
Replace the wire rope of which the diameter is reduced by 7% or more of the nominal one.

f) External and internal corrosion
In oceanic climate or in the air containing industrial emissions, the wire rope could be
corroded internally and externally. Replace the rope if it is seriously corroded.
g) Deformation
When the rope core is exposed or the strands make a “bird cage” shape, replace the wire
rope.
h) Damage caused by heat or arc welding
If the wire rope undergoes extremely high temperature, its color will change. Replace the
wire rope.
a) Always remove foreign substance from the wire rope with a brush.
b) Lubricate the wire rope according to the operating conditions.
c) Every two years, cut off a short section of the rope end that is fixed to the drum. This can
prolong the service life of wire rope. Be sure to burn the new rope end into a taper to
prevent strand looseness. Further the length of the taper shall be 1/6 the circumference of
the rope at the first layer. Move the wire rope section originally at the
Chapter 4
transverse-arrangement area to the parallel-arrangement area. This can maximize the
service life of rope by more than twice the original service life.
d) Wire rope replacement:
1) Make the crane level on a hard surface.
2) Fully retract the boom.
Table 4-2 Wire rope replacement
Ser.
Operation steps Cautions Tools
No.
Lower the hook and set it on the ground. Carefully operate!

Wind the rope orderly on
the drum.

Ser.
No.
Remove the pouch socket from the top Set the parts to the side Tools necessary:
boom section or the hook. until they are necessary. Wrench.
Remove the wire rope from the pouch Set the parts to the side Tools necessary:
socket. until they are necessary. Steel bar,
hammer and
3 wrench.
Chapter 4
Lower the hook. Reeve out the rope Manually pull out the
from the drum and pull out the wire rope wire rope at the same
manually. time.
CAUTION
If there are only three
wraps left on the drum,
the lowering limit
4
switch on the main
winch will cut off the
“reel main winch off”
movement. At this
time, press the bypass
key switch to bypass
this limitation till all
ropes reel off.

Ser.
No.
Remove the wire rope from the winch Keep the wedge well. Tools necessary:
drum. Steel bar and
hammer.
Fix the wire rope end onto the main 1 Make sure that the Tools necessary:
winch drum with the wedge. wedge is in the correct Hammer.
position.
2 Make sure that the
Chapter 4
end of wire rope should
not be exposed out of
the drum.
6
Spool up the wire rope. 1 Wind the rope Tools necessary:

orderly on the drum. Thin steel wire.
2 Make sure the wire
7 rope end is fused or
tightened with thin steel
wires.

Ser.
No.
Reeve the wire rope through the top Make sure that you
boom head pulley block and hook pulley attach the wire rope in
block in the related reeving number. the correct sequence.
Install the pouch socket and rope clamp Make sure that the Tools necessary:
onto the wire rope. wedge is in the correct Wrench and
Chapter 4
position. hammer.
CAUTION
9 Set the rope end on the
side of the pouch
socket with bevel.
The rope lock seat is
set on the rope with
load.
Mount the pouch socket onto the top Tools necessary:

boom section or the hook according to Wrench.
rope reevings.
10

Ser.
No.
Derrick the main boom up to its limit Do not lower the hook Tools necessary:
angle and lower down the hook till there excessively. Otherwise Steel bar,
are only three wraps left on the drum. the wire rope may be hammer
damaged.
11
Lift a load that applies to the rope a The max. permissible Tools necessary:
tensile force equal to 30% the maximum lifting capacity cannot be Hammer and
Chapter 4
lifting capacity for each wire strand. exceeded. wrench.
Wind the wire rope on the drum.
Weight of load: W= 0.3 NP.
12
Reeving number: N
Max. permissible lifting capacity per
strand: P
13 Remove the load from the main hook.

CAUTION
(1) Actually, the wire rope is always damaged by various factors. During wire rope
inspection, you shall consider individual factors according to relevant criteria. At
this time, let the professional service personnel determine whether the wire rope
can be used any longer.
(2) Before replacing the wire rope, check whether the damage to wire rope is caused by
any fault with the system. If so, remove the system fault at first.
WARNING
Do not check and maintain the wire rope when the crane is with a suspended load.
Chapter 4

4.6 Periodical inspection and maintenance of load-bearing parts
4.6.1 Periodical inspection and maintenance of slewing table
[Prerequisites]
a) Crack of welding seam, sealing off.
b) Structural deformation.
c) Check them according to the schedule.
Clean rag
a) Crack of welding seam, sealing off: Check that the welding seams are complete without
any defect.
b) Structure deformation: Check the structural members for obvious deformation.
Chapter 4
Inspect the welding seams. As for the overall view of main welding seams of slewing table,
please refer to Figure 4-14.
a) Clean the welding seams with clean rag.
b) Visually check for the crack of welding seam and sealing off.
c) If there is any crack or sealing off, please contact the professional service personnel.
Main boom articulated point

Slewing table wall
plate
Derricking
articulated point
Slewing table base plate
Figure 4-14 Main welding seams of slewing table

4.6.2 Periodical inspection and maintenance of boom
[Prerequisites]
b) Check it when boom is in abnormality.
Clean dry rag, adjustable wrench, welding seam tester and ladder
defect.
b) Structural deformation: Check the structural members for obvious deformation.
c) Deformation and damage of main mounting parts: Check the main mounting parts such as
the pulleys, slide blocks, pins, pin pulling post and shaft sleeves for damage and
deformation. Make sure they operate normally.
Chapter 4
Figure 4-15 Maintenance points of boom sections
a) Inspection for crack of welding seam and sealing off (for the maintenance points of boom
sections, see Figure 4-15).
1) Clean the welding seams with clean rag.
2) Check for crack of welding seams and sealing off.
3) Contact the professional service personnel for treatment if any of above occurs.

b) Structural deformation
1) Check the boom body, head and tail for obvious deformation.
c) Inspection of pulleys, slide blocks, adjusting bolts and rollers
1) Inspection of pulleys
Check the upper and lower pulleys at boom head for deformation, collision, scraping
and impairment. Timely replace the faulty pulley if necessary.
2) Inspection of slide blocks, adjusting bolts and rollers
– Check the upper slide blocks at each boom section head for improper position.
Timely adjust the slide blocks if necessary.
– Check the adjusting bolts for damage. Timely replace the faulty bolt if necessary.
– Check the rollers for deformation and damage. Check whether they rotate freely.
Replace or lubricate them according to the actual conditions.
WARNING
It is strictly prohibited for anybody other than the professional service personnel to
Chapter 4
solve the problem related to the boom.
4.6.3 Periodical inspection and maintenance of jib

[Prerequisites]
a) Crack of welding seam, sealing off
c) Check them according to the schedule.
Clean dry rag
defect.
b) Structural deformation: Check the structural members for obvious deformation.

Chapter 4
Figure 4-16 Maintenance points of jib
As for the maintenance points of jib, see Figure 4-16.

a) Inspection for crack of welding seam
1) Clean the welding seams with a clean rag.
2) Check for crack of welding seams and sealing off.
1) Check the chord member, web member and articulated-point of jib for obvious
deformation.
3) Impairment of installing parts
Check that the pulley at jib head is in good condition and can rotate freely. Check that
the rope guard is securely installed without spring-loaded pin absence.
CAUTION
Strictly inspect the weld seams in complex shape or variable shape area of steel
structural member. The main weld seams of jib subject to load are indicated by the
arrows in Figure 4-16. Inspect the welding positions and the areas surrounding the
arrows. In case of crack of weld seams or other damage, timely contact the professional
service personnel for repair.

CAUTION
When the jib is lowered, the main boom shall be fully retracted or extended only to a
small length. Otherwise tip-over of complete crane could occur.
4.6.4 Periodical inspection and maintenance of hook

[Prerequisites]
The hook is not in the operating status.
Timely replace the hook, if one of the items that follow occurs:
a) Check the surface of hook for crack and crevasse.
Chapter 4
b) Check whether the split degree of hook exceeds 10% of the original dimensions.
c) Check whether the abrasion of the dangerous sectional plane exceeds 10% of the original
dimensions.
d) Check whether the wear extent of the sectional plane in load suspended point exceeds
10% of the original height.
e) Check whether the torsion and deformation of hook exceeds 10º.
f) Check whether there is plastic deformation in dangerous sectional plane such as the tail of
hook, the screw threaded part and hook web.
CAUTION
Do not weld the hook to repair the impairments.
a) Clean the surface of hook with clean rag. Visually check the surface of hook for crack.
b) Measure the split degree of hook, the dimensions of dangerous sectional plane, and the
wear extent of the sectional plane in load suspended point with a steel tape. Check
whether they exceed 10% of the original dimensions.
c) Measure the screw threaded pitch with vernier calipers. Check it for plastic deformation.
d) Measure the hook with an angle gauge. Check whether the hook torsion exceeds 10º.

4.6.5 Periodical inspection and maintenance of counterweight
[Prerequisites]
a) The lifting cylinder detachment or detachment tendency exists.
b) Crack, local detachment, or partial detachment tendency exists on the main body.
Adjustable wrench and clean rag
a) Check the connecting bolts of counterweights for looseness, especially the counterweight
connecting bolts to slewing table.
b) Check the casting counterweight for crack due to collision.
c) Check the lifting positions for crack.
d) Check for counterweight paint peeling off.
Chapter 4
e) Check for counterweight rust.

f) Check for structural counterweight for water leakage.
g) Check counterweight for detachment and deformation due to collision.
CAUTION
If the case a), b) or c) occurs, be sure not to use the counterweight until the defect is
removed.
a) Exercise caution when transferring or turning over the counterweight, to prevent
deformation, crack and detachment.
b) When storing a counterweight, place a wood sleeper under it.
c) The slings for lifting counterweight shall have sufficient strength.
d) Before hoisting any object, properly assemble counterweights according to the rated lifting
capacity table. Otherwise tip-over of complete crane could occur.

4.7 Maintenance points of superstructure
4.7.1 Points of inspection and maintenance
Chapter 4

Chapter 4
4-44
Jib
Main boom
Wire rope Telescoping system
Hook
Hoist gear
Engine and its
peripheral system
Load moment limiter
Slewing gear
Figure 4-17 Points of inspection and maintenance, superstructure

Counterweight handler
Counterweight
ZTC Series Truck Crane（25t~80t）

4.7.2 Lubricating points
— Lubrication chart
13
12
14
11
15
10
16
9
17
Chapter 4
8
7
6
3
5
2
4
1
Figure 4-18 Lubricating points, superstructure

— Lubricating table
Pos. Description Intervals Method Lubricant type
Upper pulley block Inject with

1 Every 10 days ZL-2 Lithium base grease
(shaft) of main boom grease pump
Manually
Slide blocks of main smear or inject ZFG-4E Molybdenum
2 Every 10 days
boom with grease disulfide grease
pump
Low pulley block (shaft) Inject with
of main boom grease pump
Pulley blocks (shafts) of Inject with
main and auxiliary hooks grease pump
Upper articulated point
shaft and knuckle Inject with
5 Every week ZL-2 Lithium base grease
bearing of derricking grease pump
Chapter 4
cylinder
Low articulated point
Inject with
6 shaft of derricking Every week ZL-2 Lithium base grease
grease pump
cylinder
Operator’s cab tilting Inject with
7 Monthly ZL-2 Lithium base grease
mechanism grease pump
Manually
Slewing bearing and smear or inject
gears with grease
pump
Sliding surfaces of Manually ZFG-4E Molybdenum
9 Every 10 days
sliding beams smear disulfide grease
Manually
Outrigger telescoping smear or inject
pulley with grease
pump
Inject with
11 Counterweight handler Semi-annually ZL-2 Lithium base grease
grease pump
Main and auxiliary winch L-CKD150 Industrial gear
12 Annually Directly pour
reducers oil for closed loop
Propeller shaft of oil Inject with
13 Daily ZL-2 Lithium base grease
pump grease pump

Pos. Description Intervals Method Lubricant type
Manually
smear or inject
14 Main shaft of main boom Daily ZL-2 Lithium base grease
with grease
pump
L-CKD150 Industrial gear
15 Slewing reducer Semi-annually Directly pour
oil for closed loop
Inject with
16 Pulley block (shaft) of jib Every 10 days ZL-2 Lithium base grease
grease pump
Manually
17 Wire rope Every 10 days ZL-2 Lithium base grease
smear
CAUTION
(1) The ZL-2 lithium base grease is used for general purpose. The ZL-2
extreme-pressure lithium base grease is optional.
Chapter 4
(2) You cannot mix grease of different brands (specifications) or types.
(3) When you inject lubricant (grease) into the bushing, shaft and bearing with a grease
pump, continue the procedure until the used grease is expelled out.
(4) With the boom retracted onto the bracket, clean and lubricate the exposed piston
rod of derricking cylinder monthly.

4.8 Periodic cleaning and replacement of superstructure hydraulic valve blocks
4.8.1 Filtering screen of the combination control valve
[Prerequisites]
a) Check and replace it when necessary;

b) Replace according to the schedule (once every three months as recommended).
No heavy dust or water deposit; the crane is parked on a flat and solid ground, with the engine
shut down and the parking brake applied.
[Tools necessary]
Wrench, oil container, illuminating device and clean wipe.

Chapter 4
To check the surface of the filtering screen for damage or deposit of excessive foreign matters.
The combination control valve is as shown in Figure 4-19.
The filtering screen is

inside the check valve
Figure 4-19 Combination control valve

Fitting seat 2
Filtering screen
Fitting seat 1
Figure 4-20 Section view of the check valve
a) Remove the check valve using a fork spanner;
Chapter 4
b) Carefully detach the fitting seat 1 and 2, and prevent the spring and the valve core from
falling out;
c) Take the spring and valve core out;
d) Take the filtering screen out using a 6mm hexagon wrench;
e) Install a new filtering screen or reinstall the old one after it is cleaned;
f) Clean the check valve after it is re-installed. Install the valve into the control valve block.
CAUTION
Change of the filter element should be conducted in a dust-free environment.
4.8.2 Filtering screen of the superstructure control valve 1
[Prerequisites]

[Tools necessary]

The superstructure control valve 1 is as shown in Figure 4-21.
Filtering
screen
Figure 4-21 The superstructure control valve 1

Chapter 4
a) Remove the fitting of the Y port of the oil inlet/outlet valve using a wrench;
b) Take the soiled filter element out;
c) Install a new filter element or re-install the old one after it is cleaned;
d) Re-install the Y port and tighten the fitting.
CAUTION
4.8.3 Filtering screen of the superstructure control valve 2
[Prerequisites]

[Tools necessary]

The superstructure control valve 2 is as shown in Figure 4-22.
Filtering
screen
Chapter 4
Figure 4-22 The superstructure control valve
a) Remove the screw plug from the end cover

d) Re-install the end cover and tighten the screw plug.
CAUTION
4.8.4 Filtering screen of the winch balance valve
[Prerequisites]

[Tools necessary]

The winch balance valve is as shown in Figure 4-23. Its filtering screen is located inside the
control port X.
Chapter 4
Control port
Figure 4-23 Winch balance valve
a) Remove the screw plug from the control port X using a wrench;
d) Tighten the screw plug.
CAUTION
4.8.5 Filtering screen of the slewing cushion valve
[Prerequisites]

[Tools necessary]

The slewing cushion valve is as shown in Figure 4-24.
The filtering
screen is
under the
hose fitting
Chapter 4
Figure 4-24 The slewing cushion valve
a) Remove the overflow valve as shown in the Figure 4-24 using a wrench and expose the
filtering screen;
d) Re-install the end cover and tighten the screw plug.
CAUTION
4.8.6 Filtering screen of the derricking balance valve
[Prerequisites]

[Tools necessary]

The derricking balance valve is as shown in Figure 4-25.
Control port X
Figure 4-25 Derricking balance valve

Chapter 4
a) Remove the steel pipe and fitting from the control port X to expose the filtering screen;
d) Re-install the steel pipe and tighten the screw plug.
CAUTION
Change of the filter element should be conducted in a dust-free environment

Chapter 5 Periodical Maintenance Guidelines for
Chassis
5.1 Periodical inspection and maintenance

5.1.1 Periodical inspection and cleaning of fuel filter element
[Prerequisites]
a) Inspect and clean the filter when necessary.
b) Replace the filter according to the schedule.
Wrench, container, lighting equipment and clean rag
a) Check that there are not a number of particles on the filter element surface.
b) Check the filter element for damage.
a) Inspection and cleaning of the fuel coarse filter:
Chapter 5
1) Open the water drain valve. Loosen the air bleed screw. Collect the fuel and water
mixture from the filter with a container.
2) Remove the filter casing (including the filter element).
3) Remove the fuel-water separator from the filter casing. Clean the separator. Replace it
when necessary.
4) Check the filter element surface for damage and particle adhesion. Clean or replace
the filter element when necessary.
5) Install the new filter casing to the manual pump. Add fuel into the fuel coarse filter via
the manual pump. Tighten the air bleed screw.
6) Start the engine. Deaerate the fuel supply system. Check the fuel coarse filter for
leakage.

Manual pump
Filter casing
Fuel-water separator
Water drain valve
Air bleed screw
Figure 5-1 Fuel coarse filter
CAUTION
(1) Replace the O-ring after the fuel coarse filter is disassembled.
(2) Manually tighten the filter casing to the filter head.
(3) Run the engine for about 1 min. to deaerate the fuel supply system. If the engine
cannot be started, deaerate the fuel supply system by operating the manual pump.
b) Replacement of the fine filer:
Chapter 5
1) Loosen the filter cover. Gently pull the filter cover and filter element out of the casing.
Drain the fuel.
2) Press the lower edge of filter element to disassemble the filter element from the filter
cover.
3) Replace the seal ring.
4) Install the new filter element into the cover. Screw the filter cover and element to the
casing with 25 N ·m tightening force.
5) Start the engine to deaerate the fuel supply system. Check the fuel coarse filter for
leakage.

Filter cover
Seal ring
Filter element
Figure 5-2 Fuel fine filter
CAUTION
(1) Ensure that no foreign substance or water enters into the filter casing when
replacing the filter.
(2) Do not wipe the filter casing.
(3) Apply a little grease on the seal ring for protection purpose.
(4) While replacing the filter element, protect the surface of engine from contamination
Chapter 5
by diesel oil.
5.1.2 Periodical inspection and maintenance of air filter element

[Prerequisites]
a) The transparent portion of air filter soiled indicator turns red.
b) Inspect and maintain when necessary.
c) Inspect and replace the filter element according to the schedule.
Wrench, air compressor, lighting equipment and clean rag
WARNING
(1) Do not inspect, clean or replace the filter element during engine running.
(2) While using compressed air, wear safety goggles, dustproof mask and other
protection devices (if any), to prevent injury caused by dirt flying out.

a) Check the removed filter element for damage and incomplete separation.
b) Check the seal ring at air filter end and the dust removal valve for damage.
The maintenance method of air filter may slightly vary according to the sealing method between
filter element and casing. However, no matter which sealing method is used, the air filter
element shall be cleaned or replaced with the transparent portion of filter soiled indicator in the
inlet pipeline turning red.
a) For the air filter with axial sealing between filter element and casing, maintain the filter
element as shown in Figure 5-3:
1) Loosen the butterfly nut. Pull out the rear end cover.
2) Loosen the retaining nut of filter element. Pull out the main filter element and clean it.
Replace it when necessary.
3) Use a clean rag to cover the outlet of air filter, to prevent dirt from entering the inlet
pipeline.
4) Using a clean rag, wipe the sealing surface of filter element and the inner surface of
outlet pipe of air filter.
5) Replace it with a new filter element. Check it for damage.
6) Clean the rear end cover of air filter. Insert the filter element slightly. Tighten the
retaining nut.
7) Press the rear end cover of air filter, and tighten the butterfly nut.
Chapter 5
8) Remove the filter soiled indicator to clean it with compressed air, and reinstall it.
Meanwhile press the top of filter soiled indicator so that the indicator turns green.
Safety filter element Retaining nutMain filter element Rear end cove Butterfly nut
Figure 5-3 Air filter with axial sealing
CAUTION
When replacing the safety filter element, remove the inner retaining nut and pull out the
safety filter element.

b) For the air filter using radial sealing between filter element and casing, maintain the filter
element as shown in Figure 5 -4:
1) Loosen the rear end cover of air filter. Gently move the filter element back and forth to
separate the seal. Pull backwards the filter element while rotating it. Avoid knocking at
the filter casing.
2) Using the same method, remove the safety filter element.
3) Using a clean rag, cover the outlet of air filter, to prevent dirt from entering the inlet
pipeline.
4) Using a clean rag, wipe the sealing surface of filter element and the inner surface of
outtake pipe of air filter. At the same time, manually press the dust removal valve, to
check for elasticity loss, clogging or damage.
5) Inspect the removed filter element for leakage. Clean it. Replace it when necessary.
Before installing the new filter element, rectify the cause for leakage.
6) Check the new filter element especially the inner sealing area for damage.
7) Insert correctly the new filter element. Before tightening the filter cover, check that the
filter element is fully inserted in air filter. To achieve tight sealing, manually press the
outer edge of filter element rather than the soft center of gravity.
8) Install and tighten the rear end cover of air filter.
9) Remove the filter soiled indicator. Clean it using compressed air. Install it. Meanwhile
press the top of maintenance indicator so that the indicator turns green.
Chapter 5
Seal ring Main filter element Safety filter element
Dust removal valve
Figure 5-4 Air filter with radial sealing
CAUTION
(1) The filter element and rear end cover must be correctly installed in place. Otherwise
dust could be suctioned in, thus affecting filtration effect.
(2) Before installing the filter element, wipe the inner surface of filter casing using a wet
rag, especially the sealing surface and outtake pipe.

WARNING
Do not clean the safety filter element. For every three times of replacement of outer main
filter element, also replace the safety filter element. Before installing the main filter
element, check that the safety filter element is installed in place.
c) Using the following method, remove the dry dust from the filter element. See Figure 5-5.
1) Clean the filter element from inside towards outside along the crease using dry
compressed air.
2) Clean the filter element outside along the crease, finally clean the filter element from
inside towards outside.
3) After cleaning the filter element, check its inside using an electric torch (or lamp) for
damage. If the filter element is OK, install it to the filter casing. If not, replace it with a
new one.
Chapter 5
Figure 5-5 Cleaning the filter element
WARNING
(1) It is strictly prohibited to knock at or collide with the filter element. The compressed
air pressure shall not exceed 7 bars.
(2) It is strictly prohibited to use any wet filter element.
5.1.3 Periodical inspection and replacement of return oil filter element

[Prerequisites]
a) Inspect and replace the return oil filter element when necessary.
b) Replace the return oil filter element according to the schedule.

Wrench, oil container, lighting equipment and clean rag
Check the filter element surface for damage and excessive foreign matter.
a) Remove the top cover with a wrench. Take out the filter element.
b) Check the filter element surface for foreign matter. Clean the filter element when
necessary.
c) Check the filter element surface for damage. Replace the filter element when necessary.
d) Install the filter element in the reverse order.
e) Methods to clean the filter element:
1) Standard cleaning method
Put the dirty suction filter element into the ultrasonic cleaning machine to make the
filter element immerged in the cleaning solution, add cleaning agent and unoiling
powder, and wash it in a vibrating way.
2) Simple cleaning method
Immerse the filter element into the oil with lower viscosity (such as diesel oil and
paraffin), brush the filter element surface with hairbrush gently to avoid damaging to
the filter screen.
CAUTION
Chapter 5
Replace the filter element in a dust free environment.
5.1.4 Periodical inspection and replacement of suction oil filter element

[Prerequisites]
a) Inspect and replace the suction oil filter element when necessary.
b) Replace the suction oil filter element according to the schedule.
Wrench, oil container, lighting equipment and clean rag
Check the filter element surface for damage and excessive foreign matter.

Suction oil filter Suction oil filter element O-ring Filter element cover
Figure 5-6 Suction oil filter
a) Screw loose the filter element cover and take out the cover. At this time, the self-sealing
valve will be shut off automatically.
b) Take out the dirty filter element.
c) Replace it with a new filter element or reinstall it after cleaning.
d) Put the cover on the filter element and screw tightly the cover.
Chapter 5
CAUTION
Replace the filter element in a dust free environment.
5.1.5 Periodical inspection and replacement of air dryer

[Prerequisites]
a) Inspect and replace the air dryer when necessary.
b) Replace the air dryer according to the schedule.
Wrench, lighting equipment and clean rag
Check the filter element of air dryer for validness. Check the air reservoir for water
accumulation every day. If any, replace the filter element of air dryer. The filter element
replacement interval may not exceed six months.

a) Check the filter element of air dryer for failure as follows.
Manually pull the ring of drain valve of air reservoir and visually check for water
accumulation every day.
b) Replace the filter element of air dryer as follows.
1) Manually remove the filter element of old air dryer counterclockwise.
2) Apply anaerobic adhesive or sealing adhesive to the connecting threads of filter
element of the new air dryer. Apply uniformly grease to the rectangular seal ring.
3) Clean the interface. Place the new filter element in place. Rotate it clockwise to a
tightening torque approximately 15 N·m.
Chapter 5
Figure 5-7 Air dryer
5.1.6 Periodical inspection and replacement of hose

[Prerequisites]
a) Inspect and replace the hoses when necessary.
b) Replace the hoses according to the schedule.
Wrench, screwdriver, lighting equipment, oil container and clean rag
Check the hose for crack, aging, damage, permeation and leakage.

WARNING
Immediately replace the damaged or cracked suction hose of oil pump, otherwise
damage could be caused to the oil pump.

a) Check the hose surface for crack, aging and damage.
b) Check the hose fitting for leakage.
CAUTION
While removing the hose, cover the opening for the hose using clean material.
5.1.7 Periodical inspection and replacement of battery

[Prerequisites]
a) When turning the ignition starter switch to the ON position, the lamp glows dimly, or the
engine cannot be started smoothly, or the voltage measured by voltmeter is less than 22 V.
b) Inspect and replace the battery when necessary.
c) Maintain the battery according to the schedule.
Room temperature and no dust
The master switch of power supply is turned off.
Chapter 5
Clean rag and multimeter
a) Check the battery surface for dust and acid.
b) Check that the wires are securely connected to the posts of battery.
c) Check the posts of battery for rust.
WARNING
(1) If the battery voltage is lower than 22 V, immediately charge the battery until the
voltage rises to above 24 V. Otherwise, the battery could be excessively discharged,
thus scrapped.
(2) If the crane will not be used for more than one month, disconnect the wires of
battery from the electrical system. If the battery will not be used for a long period,
charge the battery every three months.

a) Periodically check the battery for dust and acid on its outer surface. If any, wipe it off using
a rag wet with soda, and then wash the battery surface using fresh water.
b) Periodically check the wires of battery for looseness. If any, timely tighten the stud to
ensure wires are securely connected to the terminal stud.
c) Periodically check the positive and negative terminal stud of battery for oxidization and
rust. If any, remove it completely. Then apply vaseline to the metal part.
Steps and methods for battery replacement
a) Open the battery cover.
b) Disconnect the wires from the battery.
c) Carefully remove the battery.
d) Replace the new battery in the reverse sequence of removal.
CAUTION
If the battery cannot be charged normally, or the battery is damaged due to collision, it
must be replaced. Pay attention to following points:
(1) Battery wire connection sequence: First the wire to positive terminal, then the wire
to negative terminal.
(2) Battery wire disconnection sequence: First the wire to negative terminal, then the
wire to positive terminal.
Chapter 5
(3) While transferring the battery, do not tilt it for more than 40º. It is prohibited to
reverse the battery or use its side face as the supporting face. While transferring the
battery, be careful to prevent any secondary damage.
(4) It is prohibited to place on the vehicle the battery with leakage.
(5) It is prohibited to strike or twist the posts of battery for installation purpose.
(6) Ensure that all electrical devices in the superstructure are turned off before
installing the battery.

5.1.8 Periodical inspection and maintenance of air-conditioning system
[Prerequisites]
a) Inspect the air-conditioning system when it fails to provide cooling.
b) Inspect the air-conditioning system when it fails to provide heating.
c) Inspect and maintain the air-conditioning system according to the schedule.
Normal environment
Wrench
a) Check the fittings for pipeline, compressor fixing bracket and compressor belt for
looseness. Check the hoses of cooling system for wear. Check the insulation of electrical
circuit for damage and aging. Check all inserts for looseness.
b) Check that the A/C functions for cooling and heating.
The composition of A/C is shown in Figure 5-8.
Temperature sensing package of expansion valve Evaporator Evaporator fan

Chapter 5
Low-pressure hose
Condenser
Sight glass
Driving belt
Compressor
Fluid dryer
Condenser fan
Figure 5-8 Air-conditioning system

a) Inspection of air-conditioning pipes:
Inspect all pipelines as shown in Figure 5-8 for looseness. If any, tighten the loose
pipelines.。
b) Inspection for driving band of compressor of A/C:
Check the driving band of compressor of A/C for looseness or wear. If any, immediately
replace the belt or adjust the position of the compressor of A/C.
c) Inspection of condenser assembly:
Check the radiating rib of condenser for collapsing or clogging. If any, immediately remove
the clogging.
d) Inspection of refrigerant:
Connect the service personnel for inspection and maintenance.
Chapter 5

5.2 Periodical inspection and replacement of oil
5.2.1 Periodical inspection and replacement of engine coolant
[Prerequisites]
a) Inspect and replace the engine coolant when necessary.
b) Inspect and replace the engine coolant according to the schedule.
No dust.
Wrench, coolant container, lighting equipment and clean rag
a) Check whether the coolant level in the expansion water tank of cooling system is between
the lowest level (Min) and the highest level (Max) of liquid level gauge.
b) Check that the coolant contains no excessive rust.
c) Replace the coolant after two years’ use.
a) Inspect the engine coolant level. See Figure 5- 9.
Observe the coolant level. Ensure that the coolant level is between the lowest level (Min)
Chapter 5
and the highest level (Max) of liquid level gauge. If the coolant is insufficient, open the filler
cap and add coolant.
CAUTION
(1) Before adding coolant, turn off the engine. Further, the coolant temperature already
in the cooling system should be no more than 50ºC.
(2) The added coolant shall be of the same brand and grade as the original one.
Filler cap
Liquid level gauge
Max
Min
Figure 5-9 Expansion water tank

b) Engine coolant replacement
1) Loosen the water drain screw at the radiator bottom, to drain the coolant out of the
cooling system. The capacity of the cooling system is approximately (40 – 45) L
coolant.
2) Check the radiator hose for damage and deflation. Check the clamp for looseness and
damage. If necessary, replace the clamp. Check the hose for leakage and scale
build-up. If necessary, clean and repair the hose.
3) Fill the cooling system of engine with sodium carbonate solution (adding 1 kg sodium
carbonate into 45 L water).
CAUTION
(1) For cleaning the cooling system with the cleaning agent, run the engine with
the expansion tank uncovered.
(2) While adding cleaning agent, expel the air from the cooling cavity.
4) Start the engine. Run it for 5 minutes with the coolant temperature higher than 80ºC.
Turn off the engine. Drain the cleaning agent.
5) Add fresh water into the cooling system. Run the engine for 5 minutes, with the
expansion water tank uncovered, and the coolant temperature higher than 80ºC. Turn
off the engine. Drain the coolant.
6) Add a proper amount of coolant (selecting the amount from the table according to
Chapter 5
ambient temperature).
CAUTION
While adding coolant, exhaust the air from the coolant chamber.
7) Put the cover on the expansion water tank. Start the engine. When the coolant
temperature reaches 80ºC, check the cooling system for leakage. Turn off the engine.
Check for low coolant level. If so, add a proper amount of coolant.
CAUTION
Be sure not to open the expansion water tank before adding coolant if the coolant
temperature does not fall to below 50ºC. This prevents scalding.
WARNING
(1) Be sure to wait until the engine is cooled down for checking coolant level. This
prevents burning and scalding.
(2) Since coolant is flammable. Exercise special caution against naked fire.
(3) Coolant is toxic. It contains antifreeze. While removing the drain plug, be

careful to prevent the coolant splash onto your body. In case of splash into
eyes, wash with a great deal of clean water. Immediately see the doctor.
(4) Coolant insufficiency could cause engine overheating as well as air ingress.
The latter could further cause corrosion in the cooling system.
5.2.2 Periodical inspection and replacement of engine oil

[Prerequisites]
a) Inspect and replace the engine oil when necessary.
b) Inspect and replace the engine oil according to the schedule.
No dust.
a) Check that the oil level is between the Min. mark and the Max. mark.
b) Check the hydraulic oil for foreign matter. Check that the hydraulic oil is clear without
emulsification.
a) Engine oil level inspection:
Chapter 5
1) Pull the dipstick out of engine body.

2) Wipe the dipstick with a clean rag.
3) Insert the dipstick into the engine body.
4) Pull out the dipstick again. Observe the oil level on the dipstick. When engine oil is
cold, the engine oil level shall be between the Min. and the Max. marks, but near the
Min. mark. When engine oil is hot, the engine oil level shall be between the Min. and
the Max. marks, but near the Max. mark.
5) If the engine oil level falls beyond the range, add or drain a proper amount of engine
oil according to actual situation. Check engine oil level again. Repeat the process
until engine oil level is acceptable.
CAUTION
(1) After inspecting the oil level on the dipstick, insert the dipstick in place to prevent
engine oil leakage.
(2) Add new engine oil of the same grade as the previous engine oil. If the grade of new
engine oil is different from that of the previous one, the engine oil replacement
interval in future shall be determined by the engine oil of lower grade.
(3) In case of abnormal engine oil consumption, be sure to carefully check the dipstick,

turbocharger and air compressor for engine oil leakage. If any, remove the cause.
b) Engine oil replacement:
1) Remove the oil drain plug from the oil sump. Drain the engine oil into the container.
2) Clean the oil drain plug. Replace the O-ring. Put on the oil drain plug again and screw
tightly.
3) Refer to the Table for Oil and Medium Capacities in this manual. Add engine oil via the
filler hole until the engine oil level rises between the Min. and the Max. marks.
4) Start the engine. Run the engine at idle speed. Observe the engine oil pressure gauge
until it indicates a pressure value.
5) Turn off the engine. After approximately 5 minutes, inspect engine oil level. If
necessary, add engine oil until the engine oil level reaches the Max. mark on dipstick.
CAUTION
(1) If the engine oil pressure gauge does not indicate a pressure value after the
engine runs at idle speed for 10 seconds, turn off the engine and check the
engine oil filter and oil drain plug of leakage.
(2) When replacing engine oil, be sure to also replace the engine oil filter element.
Otherwise the engine oil is very easily contaminated.
5.2.3 Periodical inspection and replacement of gear oil of transmission

[Prerequisites]
Chapter 5
a) Inspect and replace the gear oil of transmission when necessary.
b) Inspect and replace the gear oil of transmission according to the schedule.
No dust or rain.
Check the gear oil for foreign matter. Check that the gear oil is clear without emulsification.
Check that the oil level reaches the lower edge of filler hole.
a) For the inspection of gear oil level of transmission, see Figure 5-10.
1) Set the transmission at neutral position.
2) Loosen the oil fill plug. Check that the gear oil level is at the lower edge of oil fill hole. If
the oil level is low, add oil.

Oil filler hole
Oil drain plug
Figure 5-10 Gear oil fill and drain of transmission
b) Oil replacement and maintenance:

1) Set the transmission at neutral position.
2) Loosen the oil drain plug of transmission. Drain all the oil from the transmission into
the container.
3) Clean the magnet of oil drain plug. Replace the seal ring of oil drain plug.
4) Tighten the oil drain plug with a torque 60 N· m.
5) Refer to the Table for Oil and Medium Capacities in this manual. Add oil via the oil fill
hole until the oil level reaches the lower edge of the oil fill hole or overflows.
CAUTION
When replacing gear oil of transmission, be sure to also replace the seal ring of oil
Chapter 5
drain plug
5.2.4 Periodical inspection and replacement of gear oil of driven axle

[Prerequisites]
a) Inspect and replace the gear oil of driven axle when necessary.
b) Inspect and replace the gear oil of driven axle according to the schedule.
None
Container, clean rag, adjustable wrench and Allen wrench.
a) Check the gear oil for foreign matter. Check that the gear oil is clear without emulsification.
b) Check that the oil level reaches the lower edge of filler hole.

On the left is the central reducer. And on the right is the wheel reducer.
See Figure 5 -11.
Oil drain plug
Oil fill plug Oil drain plug Oil fill plug Oil drain plug
Figure 5-11 Oil fill plug and oil drain plug of driven axle
a) Oil level inspection of driven axle:

1) Extend the outriggers to raise the tires from the ground. Rotate the wheel to make the
oil drain plug of wheel reducer face down.
2) Loosen the oil fill plug. Check that the gear oil level of drive axle reaches the lower
generatrix of oil fill hole. A little overflow is permissible. The lowest level is 8 mm
below the lower generatrix of oil fill hole. Add oil if the oil is insufficient.
Chapter 5
CAUTION
After oil level inspection, tighten the plug of observation hole.
b) Replacement and maintenance of gear oil of driven axle:

1) Extend the outriggers to raise the tires from the ground. Rotate the wheel to make the
oil drain plug of wheel reducer face down.
2) Open all the oil drain plugs on the axle. Drain the oil from the axle into the container.
3) Clean the magnet of oil drain plug. Replace the seal ring of oil drain plug.
4) Refer to the Table for Oil and Medium Capacities in this manual. Add gear oil via all the
filler holes in axle until a little oil overflow occurs. Restore and tighten the oil fill plug.
5) Start the engine. Set the transmission at a lower gear. Run the drive axle at low speed
for (1 – 3) min. Observe oil level via the oil fill hole. If the oil level falls, add oil. Repeat
the process for several times until the oil level does not fall any longer.
5.2.5 Periodical inspection and replacement of hydraulic oil

[Prerequisites]
a) Replace the hydraulic oil when it deteriorates.
b) Inspect and replace the hydraulic oil when necessary.
c) Inspect and replace the hydraulic oil according to the schedule.

CAUTION
(1) This crane adopts hydraulic drive. The quality, viscosity and cleanliness of
hydraulic oil are of great importance to the normal operation of the crane.
Neglecting hydraulic oil replacement easily causes various faults of the crane even
seriously reduces its service life. The consequence caused by hydraulic oil
replacement not meeting the requirements set down in this manual shall not be
borne by Zoomlion Mobile Crane Branch Company.
(2) Whenever serious contamination is detected of hydraulic oil, replace the hydraulic
oil immediately.
(3) Select proper hydraulic oil according to ambient temperature.
(4) Do not mix hydraulic oil of different grades.
(5) The hydraulic oil may not be used for more than 18 months. After 18 months, you
cannot use the hydraulic oil even though it is filtered.
Please ensure that the following preconditions for the periodical inspection and replacement of
hydraulic oil are met:
a) In the normal environment without pollution, the upper and lower portions of crane are
restored to the initial out-of-operation status.
b) The engine is turned off.
Chapter 5
c) The outrigger extension cylinders and swing cylinders are fully retracted.
d) The hydraulic oil is moderately warm.
Container, wrench, lighting equipment and clean rag
a) Check that the oil level is between the Min. mark and the Max. mark.
b) Check the hydraulic oil for foreign matter. Check that the hydraulic oil is clear without
emulsification.
a) Oil level inspection:
Via the dipstick, inspect the steering oil level. With the steering wheel set at the middle position,
the steering oil level shall be between the Max. and Min. levels of dipstick. Add oil if the level is
too low.
b) Oil replacement:
1) Loosen the oil drain plug. Drain the hydraulic oil from the tank. Clean the tank and filter
using new hydraulic oil. Tighten the oil drain plug.
2) Disconnect the return oil pipe from the oil tank. Fix the plug to the return oil hole of the
tank.

3) Set the transmission at neutral position. Start the engine. Run it at low speed to start
the oil pump. Turn the steering wheel left and right. Expel the used oil from the circuits
of hydraulic system using new hydraulic oil. The used oil shall not return to the oil tank.
Run the engine until new oil flows out of the return oil pipe.
WARNING
While replacing oil, be sure to continuously add new hydraulic oil into the hydraulic
oil tank, to prevent the pump from suctioning seriously and being damaged.
4) Connect the return oil pipe to the oil tank. Add oil into the tank until the oil level
5) Start the engine. Run it at low speed. Turn the steering wheel left and right for several
times to exhaust air from the steering system.
6) Turn off the engine. Check whether the hydraulic oil level meets the requirement. Add
oil if the level is too low.
5.2.6 Periodical addition of grease

[Prerequisites]
Chapter 5
Grease pump, clean rag, lighting equipment
WARNING
(1) It is strictly prohibited to perform crane maintenance while the crane starts or is
travelling.
(2) Be sure to apply the parking brake before performing crane maintenance.
(3) The replacement cycle starts from the previous maintenance or replacement.
(4) Before performing crane maintenance, check that the ambient environment is safe
and take preventive measures.
Check that there is sufficient grease at each lubrication point.

Add grease using a common grease pump. See Figure 5-12.
a) Using a clean rag, clean the grease cup.
b) Insert the nozzle of grease pump into the grease cup. Press repeatedly the handle and
cylinder using your hands.
c) Add grease to each lubrication point until the used grease is expelled out.
d) Remove the used grease expelled out.
Figure 5-12 Add grease using grease pump
CAUTION
For maintenance only use grease of the grade required in this manual. It is strictly
prohibited to use the grease being contaminated or containing foreign matter. It is
strictly prohibited to mix grease of different grades.
(1) Be sure to periodically lubricate the sliding surfaces that are not listed in this
Chapter 5
manual.
(2) NLGI-2 Mobil grease must be used for the maintenance of intermediate support of
propeller shaft.
(3) Graphite calcium-based grease must be used for the maintenance of leaf spring.
(4) If the used grease expelled out is not removed, sand or dust may stick to it, causing
wear of rotating parts.
(5) Increase the maintenance frequency if the crane is frequently used.

5.3 Periodical inspection and tightening of key fasteners
[Prerequisites]
a) Inspect and tighten the key fasteners when necessary.
b) Inspect and tighten the key fasteners according to the schedule.
No dust.
CAUTION
If the crane is positioned on a slope, place blocks under tires to prevent the crane from
moving unexpectedly!
Torque wrench and small pry bar
CAUTION
The fasteners must be tightened to specified torque to ensure the safety of crane.
Chapter 5
WARNING
It is strictly prohibited to perform crane inspection and maintenance while the crane
starts or is travelling!

Table 5-1 Tightening torque of nuts
Use Maintenance focus

thread-
Tightening
Description Specification locking Very Extremely
torque Important
fluid or important important
not?
Wheel 25T–55T (550–600)N·m No ★★★

M22×1.5
nuts 60T–80T (820–870)N·m No
BY
Nut of propeller shaft (200–230)N·m No ★★★
M14×1.5F-10
Transmission
BY
intermediate bearing (200–230)N·m No ★★★
M14×1.5F-10
nuts
BY
Nut of thrust rod (490–510)N·m No ★★★
M18×1.5F-10
U-bolt and nut BY

(560–620)N·m No ★★★
(front) M22×2.5F-8
Chapter 5
U-bolt and nut BY (1527–1627)N·

No ★★★
(rear) M27×3F-10 m
Ball joint nut of

M24×1.5 (160–180)N·m No ★★☆
steering linkage
Clamp nut of
M14×1.5 (160–180)N·m No ★★☆
steering linkage
CAUTION
The nuts which not use thread-locking fluid are check nuts in the above table.
When the crane has covered a specified mileage, pre-tight the nuts crosswise, then tighten
them in the same order. See Figure 5-13.
a) Tighten all the wheel nuts upon delivery or after the crane has traveled 100 km.
b) Tighten all the wheel nuts again upon delivery or after the crane has traveled 1000 km with
replaced tires.
c) Tighten all the wheel nuts again upon delivery or after the crane has traveled 5000 km with
replaced tires. After that, tighten the wheel nuts every 5000km.

d) Refer to the following table for tightening torque when tightening the wheel nuts:
Table 5-2 Tightening torque of wheel nuts
Vehicle type 25T–55T 60T–80T

Tightening torque of wheel
(550–600) N·m (820–870) N·m
nuts
Figure 5-13 Tightening order of nuts
Chapter 5

5.4 Periodical inspection and maintenance of mechanisms and
systems
5.4.1 Periodical inspection and adjustment of outrigger telescoping
mechanism
[Prerequisites]
a) Inspect and adjust the outrigger telescoping mechanism when necessary.
b) Inspect and adjust the outrigger telescoping mechanism when the outrigger cannot be
extended or retracted freely.
No dust.
Adjustable wrench
a) Check that dimensions of full extension and full retraction meet the requirements.
b) Check the pulley assembly for wear or clamping.
Chapter 5
a) Transverse spread of outriggers

For the two-section sliding beam cranes, adjust the extension wire rope and retraction wire
rope as required. A short section of the sliding beam section 2 cannot be retracted, with
the horizontal cylinder fully retracted. At the moment, adjust the retraction wire rope of
sliding beams.
1) Retract the boom onto the bracket.
2) Loosen the locknut for extension. Adjust the sliding beam section 2 to full retraction
position.
3) Tighten the adjusting nut until the extension wire rope is just tensioned.
4) Tighten the locknut.
When the horizontal cylinder is fully extended, the outrigger spread is still less than the
required value. At the moment, adjust the extension wire rope of sliding beam.
1) Retract the boom onto the bracket. Fully extend the outrigger transversely. Fully
extend the vertical cylinder.
2) Loosen the locknut for retraction. Tighten the adjusting nut until the retraction wire
rope is just tensioned.

3) Tighten the locknut.
Adjusting nut for extension rope
Lock nut for extension rope
Adjusting nut for

retraction rope
Locknut for
retraction rope
Figure 5-14 Adjustment for retraction rope of sliding beam
Chapter 5
CAUTION
Do not excessively tighten the adjusting nuts for extension and retraction wire ropes.
Tighten the locknuts again after the adjustment.
b) Wire rope
For the two-section sliding beam cranes, be sure to maintain the extension and retraction
wire ropes. When any of the following cases occurs, please replace the wire rope in
question.
1) The number of broken wires in a strand exceeds 10 %.
2) The diameter of wire rope is reduced by more than 7 %.
3) Wire rope tangle exists.
4) The wire rope is markedly deformed or the rope core is exposed.
c) Adjustment of vertical clearance of outrigger
1) Fully retract the crane outrigger.
2) If the sliding beam section 1 tilts downwards, turn the adjusting bolt, or add an
adjusting pad or replace the slide block I, as shown in Figure 5-14.

3) If the sliding beam section 2 tilts downwards, add an adjusting pad or replace the slide
block II, as shown in Figure 5-15. The clearance between the sliding beam section 2
and the lower cover plate of section 1 shall be approximately 3 mm.
Slide block II Adjusting pad

Slide block I Adjusting pad
Chapter 5
Figure 5-15 Adjustment pad of sliding beams
CAUTION
(1) While adjusting the outrigger clearance, keep the slide block of adjusting bolt at
proper position and do not use too many adjusting pads. Ensure that the outrigger
can telescope normally.
(2) For one-section sliding beam cranes, adjusting the clearance between fixed
outrigger and sliding beam using the same method.
d) Abnormal sound during outrigger telescoping
Abnormal sound is produced during the outrigger telescoping, and there is an obvious
scrape on the outrigger bottom plate. In this case, adjust the supporting points, and apply
grease to the sliding planes of sliding beam.
e) Hydraulic components of outrigger telescoping mechanism
1) Tighten the fittings frequently.
2) Check that the seal rings are reliable.
3) Check the hoses for aging and damage. If any, replace the faulty hose.

5.4.2 Periodical inspection and maintenance of engine and its peripheral
systems
[Prerequisites]
a) Check and maintain the engine and its peripheral systems when necessary.
No dust.
Clean rag, adjustable wrench, flat-tip screwdriver and lighting equipment.
The peripheral systems of engine mainly include the intake system, exhaust system, fuel
supply system, cooling system, inter-cooling system, and heater. Please perform the inspection
and maintenance of these systems referring to the Chapter 2, 3, 5 and 7 in this manual.
a) Check the engine fan belt for damage. Check the fan connecting bolt at the front end of
engine for looseness.
b) Check the engine mounting bolt looseness. Check the rubber pad for damage and obvious
aging.
c) Check the mounting bolts of water tank, intercooler, air filter, AdBlue tank and SCR tank for
Chapter 5
looseness.
d) Check the water tank and the cooling surface of intercooler for foreign matter.
e) Check the cooling water pipe, intercooler and intake pipe for aging, damage and
deformation. Check the cooling water pipe and inter-cooling pipe for looseness.
f) Check the fuel tank, fuel coarse filter, fuel pipeline and AdBlue pipe for looseness.
g) Check the fuel pipe and AdBlue pipe for ageing, damage and deformation.
h) Check the silencer and exhaust pipe for looseness.
i) Check the tightness of exhaust pipe.
CAUTION
Perform engine maintenance according to the attached manuals: OPERATOR'S
MANUAL FOR ENGINE and MAINTENANCE MANUAL FOR ENGINE.
a) In case of damage of engine fan belt, replace the belt. In case of looseness of fan
connecting bolt at the front end of engine, tighten the bolt.
b) In case of looseness of engine mounting bolt, tighten the bolt. In case of ageing or damage
of the rubber pad, replace the pad.
c) In case of looseness of mounting bolts of water tank, intercooler, AdBlue tank, SCR tank

and air filter, tighten them.
d) Periodically clean the water tank and the cooling surface of intercooler using water.
e) In case of ageing, damage or deformation of cooling water pipe, inter-cooling pipe and
intake pipe, replace them. Tighten the clamps. Replace the broken clamps.
f) In case of looseness of fuel tank, fuel coarse filter and fuel pipeline, and AdBlue tank,
tighten them.
g) In case of ageing, damage or deformation of fuel pipe and AdBlue pipe, replace the pipe.
h) In case of looseness of silencer and exhaust pipe, tighten them.
i) Start the engine. Check the exhaust pipe fitting for leakage. In case of leakage, re-install
and tighten the pipe. In case of damage, replace the pipe.
j) Replace the hose of cooling system, inter-cooling hose, intake hose, fuel hose and various
rubber pads every two years.
5.4.3 Periodical inspection and adjustment of transmission control

mechanism
[Prerequisites]
a) Inspect and adjust the transmission control mechanism when necessary.
b) Inspect and adjust the transmission control mechanism according to the schedule.
Chapter 5
Torque wrench, lighting equipment and clean rag
a) Pneumatic unit and its connection
Check the air pipe for leakage, damage and looseness.
b) Idle travel and neutral position of the control system
Check that the idle travel of the mechanism is small with smooth and secure gear selection
and gear shift.
c) Tightness of mounting coupling bolts of the control mechanism and wear of cable
d) Check that the mounting bolt of transmission is tightened to the required torque. See
Section 5.3.
e) Check that the ventilation plug of transmission and ensure the poromeric plug works
normally.
a) Pneumatic unit and its connection
Check the air pipe for leakage, damage and looseness. In case of leakage or looseness,
tighten the pipe. In case of damage, replace the pipe.
b) Idle travel and neutral position of the control system

Slightly push and pull the control lever to check its idle travel. The idle travel shall be less
than 40mm. Check that the gear selection and gear shift are both smooth and secure. If
not so, tighten the reflexible shaft. For tension purpose, tighten the nuts at both ends of the
reflexible shaft. Ensure there is a certain length of travel during moving the joysticks
forwards, backwards or neutrally. The neutral position can be determined by the length of
flexible shaft.
c) Tightness of coupling bolts of the control mechanism and wear of cable
Check the mounting bolt for looseness. If any, tighten the bolt. Check the reflexible shaft
for abnormal wear and broken strand. In case of broken strand, replace the cable.
d) Check transmission installation
Check the mounting bolt for looseness. If any, tighten the bolt.
e) Check the ventilation plugs of transmission
Often remove the ventilation plug of transmission and clean it to ensure its functionality.
5.4.4 Periodical inspection and adjustment of clutch operating mechanism

[Prerequisites]
a) When necessary, inspection and maintenance should be made.
No dust.
Chapter 5
Clean rag, adjustable wrench and electric torch
See Figure 5-16 for the clutch operating mechanism.
a) Brake fluid level of clutch
Often check the brake fluid level in the cup. The level shall be between the Max. and Min.
levels (H and L).
WARNING
The brake fluid used in the clutch operating system must be the automobile brake fluid
meeting the requirements of GB12981-2003 HZY3. It is strictly prohibited to mix brake
fluid of different grades (Laike 901 automobile brake fluid is added to this crane when
the crane is delivered out of the plant).
b) Check fluid pipe for tightness

Check periodically the pipes for leakage.
c) Check the air pipe for looseness, leakage and damage.
d) Brake fluid of clutch

Periodically check the brake fluid of clutch for poor quality including emulsification and
deterioration.
Oil cup
Master cylinder of clutch

Booster cylinder
Oil pipe Air pipe
Figure 5-16 Operation of clutch

a) Brake fluid level of clutch
Check periodically the brake fluid level in the cup. The level shall be between the Max. and
Min. levels (H and L). Immediately add brake fluid if the level is lower than the Min. level L.
b) Check oil pipe for tightness
Check periodically the oil pipe for permeation and leakage. If any, tighten or replace the
pipe.
c) Check air pipe:
Check periodically the air pipe for looseness, leakage and damage. In case of looseness,
Chapter 5
tighten the pipe. In case of leakage or damage, replace the pipe.

d) Brake fluid of clutch
Check periodically the brake fluid of clutch for poor quality including emulsification and
deterioration. If any, replace the brake fluid.
Do not add new brake fluid until the brake fluid of poor quality is removed. After replacing
the fluid, bleed the fluid circuit as follows.
1) Connect one end of the hose to the bleeding plug of clutch booster cylinder. Insert the
other end of the hose into the container that is filled with brake fluid.
2) Bleed the fluid circuit with the help of another person. Slowly depress the clutch pedal.
With the clutch pedal depressed, the other person loosens the bleeding plug to
remove air from the brake fluid, then tightens the bleeding plug. Release the clutch
pedal. Repeat the operation until the brake fluid flowing out contains no bubble.
Finally tighten the bleeding plug.

CAUTION
After bleeding the fluid circuit, inspect the fluid level. If the level is too low, add fluid to
the required level.
5.4.5 Periodical inspection and adjustment of brake

[Prerequisites]
a) Check and maintain the brake in case of brake deviation or stagnation.
No dust or rain.
Wrench, feeler gauge, abrasive paper, spring pliers and clean rag
a) Friction plate thickness
Visually check the friction plate thickness quarterly according to the crane service
conditions.
b) Brake shoe
Check the anti-slip grid on the brake shoe surface for wear, corrosion and damage. Check
Chapter 5
the brake shoe for deformation.
c) Brake drum
Check the brake drum for crack, kerf and wear.
d) Slave cylinder of brake
Check the bellows for damage. Check the automatic adjusting device and the adjusting
bolt for stagnation.
a) Remove the plug of dust cap.
b) Remove the brake drum.
c) Check whether the wear of friction plate is acceptable. If the wear-resistant layer of friction
plate is rubbed away, be sure to replace the friction plate. When the fraction plate
thickness approaches the limit, the inspection interval shall be shortened.
CAUTION
Be sure to use authentic parts!
Be sure to have the friction plate riveting performed by an authorized specialist
company. Replace all the friction plates of the entire axle!

5.4.6 Periodical inspection and maintenance of suspension system
[Prerequisites]
a) When necessary, inspection and maintenance should be made.
No dust.
Torque wrench, grease pump, clean rag and lighting equipment
WARNING
Turn off the engine before maintenance and replacement of components.

a) Check the thrust rod and support for deformation and crack. Check the fastening bolt for
looseness.
b) Check the leaf spring for crack and deformation. Check the rubber spring for ageing and
crack.
c) Check the balance beam and support for crack and deformation.
d) Check the shock absorber for deformation and crack. Check the fastening bolt for
Chapter 5
looseness.
a) Inspection of thrust rod and support
1) Check the thrust rod and support for crack and deformation. If any, timely replace
them.
2) Check the ball joint of thrust rod for deformation, crack and looseness. If any, timely
replace the joint.
3) Check the fastening bolt of thrust rod and support for looseness. If any, tighten the
bolts to the tightening torque specified in Section 5.3.
b) Inspect the leaf spring and rubber spring. For inspection of leaf spring, see Figure 5-17.
1) Check the U-shaped bolt for looseness. If any, tighten the bolt to the tightening torque
specified in Section 5.3.
2) Check the U-shaped bolt for breakage and deformation. If any, timely replace the bolt.
3) Check the buffer block for damage and deformation. If any, replace the buffer block.
4) Check the leaf spring for looseness, crack and deformation. If any, tighten or replace
the spring.
5) Check the leaf spring for breakage and deformation. If any, contact the service
personnel for replacement.

6) Check the rubber spring for ageing, deformation and crack. If any, contact the service
personnel for solution.
Leaf spring block

Nut
Leaf spring
Lug
Bolt
Figure 5-17 Leaf spring
c) Inspection of balance beam and support

1) Check the balance beam and support for crack and deformation. If any, contact the
service personnel for replacement.
2) Check the shaft sleeve and bearing of the balance beam and support for looseness. If
any, contact the service personnel for replacement.
3) Check the ball joints at both ends of the balance beam connected to the axle for
looseness. If any, contact the service personnel for replacement.
Chapter 5
4) Check the connection of balance beam to the support for insufficient grease. If any,
timely add grease.
d) Inspection of shock absorber
1) Check the shock absorber for crack and deformation. If any, contact the service
2) Check the connection of shock absorber for looseness. If any, tighten the connection.
5.4.7 Periodical inspection and maintenance of propeller shaft

[Prerequisites]
a) Inspection and maintenance are necessary if abnormal vibration or noise is produced
during the crane travelling.
Engage the rigid lock.
Extend the outriggers to raise the chassis.

Torque wrench, electric torch and clean rag.
a) Propeller shaft installation and connection: Check the connecting bolts and nuts of the
flange and intermediate shaft bearing for looseness. Check the teeth on flange end face
for damage. The tightening torque shall be 200 N·m – 230 N·m for the connecting bolts
and nuts of the flange and the intermediate shaft bearing.
b) Propeller shaft: Check the cross shaft and yoke for looseness, damage and deformation.
Check the propeller shaft tube for bending, damage, crack, balance block detachment,
and abnormal vibration and noise.
c) Intermediate shaft bearing: Check the intermediate shaft bearing for looseness, damage
and rubber extrusion.
d) Lubrication: Check the cross shaft, intermediate shaft bearing and sliding spine for poor
lubrication.
See Figure 5-18.
a) Flange connection of propeller shaft
Check the connecting bolts of flange and intermediate shaft bearing for looseness visually
or using a torque wrench. If any, tighten the bolts to the specified torque. If the teeth on
flange end face are damaged due to looseness, replace the propeller shaft, bolts and nuts.
b) Propeller shaft:
Check the cross shaft and yoke for looseness, damage and deformation visually or by
Chapter 5
shaking the propeller shaft manually. If any, replace the propeller shaft. Check visually the
propeller shaft tube for bending, damage, crack, and balance block detachment. If any,
replace the propeller shaft. If necessary, lock the suspension, and extend the outriggers to
raise the tires from the ground. Start the engine. Observe the propeller shaft running and
check for abnormal vibration and noise. If any, detect the location then turn off the engine
for further inspection.
DANGER
Never contact any rotating parts of the running propeller shaft and wheels.
a) Intermediate shaft bearing

Check the intermediate shaft bearing for looseness, damage and rubber extrusion visually
or by shaking the propeller shaft manually. If any, replace the intermediate shaft bearing or
propeller shaft.

b) Check the lubrication status:
Visually check the cross shaft, intermediate shaft bearing and sliding spline for poor
lubrication. If any, add grease.
Cross Shaft
Connecting flange shaft fork Intermediate shaft bearing Teeth on flange end face
Sliding spline
Figure 5-18 Propeller shaft
5.4.8 Periodical inspection and adjustment of wheel alignment

[Prerequisites]
a) Abnormal wear of tire occurs.
Chapter 5
b) Check when necessary.
c) Inspect and adjust according to the schedule.
Shut down the engine.
Clean rag, wrench, pipe tongs, line tape and fine wire
a) Check the steering linkage for deformation. Check the steering ball joint and connecting
fork for looseness.
b) Check the steering rocker arm for crack and deformation. Check the bearing for
looseness.
c) Check the trapezoid mechanism of steerable axle for crack and deformation. Check the
ball joint for looseness.
d) Check that the toe-in of wheel of steerable axle is 4 mm – 6 mm.
e) Check the steerable wheel for deviation and incorrect alignment.

CAUTION
After the break-in period of the new crane expires, be sure to inspect and adjust the
wheels to ensure correct alignment. After that, inspect and adjust the wheels every
8,000km or every 6 months.

a) Inspection of steering linkage, ball joint and connecting fork. See Figure 5-19.
1) Check the steering linkage for deformation. If any, contact the service personnel for
correction or replacement.
2) Check the steering ball joint and connecting fork for looseness. If any, replace them.
3) Check the fastening nut of ball joint shank for looseness. If any, retighten it to the
torque (160 – 180 )N·m.
4) Check the clamp for looseness. If any, retighten it to the torque (160 – 180 )N·m.
Ball joint
Fastening nut of
ball joint shank
Clamp
Chapter 5
Figure 5-19 Ball joint
b) Inspection of steering rocker arm

1) Check the steering rocker arm for deformation and crack. If any, contact the service
2) Check the bolt of bearing clamping plate for looseness. If any, retighten the bolt.
3) Check the bearing of steering rocker arm for wear, by shaking the rocker arm manually.
In case of excessive clearance, replace the bearing.
4) Add ZL-2 lithium base grease to the bearing.

Steering rocker arm
Bearing of steering rocker arm
Grease nozzle
Bolt of bearing clamping plate

Connecting fork
Bearing of
connecting fork
Figure 5-20 Steering rocker arm
c) Inspection of the trapezoid mechanism of steerable axle and ball joint

1) Check the trapezoid arm of steerable axle and the tie rod for crack and deformation. If
any, contact the service personnel for replacement.
2) Check the ball joint of trapezoid mechanism of steerable axle for looseness, by
shaking the ball joint manually. In case of excessive clearance, replace the ball joint.
3) Check the fastening nut of ball joint shank for looseness. If any, retighten it.
4) Check the clamp for looseness. If any, re-tighten the clamp.
Chapter 5
Ball joint
Clamp
Fastening
nut of ball
joint shank
Ball joint of
trapezoid
mechanism
Figure 5-21 The trapezoid mechanism of steerable axle and ball joint
d) Inspection and adjustment of toe-in of steerable axle

1) Via the tie rod of trapezoid mechanism, adjust the toe-in of wheel of steerable axle to
generally 4 mm – 6 mm. See Figure 5-22. The toe-in of wheel of steerable axle: (B－
A)≤5 mm. Adjust the toe-in as follows:

A
Crane travel
direction
Figure 5-22 Toe-in of steerable axle
2) Position the crane and wheels facing the front.

3) Select proper measuring points G on the front left and front right wheels. Make a mark.
4) Measure the distance A between the points G on the front left and front right wheels.
5) Move the crane backwards. Turn the wheels 180º.
6) Measure the distance B between the points G on the rear left and rear right wheels.
7) Calculate the value of B-A. If the value B-A is positive and between 4mm and 6 mm,
the toe-in is normal. If the value B-A is positive and more than 6 mm, the toe-in is
excessively great, requiring adjustment. If the value B-A is negative or B–A less than
4 mm, the toe-in is excessively small, requiring adjustment.
Chapter 5
8) Adjust the toe-in as follows. Loosen the clamp of tie rod of trapezoid mechanism.
Rotate the tie rod for increasing or reducing length. Adjust the toe-in according to the
value B-A. If the toe-in is more than 6 mm, reduce the tie rod length. If the toe-in is
negative or B–A less than 4 mm, increase the tie rod length. Do not rotate the tie rod
for more than one turn each time. After the rotation, re-measure the toe-in. If the
toe-in is insufficient, rotate the tie rod again. In case of excessive rotation, reverse the
tie rod to a proper number of turns until the toe-in is acceptable.
9) After the adjustment, lock the clamp of tie rod of trapezoid mechanism.
CAUTION
Measure the dimensions A and B from the same point on wheel. Turn the wheels.
Measure the dimensions at the equal-height place of the front and rear of axle
respectively.
e) Inspection and adjustment of steerable wheel alignment

Perform the steps a, b, c and d, to check that the crane is correctly positioned. Check
whether the steerable wheel deviates from the longitudinal axis. In case of deviation,
adjust the length of drag link connected to the steerable axle. The wheels are thus aligned.

When the length of drag link is increased, the wheel will turn right. When the length of drag
link is reduced, the wheel will turn left. According to the actual situation, increase or reduce
the length of drag link.
The steps and methods for wheel alignment are as follows:
1) Move the crane back and forth to the correct position.
2) According to the wheel deviation, check whether the length of drag link shall be
increased or reduced.
3) Loosen the clamps at both ends of the drag link.
4) Adjust the length of drag link.
For some cranes, the threaded nut sleeves are used at both ends of drag link. See Figure
5-23. Loosen the clip and clamp the tube of drag link. Rotate the threaded nut sleeve using
a wrench, clockwise or counterclockwise to increase or reduce respectively the length of
drag link. If using the threaded nut sleeve at one end of drag link to adjust is insufficient,
adjust the threaded nut sleeve at the other end. There are two threaded sleeves. After the
adjustment, lock the clip.
If no adjusting threaded nut sleeve is provided on the drag link, the length shall be
adjusted as follows. Loosen the clip and clamp the tube of drag link. Rotate the clip
clockwise or counterclockwise to increase or reduce the length respectively.
1) Check the wheel alignment. When necessary, drive the crane back and forth covering
a short straight distance.
2) Make fine adjustment to the wheel alignment if necessary.
Chapter 5
3) After the adjustment, lock the clip on the drag link.
Nut sleeve
Clamp
Tube of drag link
Figure 5-23 Drag link
CAUTION
For the crane with multiple axles and all wheels steering items, if the wheel alignment
fails to meet the requirement, contact the service personnel for multiple wheel
alignment.

5.5 Periodical inspection for load-bearing parts
5.5.1 Periodical inspection of chassis frame
[Prerequisites]
a) Crack of welding joint, loose welding joint
b) Structure deformation.
No dust.
Fresh water and rag
The key weld seams of chassis frame are shown in Figure 5 -24.
Chapter 5
3
2
1
Figure 5-24 Key weld seams of chassis frame

Table 5-3 Key weld seams of chassis frame
Illustration Note
The weld seam connecting the

support of rocker arm to the
chassis frame
Position 2 in Figure 5-24 The weld seam connecting the

upper cover plate of the chassis
frame
Position 3 in Figure 5-24 The flange weld seam
Position 4 in Figure 5-24 The weld seams connecting the

side plate of chassis frame to the
upper and lower cover plates.
Chapter 5
All the weld seams of the support
of suspension, the support of
thrust rod and the chassis frame
must be inspected.
The weld seam of the reinforcing

Position 4 in Figure 5-24
rib of rear outrigger
Inspection of weld seam
For the main weld seams on chassis frame, see Figure 5-24.
a) Clean the welding joints using a clean rag.
b) Check visually all the welding joints for crack and looseness. If any, contact the service

5.5.2 Periodical inspection of sliding beam
[Prerequisites]
a) Crack of welding joint, loose welding joint.
b) Structure deformation.
Normal environment
The outriggers are clean.
Fresh water and rag
a) Crack of welding joint, loose welding joint: Check that the welding joints are complete
without being damaged.
b) Structure deformation: Check the structural members for obvious deformation.
The maintenance is introduced based on the portal-type plate. See Figure 5-25.
Portal-type plate
Portal-type plate
Chapter 5
Figure 5-25 Sliding beam
a) Inspection of structural members: inspect the members one by one to locate the fault.
1) If the upper cover plate of sliding beam is formed by splicing, check the welding joints
of the splicing.

2) Check the welding joints connecting the side plate (including the reinforcing plate) to
the upper and lower cover plates. For the locations of welding joints, see Figure 5-26.
A total of A total of
four four
locations locations
Figure 5-26 Welding joints of sliding beam
3) If the lower cover plate of sliding beam is formed by splicing, check the welding joints
of the splicing.
4) Check the welding joint connecting the portal-type plate to the side plate, and the
welding joint of splicing of the portal-type plate itself.
5) Check the welding joint of the reinforcing plate on the side plate
b) Inspection of outrigger telescoping mechanism
For the inspection of outrigger telescoping mechanism, see Section 5.4.1.
Chapter 5
5.5.3 Periodical inspection of axle
[Prerequisites]
a) Be sure to inspect the axle in case of excessively high temperature, oil leakage or air
leakage of axle.
No dust or rain.
WARNING
It is strictly prohibited to perform maintenance while the crane is in operation or the axle
temperature remains high. This prevents scalding and burning!
Allen wrench, small pry bar, funnel, grease gun and clean rag
a) Check the oil for poor quality, including emulsification, blackening or deterioration. Check

that the oil level reaches the observation hole.
b) Check the grease for dirt and insufficiency.
c) Check the axle housing for deformation and crack.
a) Inspection of oil grade and oil level
See Section 5.2.5. Periodical Inspection and Replacement of Gear Oil of Drive axle
b) Grease: For the lubrication points, see Figure 5-27 and Figure 5-28. For the lubrication
method, see Section 5.2.7.
Clean the breather cap using a clean rag.
c) Visually check the axle housing for crack and deformation. If any, contact the service
Visually check the welding joints of axle housing, support of leaf spring and support of
thrust rod for crack. If any, contact the service personnel for solution.
Chapter 5
Grease Grease
nipple nipple
Figure 5-27 Lubricating points of axle

Oil drain hole
Oil fill hole (oil level observation hole)
Breather hole Breather hole
Chapter 5
Figure 5-28 Gear oil filling and draining of axle
5.5.4 Periodical inspection and exchange of wheels

[Prerequisites]
a) Inspect and maintain the wheels in case of tire leakage, nut looseness or tire swing
vibration.
Threaded sleeve, pneumatic wrench and small pry bar
WARNING
It is strictly prohibited to drive the crane with any tire seriously damaged. Otherwise the
tire could burst.

a) Check the valve mouth for leakage.
b) Check that the wheel nuts meet the required torque requirement.
c) Check the rim for crack and deformation.
a) Check the valve mouth:
Apply a proper amount of soap water to the valve mouth to detect leakage. In case of
leakage, contact the service personnel.
b) Wheel exchange:
Exchange the wheels according to Chapter 2: Maintenance Schedule. For the exchange
sequence, see Figure 5-30.
c) Inspection and maintenance of wheel nut:
See Figure 5-29. Pre-tighten the nuts crosswise. Then tighten all the nuts in the same
sequence.
1) Tighten all the wheel nuts upon delivery or after the crane has traveled 100 km.
2) Tighten all the wheel nuts again upon delivery or after the crane has traveled 1000 km
with replaced tires.
3) Tighten all the wheel nuts again upon delivery or after the crane has traveled 5000 km
with replaced tires. After that, tighten the wheel nuts every 5000km.
Refer to the following table for tightening torque when tightening the wheel nuts:
Chapter 5
Table 5-4 Tightening torque of wheel nuts
Vehicle type 25T–55T 60T–80T
Tightening torque of wheel

(550–600) N·m (820–870) N·m
nuts
d) Rust removal and paint application:
Check the rim for rust and paint peeling. If any, remove the wheel, to remove the rust and
apply paint. Then install the wheel.
Figure 5-29 Tightening order of nuts

Figure 5-30 Wheel exchange order Chapter 5
Note: The arrow indicates the crane travel direction.
5.6 Main maintenance points of chassis

5.6.1 Points of inspection and adjustment

Chapter 5
5-50
Steering system Outrigger telescoping mechanism Nuts and bolts of steering system
Wheels and bolts Bolt and nut of thrust rod
Engine and its peripheral system Chassis frame
Transmission control mechanism

Axle
ZTC Series Truck Crane（25t~80t）

5.6.2 Lubrication points
●Chassis lubrication diagram

Table 5-5 Chassis lubrication diagram
2
1
Chapter 5
3
4

5 6
Chapter 5
8
7
9 10

11
12
Chapter 5
13 14
15 16

17 18
19
Chapter 5
2
20

●Chassis lubrication table
Table 5-6 Chassis lubrication table
Pos. Description Intervals Method Grease type
1 Battery terminal 5000 km Brushing Industrial Vaseline LF40
5000 km Oil filling CH-4 15W/40 diesel engine

oil (national standard IV)
2 Oil sump of engine Replace the CJ-4 15W/40 diesel engine
10000 km
oil oil (national standard V or
Jing V)
5000 km Oil filling

3 Transmission Replace the GL-5 85W/90
20000 km
oil
Sliding fork of propeller Grease
4 5000 km ZL-2 Lithium base grease
shaft pump
Intermediate shaft
Grease
5 bearing of propeller 1500 km XHP-222 lubricating grease
pump
shaft
Bearing of universal Grease
joint of propeller shaft pump
Chapter 5
5000 km Oil filling
Wheel reducer of drive GL-5 85W/90 gear oil of
7 Replace the
axle 20000 km heavy-duty crane
oil
5000 km Oil filling

Central reducer of drive GL-5 85W/90 gear oil of
8 Replace the
axle 20000 km heavy-duty crane
oil
King pin of steerable Grease
axle pump
Connecting shaft of Grease
steering rocker arm pump
Universal joint of Grease
11 5000 km HJ-20 mechanical oil
steering propeller shaft pump
Ball head pin of steering Grease
drag link pump
Steering hydraulic oil Replace the
13 10000 km L-HM46 hydraulic oil
tank oil
14 Front and rear leaf 30000 km Brushing ZG-S graphite

Pos. Description Intervals Method Grease type
springs calcium-based grease
Pin shaft of front and Grease

rear leaf springs pump
Balance beam of rear Grease
suspension pump
Bearing of front wheel Grease
hub pump
Braking camshaft, front, Grease
intermediate, and rear pump
Support of gear shift
Grease
19 lever, and the fork of 5000 km HJ-20 mechanical oil
pump
universal joint
Grease
20 Ball head pin of tie rod 5000 km ZL-2 Lithium base grease
pump
Chapter 5

Chapter 6 Oil Medium Selection
Table for oil medium capacities
— Table for oil medium capacities for 25 T series truck cranes

Total Replacement
Oil Filling Ambient
Oil type capacity: amount: Remarks
medium position temperature
about (L) about (L)
-50 # diesel -29°C – -44°C
-35 # diesel -14°C – -29°C
-20 # diesel -5°C – -14°C
Fuel Fuel tank 250 —
-10 # diesel 4°C – -5°C
0 # diesel 8°C – 4°C
5 # diesel ≥ 8°C
Antifreeze -25°C
Cooling
medium Radiator FD-2B type 55 —
(antifreeze) multi-purpose -40°C
antifreeze
Chapter 6
Weichai
CH-4 15W/40 -25°C – 40°C
national
standard V
CH-4 5W/30 -30°C – 20°C
Engine oil Weichai Engine 24 — and Jing V
engines
CH-4 0W/30 -40°C – 0°C use CJ-4

grade oil.
L-CKD220
Winch Industrial
1.5 – 2 1.5 – 2
reducer gear oil for
Made in
Gear oil closed loop -15°C – 50°C
China
L-CKD150
Slewing reducer Industrial 4.5 4.5
gear oil for
ZTC Series Truck Crane (25t ~ 80t) 6-1

Total Replacement
Oil Filling Ambient
about (L) about (L)
closed loop
9JS119TA-
13
transmission
Pre-assembly of
Zoomlion GL-5 85W/90 -10°C – 49°C

20
Gear oil non-steer drive GL-5 80W-90 — -15°C – 30°C
axle GL-5 75W -40°C – 30°C
Pre-assembly of
Zoomlion through 22
drive axle
L-HM 68 Above 10°C
AE 46 -10°C – 40°C
Made in
Hydraulic oil Hydraulic oil tank 560 735
L-HV 32 -20°C – 40°C China
10# aviation
-50°C – 0°C
hydraulic oil
Propeller shaft 0.05 kg
Front and rear ZL-2 Lithium

0.2 kg
suspensions base grease
— -20°C – 120°C
Transmission 0.1 kg
Grease
Chapter 6
ZL-3 Lithium
Steer driven axle 0.1 kg
base grease
Intermediate XHP-222
Specificati
support of lubricating 0.1 kg -20°C – 140°C
on: NLGI-2
propeller shaft grease
AdBlue AdBlue tank DIN70070 35 — < 50°C Chassis
901 T3 Lake
Brake fluid Clutch 1.5 — — Chassis
brake fluid
Air
R-134a
conditioning
Condenser mineral 1.2 kg — — Chassis
cooling
insoluble oil
medium
6-2 ZTC Series Truck Crane (25t ~ 80t)

— Table for oil medium capacities for 50 T / 55 T series truck
cranes
Total Replacement
Oil Filling Ambient
about (L) about (L)
-50 # diesel -29°C – -44°C
-35 # diesel -14°C – -29°C
-20 # diesel -5°C – -14°C
-10 # diesel 4°C – -5°C
5 # diesel ≥ 8°C
Antifreeze -25°C
Cooling
antifreeze
Weichai
CH-4 15W/40 -25°C – 40°C
national
Chapter 6
standard V
CH-4 5W/30 -30°C – 20°C
engines
CH-4 0W/30 -40°C – 0°C use CJ-4

grade oil.
L-CKD220
Winch Industrial
1.5 – 2 1.5 – 2
closed loop Made in
-15°C – 50°C
L-CKD150 China
Gear oil Industrial

Slewing reducer 4.5 4.5
gear oil for
closed loop
10JSD160TB 13

Total Replacement
Oil Filling Ambient
about (L) about (L)
transmission
Pre-assembly of
Zoomlion
Gear oil GL-5 85W/90 10 -15°C – 49°C
non-steer drive
GL-5 80W-90 -15°C – 30°C
axles
GL-5 75W -40°C – 30°C
Pre-assembly of
Zoomlion through 12.5
drive axle
Pre-assembly of
Hande non-steer 11.5
drive axle
Pre-assembly of —
Hande through 12.5
drive axle
L-HM 68 Above 10°C
AE 46 -10°C – 40°C
Made in
L-HV 32 -20°C – 40°C China
10# aviation
-50°C – 0°C
hydraulic oil
Cross coupling of
propeller shaft 0.05 kg

Chapter 6
and spline
ZL-2 Lithium
Front and rear
base grease 0.2 kg
suspensions -20°C – 120°C
Grease Transmission —
0.1 kg
Steer and driven ZL-3 Lithium
axle base grease
Specificati
on: NLGI-2
AdBlue AdBlue tank DIN70070 50 — < 50°C
901 T3 Lake
Brake fluid Clutch 1.5 — —
brake fluid

Total Replacement
Oil Filling Ambient
about (L) about (L)
Air
R-134a
conditioning
Condenser mineral 1.2 kg — —
cooling
insoluble oil
medium
Chapter 6

— Table for oil medium capacities for 70 T series truck cranes
Total Replacement
Oil Filling Ambient
about (L) about (L)
-50 # diesel -29°C – -44°C
-35 # diesel -14°C – -29°C
-20 # diesel -5°C – -14°C
-10 # diesel 4°C – -5°C
5 # diesel ≥ 8°C
Antifreeze -25°C
Cooling
antifreeze
Weichai
CH-4 15W/40 -25°C – 40°C
national
standard V
CH-4 5W/30 -30°C – 20°C
Chapter 6

engines
CH-4 0W/30 -40°C – 0°C use CJ-4

grade oil.
L-CKD220
Winch Industrial
1.5 – 2 1.5 – 2
closed loop
-15°C – 50°C
L-CKD150
Gear oil Industrial
Slewing reducer 4.5 4.5
gear oil for
closed loop
10JSD160TB
13
transmission

Total Replacement
Oil Filling Ambient
about (L) about (L)
Pre-assembly of
Zoomlion
10
Gear oil non-steer drive GL-5 85W/90 -15°C – 49°C
axles GL-5 80W-90 -15°C – 30°C
Pre-assembly of GL-5 75W — -40°C – 30°C
Zoomlion through 12.5
drive axle
Pre-assembly of
drive axle
Pre-assembly of
Hande through 12.5
drive axle
L-HM 68 Above 10°C
AE 46 -10°C – 40°C

L-HV 32 -20°C – 40°C
10# aviation
-50°C – 0°C
hydraulic oil
Cross coupling of
and spline
ZL-2 Lithium
Chapter 6
Front and rear
base grease 0.2 kg
Grease
Transmission —
0.1 kg
Steer driven ZL-3 Lithium
axles base grease
Specificati
on: NLGI-2
901 T3 Lake
brake fluid

Total Replacement
Oil Filling Ambient
about (L) about (L)
Air
R-134a
conditioning
cooling
insoluble oil
medium
Chapter 6

— Table for oil medium capacities for 80 T/110 T series truck
cranes
Total Replacement
Oil Filling Ambient
about (L) about (L)
-50 # diesel -29°C – -44°C
-35 # diesel -14°C – -29°C
-20 # diesel -5°C – -14°C
-10 # diesel 4°C – -5°C
5 # diesel ≥ 8°C
Antifreeze -25°C
Cooling
antifreeze
Weichai
CH-4 15W/40 -25°C – 40°C
national
Chapter 6
standard V
CH-4 5W/30 -30°C – 20°C
engines
CH-4 0W/30 -40°C – 0°C use CJ-4

grade oil.
L-CKD220
Winch Industrial
1.5 – 2 1.5 – 2
closed loop
-15°C – 50°C
L-CKD150
Industrial
Gear oil Slewing reducer 4.5 4.5
gear oil for
closed loop

Total Replacement
Oil Filling Ambient
about (L) about (L)
10JSD180A
16
transmission
Gear oil
Pre-assembly of
Zoomlion
12
non-steer drive
axles GL-5 85W/90 -15°C – 49°C
Pre-assembly of GL-5 80W-90 — -15°C – 30°C

GL-5 75W -40°C – 30°C
Zoomlion through 14
drive axle
Pre-assembly of
drive axles
Pre-assembly of
Hande through 14.5
drive axles
L-HM 68 Above 10°C
AE 46 -10°C – 40°C

L-HV 32 -20°C – 40°C
10# aviation
-50°C – 0°C
hydraulic oil
Chapter 6
Cross coupling of
and spline
ZL-2 Lithium
Front
base grease 0.2 kg
Grease Transmission —
0.1 kg
ZL-3 Lithium
Steer driven axle
base grease

Total Replacement
Oil Filling Ambient
about (L) about (L)
901 T3 Lake
brake fluid
Air
R-134a
conditioning
cooling
insoluble oil
medium
Remarks:
Because of the additive (fluorescent agent) in the hydraulic oils for leakage detection, the
color of hydraulic oils will be orange and nontransparent, which is normal and will not
influence their performance.
Chapter 6

Chapter 7 Diagnosis and Troubleshooting for Common
Failures
7.1 Electrical system, superstructure

7.1.1 Electrical system
Problems Causes Remedy
The bulb is damaged. Replace
The fuse has burnt out. Repair and replace

The work light does
Poor grounding occurs. Repair
not illuminate.
The line is broken. Repair
The switch is defective. Repair or replace
The control/warning The switch is defective. Replace

light on the control
panel does not The line is broken. Repair
illuminate.
The warning light The hoisting limit switch or lowering limit

Repair
“Hoisting limit switch” switch is defective.
/”Lowering limit switch”
The cable reel is defective. Repair
is activated and stays
on with sound alarm. The line is broken. Repair
The fuse has burnt out. Repair or replace
The wipers do not The switch is defective. Repair or replace

work. The electric motor is damaged. Replace
The fuse has burnt out. Repair and replace

Chapter 7

The horn does not
The K22 relay is defective. Replace
sound.
The horn is damaged. Replace
The buzzer does not The fuse has burnt out. Repair and replace
sound. The relay is defective. Replace

The buzzer is damaged. Replace
The conductive ring is disconnected. Repair or replace

The superstructure
The PTO signal switch is damaged. Replace
has no power.
The circuit breaker has burnt out or is loose. Repair or replace

You cannot start the The line is broken. Repair
engine in the
The ignition starter switch is broken. Replace
operator’s cab.
The conductive ring is disconnected. Repair or replace
The emergency stop switch is defective. Repair or replace
The deadman switch on the joystick is

No movement is Repair or replace
invalid.
performed.
Solenoid valve Y1 is invalid. Repair or replace
The hoisting limit switch is defective. Replace
The cable reel is shorted to the ground. Repair

The hoisting limit
switch does not The relay is defective. Replace
operate.
The line is broken. Replace.
Solenoid valve is invalid. Repair or replace
The lowering limit switch is defective. Repair or replace

The lowering limit
The K2 relay is defective. Replace
switch does not
The line is broken. Replace.
operate.
Chapter 7
Solenoid valve is invalid. Repair or replace

7.1.2 Hydraulic pump
The hydraulic oil level in the hydraulic oil tank is

Fill oil
too low.
The air is in the oil suction pipeline and the oil
Repair
suction pipeline is blocked.
The hydraulic pump The air filter of hydraulic oil tank is blocked. Clean or replace
makes unusual noises. The oil suction resistance is big because the oil
Replace
is cold.
The mounting bolts of oil pump bracket are
Tighten
poorly seated.
The butterfly valve is not opened completely. Open
The hydraulic pump The fitting is loose. Tighten

leaks. The sealing element is damaged. Replace
Chapter 7

7.1.3 Hoist gear
The relief pressure of main valve is set too low. Adjust
The winch motor is defective. Replace

The hook cannot be
The main valve is defective. Repair
lifted.
The combination control valve is defective. Repair
The winch brake does not engage. Repair
The winch motor is defective. Repair

The hook cannot be
lowered.
The combination control valve is defective. Repair
The balance valve is defective. Repair
The winch brake does not engage. Repair

Chapter 7

7.1.4 Derricking gear

The cylinder cannot
The main valve leaks internally. Repair
extend.
The cylinder leaks internally. Repair
The derricking balance valve is defective. Repair or replace

The cylinder cannot
retract. The pressure of secondary relief valve of main
Adjust
valve is set too low.

The cylinder retracts
inadvertently.
The derricking balance valve is defective. Repair
Chapter 7

7.1.5 Telescoping system
The telescoping balance valve is defective. Repair
The boom cannot The pressure of secondary relief valve of main

Adjust
retract. valve is set too low.
The main valve leaks internally. Repair
The pressure of main relief valve is set too low. Adjust

The boom cannot
The control valve is defective. Repair
extend.

The boom retracts
The telescoping balance valve is defective. Repair
inadvertently.
The cylinder, valve or fitting leaks. Repair
The boom cannot fully

The boom retraction rope is loose. Adjust
retract.
CAUTION
It is difficult to dismantle the telescopic cylinder since its structure is complex.
If the telescoping cylinder fails to work, it must be repaired by the special person
assigned by the manufacturer or qualified personnel with considerable technical
experience as soon as possible.
The cylinder leaks The sealing element of guide sleeve is damaged. Replace
externally. The surface of piston rod is scratched. Repair or replace
The cylinder The sealing element is damaged. Replace

leaks The inner surface of cylinder is
internally. Replace
scratched.
The telescoping cylinder
The balance valve leaks internally. Replace or repair
telescopes in The
Chapter 7
inadvertently. The O-ring of balance valve is

balance Replace
damaged.
valve is
defective. The surface of the mounting hole
Repair or replace
of balance valve is damaged.
The piston or piston rod is blocked (due to foreign
The telescoping cylinder Repair or replace
materials or deformation of the cylinder).
cannot telescope in or
out. The balance valve is blocked or the control
Repair or replace.
pipeline is blocked.

7.1.6 Slewing gear
The brake is defective. The brake lining wears. Replace
The relief pressure of chassis control valve is set

Adjust
too low.
The relief pressure of slewing valve is set too

Adjust
low.
The pressure of slewing cushion valve is set too

Adjust
The superstructure low.
cannot move left or right.
The slewing valve is defective. Replace
The slewing motor is damaged. Replace
The slewing reducer is defective. Repair
The brake does not engage. Repair
The relief pressure of chassis control valve is set

Adjust
too low.
The relief pressure of slewing valve is set too

Adjust
The superstructure low.
moves too slowly. The slewing valve is defective. Repair
The slewing cushion valve is defective. Repair
The slewing motor is damaged. Repair

Chapter 7

7.1.7 Counterweight handler
The pressure of relief valve is set improperly. Adjust
The solenoid valve on the changeover valve is

Replace the coil.
not energized.
The cylinder has no
movements. The changeover valve spool for air-conditioning Replace or repair
and counterweight lifting is stuck the coil.
Replace or repair
The relief valve spool is stuck.
the coil.
The cylinders do not

move simultaneously The flow valve has different flow after
Adjust
(the movement is in adjustment.
different speed).
The cylinders do not

move simultaneously The electro-hydraulic directional control valve Replace or repair
(one moves while the cannot be controlled normally. the coil.
other does not).
Replace or repair
The two-way hydraulic lock is defective.
The cylinder retracts the coil.
inadvertently.
Chapter 7

7.1.8 Display detection and diagnosis
The instrument indication area in the lower right position of the LML’s screen, as shown in
Figure 4-21, can be used for detection and diagnosis of certain malfunction through its different
indications.
1
2
3 4
6
7
Figure 4-21 Instrument indication interface
Pos. Description Pos. Description

Chapter 7
1 Pressure at port P 6 Front and rear area display

Hydraulic oil temperature, open
2 7 Fuel reserve
system
3 Pressure at port L 8 Length and speed of main hoist rope
4 Engine oil pressure 9 Supply voltage
5 Coolant temperature

1 3
2
5
Figure 7-2 Speed and function switches
No. Description No. Description

Speed gear (high/medium/slow) or
1 2 Engine RPM and working hours
speedless adjustment percentage
Superstructure ECO mode display and Derricking-spooling/reeling
3 4
clogged filter indication simultaneous movement switch
Deflection compensation function
5
switch
Malfunction description and troubleshooting method is as shown in the table below:
Description Cause analysis Troubleshooting method
Check whether the connectors between the

following CAN bus are loosened:
Engine ECU – chassis PLC - Center
Engine RPM is collecting ring - PLC in the operator’s cab
displayed as 0 after CAN bus open circuit (No. 618 and 620 wire) – LML (No. 351 and
the engine is started 353 wire).
If any one of them is loosened, refasten it;
otherwise contact a service engine for
onsite troubleshooting.
Chapter 7
After the Insufficient diesel left in

Refill diesel timely
superstructure’s the fuel tank
power supply is
switched on, the
remaining fuel is The fuel level sensor is Contact a service engineer for replacing the
displayed as 0 faulty fuel level sensor or troubleshoot its wirings.

The engine oil pressure is
The warning light for lower than 0.5bar at
Contact professional personnel for
engine oil pressure engine idle speed, or
troubleshooting
low illuminates lower than 2.5bar at a
rated RPM
The warning light for Engine coolant
engine coolant temperature is ≥98℃, and Contact professional personnel for
over-temperature the engine cooling system troubleshooting
illuminates is faulty
Contact a service engineer for onsite
The pressure sensor is
troubleshooting or replace the pressure
faulty
sensor
Check if connectors of the CAN bus (No.
Pressure measured 351 and 353 wire) between the PLC inside
at Port P is 0 at the electrical control box on the slewing
engine idle speed CAN bus open circuit or table and the LML computer are loosened; if
sensor short circuit any one of them does, refasten it;
Check the sensor’s wire (No. 1705 and
405), or contact a service engineer for
Faulty pressure sensor troubleshooting or replace the pressure
sensor
The pressure Check if connectors of the CAN bus (No.
measured at Port Ls 351 and 353 wire) between the PLC inside
is 0 when the the electrical control box on the slewing
CAN bus open circuit or
superstructure table and the LML computer are loosened; if
pressure sensor short
moves any one of them does, refasten it;
circuit
Chapter 7

Open-type oil
Faulty temperature sensor troubleshooting or replace the pressure
temperature is 0
sensor

Check if connectors of the CAN bus (No.
351 and 353 wire) between the PLC inside
the electrical control box on the slewing
CAN bus open circuit or
table and the LML computer are loosened; if
temperature sensor short
any one of them does, refasten it;
circuit
Warning light for Check whether the oil filter element is
Faulty circuits or clogged
clogged hydraulic oil clogged and check related circuits (No.
oil filter element
filter illuminates 1714 and 414 wire)
Abnormal indication
Faulty circuits or center Check control circuits of the center
of crane’s working
collecting ring collecting ring and PLC
areas
Remark:
The pressure sensor and temperature sensor are 4 - 20MA current-type sensors.
Chapter 7

The alarm bar in the main interface is as shown in Figure 7-3.
LML error Wind

Main and speed The 5th
code Early
auxiliary winch early CAN bus outrigger
Voltage low warning
overlowered warning alarm overpressure
Main and
Counter Overloading Wind speed GPS error
auxiliary winch
handler warning warning code
overlowered
Figure 7-3 Alarm bar
Corresponding malfunction description and troubleshooting method are as shown in the table
below:

Press “Communication Monitoring” in
the LML main interface to enter the
CAN bus status query interface.
CAN_BUS alarming The corresponding controller or Confirm the faulty controller according
icon appears in the the LML display’s CAN bus is to reminding in the screen. Disconnect
main interface faulty and plug in the CAN bus connector of
the faulty controller.
If the malfunction persists, contact
professional personnel for inspection.
Press “Fault Query” in the LML main
interface to enter the LML fault code
query interface. Conduct
LML alarming icon
troubleshooting according to the
appears in the main Faulty LML
troubleshooting method provided in
interface
Chapter 7
the table.
professional personnel for inspection.
LML early warning The weight of actual lifted load
Be careful during operations to avoid
icon appears in the reaches or exceeds 90% of the
occurrence of an accident
main interface rated one

Press down the bypass switch and the
operation into a dangerous direction
LML warning icon Weight of the actual lifted load
can be continued. As the crane is
appears in the main reaches or exceeds 100% of
already overloaded, be extremely
interface the rated one
careful during operation, otherwise
there is a risk of severe accident!
The main and auxiliary hook Operate the main winch to reel off wire
reaches the limit position at the rope or derrick up the main boom while
Overwinding boom head telescoping it in
alarming icon Install the lifting height limit switch as
The lifting height limit switch is
appears required, or replace it with a new one
not installed or is damaged
when it is damaged
Other faulty circuits Contact professional repair personnel
Less than 3 winds of wire rope
Operate the main winch to spool up
are left on the main or auxiliary
the wire rope
Overlowering winch
alarming icon The overlowering alarm switch
Change the overlowering alarm switch
appears is damaged
Short circuit or other faulty
Contact professional repair personnel
circuits
The crane is overloaded when working
over front, and further operations are
th
The 5 outrigger overpressure forbidden, otherwise there is a risk of
th
The 5 outrigger serious accident of unbearable
overpressure consequence!
th
alarming icon The 5 outrigger pressure Change the 5th outrigger pressure
appears switch is damaged sensor
Short circuit or other faulty
professional personnel for onsite
Chapter 7
circuits
troubleshooting
。Check according to reminding in the
GPS status monitoring interface in the
Faulty GPS Faulty module or circuits LML screen and GPS nixie tube, or
contact professional personnel for
onsite troubleshooting
Power supply voltage The generator fails or faulty Contact professional repair personnel
low icon appears circuits for onsite troubleshooting

7.1.9 Telescoping mechanism
Troubleshooting
Description Cause analysis
method
Change the damaged
The mounting shaft of the nylon plate is nylon plate; clean off the
damaged, deformed or with oil dirt; the grease; replace the
The left and right nylon
spring is damaged. damaged spring with a
plate fails to spring
new one.
back freely
Repair or change
The nylon plate is scratched, damaged due
according to site
to collision, has spurs or deforms.
conditions
The detection switch is
damaged, the detection
distance is too large, the
After the boom pins are released to target
Boom pins are not connector of the switch is
position, no in-position signal is received.
released to target loosened, or its circuits
position are faulty. Troubleshoot it
according to actual cause.
Insufficient elastic force from the boom pin
Change the spring
spring
Faulty mounting height of the pin pulling Adjust the mounting
pillar height
False signal of boom
There is metal materials attached to the
pin retracting to Clean the materials off the
surface of the boom-pin-retracting-to
position surface and wipe it clean
-position detection switch
Faulty detection switch wiring Check and troubleshoot it

Chapter 7

7.2 Chassis
7.2.1 Engine system
The oil inlet screen or the hose of fuel

Clean up the dirt.
delivery pump is blocked.
The air is in the fuel supply system. Exhaust the air.
The oil pump is defective. Repair or replace
The oil injector is defective. Repair
You cannot start the The distribution or oil supply initial angle is
Check and adjust
diesel engine. misaligned.
The high-pressure oil pipe is damaged and
Repair and replace
leaks.
The compression pressure in cylinder is
Repair or replace
insufficient.
Add the preheating
The ambient temperature is too low.
equipment.
The fuel filter is blocked. Clean or replace
The air is in the fuel supply system. Exhaust the air.
The engine stops soon The fuel delivery pump does not work. Clean and repair
after started.
The quality of fuel is poor. And the fuel
Clean and replace
contains too much water.
The idle speed is set too low. Readjust.
The air is restricted (The air filter is

Clean or replace
blocked).
The exhaust back pressure is too high. Adjust and repair
The pressure in supercharging system is

Chapter 7
Check and repair

insufficient.
The power is The supercharger works abnormally. Replace.
insufficient.
The intercooler is damaged and leaks. Replace or repair
The fuel pipeline leaks or is blocked. Repair or clean, replace
The quality of fuel is poor. Clean and replace
The injection pump or the speed regulator

Repair or replace
excessively wears.

The diaphragm of injection pump smoking

Repair or replace
limiter is broken.
The air tube of smoking limiter is damaged
Replace
and leaks.
The atomization of fuel injector is not good. Adjust and repair

The high speed of speed regulator is set too
Adjust
low.
The oil level in oil pan is rather high. Check
Replace the damaged

The cylinder gasket leaks.
cylinder gasket
The piston ring wears and is fractured. And
Replace the worn parts
the bearing shell clearance is excessively
or overhaul the engine.
large.
The air is restricted (The air filter is
Check and clean
blocked).
The exhaust back pressure is too high. Check and clean
The quality of fuel is poor. Replace the fuel.
The fuel pipeline is blocked. Check and repair
The fuel pipeline leaks. Check and repair
Check and adjust or

The atomization of fuel injector is not good.
The fuel consumption repair
is excessively high.
The cylinder gasket leaks. Check the pressure.
The bearing shell clearance is too large. Check and overhaul
The piston is stuck to the cylinder. Replace
The pressure in supercharging system is

Check and repair
insufficient.
Chapter 7
The supercharger works abnormally. Check and replace
The intercooler is damaged or leaks. Replace or repair

The air suction is blocked or the exhaust
Clean
back pressure is rather high.
Black smoke emits. The quality of fuel is poor. Clean and replace
The atomization of fuel injector is not good. Check, repair or replace

Check and adjust (by

The injection pump has too much oil. professional service
personnel)
The pressure in supercharging system is Check whether any
insufficient. pipeline and joint leaks.
Check and replace the
The supercharger works abnormally.
assembly.
The intercooler is damaged or leaks. Replace or repair
Readjust (by
The smoking limiter functions at a wrong
professional service
point.
personnel)
Replace the fuel.
contains too much water.
The cooling water temperature is too low. Check and replace
The air distribution or fuel supply timing is

Check and adjust
incorrect.
The atomization of fuel injector is not good. Check and repair
The compressed air power is rather weak.

The fuel is not completely burned. And the Check and repair
piston is stuck to the cylinder.
White or blue smoke The piston ring and the cylinder sleeve
Continue to run in.
emits. feature poor running-in.
The opening of piston ring is not alternated. Adjust and reassemble
The oil ring of piston has failed. Replace
The clearance of piston and cylinder sleeve

Repair and replace
is excessively large.
The sealing ring of supercharger wears. Check and replace

Chapter 7
The thrust bearing of supercharger wears. Check and replace
The oil return pipeline of supercharger is

Clean or repair
blocked.
The sealing performance of supercharger is
Repair or adjust
The air inlet and intake poor.
tube of supercharger The oil-gas separator has failed. Adjust and replace
collects too much oil.
The oil level in oil sump is rather high due to Check and drain oil.

excessive oil added.

Clean and replace
contains water or wax.
Check and exhaust the
The air is in the oil suction pipeline.
air.
Check and repair (by
The weight and spring of speed regulator do
professional service
not work properly.
The engine RPM is personnel)
unstable. Check and adjust (by
The oil supply is uneven. professional service
personnel)
The atomization of fuel injector is unstable. Check and repair
The supercharger is surging. Check, clean and repair
The bearing of supercharger is damaged. Replace
The oil level in oil sump is rather low or lack

Check and add more.
of oil.
The main oil line of pressure regulator is
Check, clean and repair
defective.
Check whether the oil catcher and filter,
engine oil pipeline, fitting shim, and other Check and repair
parts are blocked or broken.
The oil grade is not in conformity with the
Replace
provisions.
The engine oil The inlet pipe of oil pump leaks. Check, repair or replace
pressure is too low. The coolant temperature is too high and the
Check and rectify
engine oil temperature is too high.
The oil filter has too great resistance and
Replace
Chapter 7
the engine oil temperature is too high.
The oil cooler is blocked. Check and clean
The main oil line is blocked. Check and clean
The clearance of bearing shell is too large

Check and replace
or the bearing shell is damaged.
The components are excessively worn. Check
The coolant The water level in water tank is too low. Check and add more

temperature is too water.

high.
The water tank is blocked. Check, clean or repair
The belt of water pump is loose. Adjust its tension force.
The gasket of water pump is damaged or its Check and repair or

impellers wear. replace
The thermostat is defective. Replace
The water pipe is damaged with air in. Check and replace
The oil level in oil sump is rather low or lack Check, repair and add
of oil. more oil.
Check and replace it
The air filter element is unqualified or worn.
with a qualified element.
Check whether the air intake system is
Check, repair or replace
shorted.
The oil level in oil sump is rather low or lack Check, repair and add
of oil. more oil.
The oil line is blocked. Clean the oil line.
The oil grade is not in conformity with the

Replace
provisions.
The piston ring is fractured or worn. Replace

The parts worn too The cylinder sleeve or piston is worn or the
fast. Check and overhaul
cylinder bore is scuffed.
The engine oil filter element has not been
Replace
timely replaced.
The parts are excessive worn and need
Check and overhaul
overhauling.
The crankshaft is in misalignment with the
Check and repair
Chapter 7
follower spindle.
Adopt the engine oil of
The crankshaft is in misalignment with the the grade in compliance
follower spindle. with the standard
provisions.
The quality of fuel is poor. Replace the fuel.

The noise level is too
Check and replace if
high. The coolant temperature is too low.
necessary.

The air distribution or fuel supply timing is

Check, repair and adjust
incorrect.
The atomization of fuel injector is not good. Check, repair and adjust
Check and adjust (by

The fuel injection pump has too much oil. professional service
personnel)
The shock absorber is damaged. Check and replace
The air valve leaks or is improperly

Adjust
adjusted.
The clearance of gear is excessive large or
Check and replace
the teeth is fractured.
The cylinder sleeve or piston is worn or the
Check, repair or adjust
cylinder bore is scuffed.
The thrust rod is bent or broken. Replace
The piston ring is fractured or worn. Check or replace
The bearing shell is excessively worn. Check and replace
The clearance of crankshaft thrust is

Replace
excessive large.
The main bearing shell is decentralized. Check and repair.
The crankshaft is in misalignment with the

Check and repair.
The noise level is too follower spindle.
high. Check to determine

The components are excessively worn. whether overhauling is
needed.
The supercharger is surging. Clean
The sealing ring of supercharger is sintered. Replace

Chapter 7
The supercharger bearing is damaged. The

Replace
moving parts interfere with the fixing parts.
The turbocharger or compressor impeller is
Replace
contaminated with foreign matters.
Check, charge, or
The starting motor does not work.
replace
The starting motor
does not work. The wire harness is poorly contacted. Clean
The fuse has burnt out. Replace

The brush is poorly contacted. Clean and replace
The starting motor is shorted. Repair and replace
The battery voltage is insufficient. Charge or replace
The bearing bush is worn. Replace
The brush is poorly contacted. Clean or replace

The starting motor has
The reverser is dirty or sintered. Clean or replace
insufficient power.
The line terminals are loosely welded. Weld it again.
The switch is not well contacted. Check and repair
The friction clutch is sliding. Adjust or replace
The wiring is broken or shorted. And it is

Repair
with loose contacts.
The rotor and stator coil is partially shorted
Repair or replace
or disconnected.
The generator belt is loose. Check and adjust
The generator does The rectifier tube of generator is damaged.

Repair
not work. And this results in bad contact of the brush.
The voltage of regulator is set too low. Adjust
The field coil or resistor wiring of regulator is

Repair or replace
disconnected.
The battery electrolyte is insufficient or the
Add or replace
battery is too old.
The rotor and stator coil is to be shorted and
Repair or replace
disconnected.
The brush is poorly contacted. Repair

The charging current is The wiring terminals are loose or poorly
Chapter 7
unstable. Repair
contacted.
The voltage regulator is damaged. Repair
The voltage is improperly adjusted. Check and adjust

7.2.2 Transmission
The transmission bearings or gears are

Check
defective.
Abnormal noise
Noise sounds from the gear. Check
The clutch is not completely disengaged. Check

The gear shift operating mechanism has
The range selector is Check and adjust
something wrong.
difficult to operate.
The main shaft of the transmission has
Check
something wrong.
The range selector has something wrong. Check
The compression spring or self-locking

Check
The range selector is mechanism is worn or broken.
out of gear.
The operating mechanism is loose. Check
The transmission has something wrong. Check
The transmission is The air pressure is low. Check

always engaged in the The air system and range gear control
Check
neutral position. system have something wrong.
The fast and slow The air pressure is low. Check

gears can not be The air system and range gear control
Check
switched. system have something wrong.
The inlet and outlet air filter / regulator are
Check and replace
damaged.
Air leakage Further check the air
The ventilation plug of transmission leaks
and oil sealing
internally.
performance.
Chapter 7

7.2.3 Propeller shaft
The universal joint has its cross shaft and

Replace the
The vehicle sounds needle roller worn and loose or the roller pin
corresponding parts.
abnormally in time of is broken.
starting-up, The propeller shaft spline and the telescopic Replace the
acceleration and joint splineway are excessively worn. corresponding parts.
deceleration. The transmission has its second shaft spline Replace the
and flange splineway excessively worn. corresponding parts.
Periodic noise appears The transmission shaft is bent or the
Replace the propeller
in time of running. The transmission shaft flange and the shaft tube
shaft.
faster the vehicle runs, are welded in misalignment.
the higher the noise The support of intermediate bearing has I
Tighten or replace
should be. And when it ts fixing bolts loose or misplaced.
is rather serious, the The adjacent propeller shafts have their
Tighten
vehicle body will shake connecting bolts loose.
and the steering wheel The propeller shaft has its balance block
Replace or repair
is hard to operate. fallen off.
Abnormal sound The intermediate support is askew and
Adjust or replace
appears in time of excessively worn.
running. And the faster The intermediate support has its bearing
Replace the bearing
the vehicle runs, the balls fallen off.
higher the noise should Add 2# lithium-based
The intermediate support has insufficient oil.
be. grease.
Chapter 7

7.2.4 Drive axle

Noise sounds like "hiss" during accelerating
or decelerating: meshing clearance of gears Adjust
too small or poorly meshed.
Observe after its
New gear poorly meshed
break-in period.
Noise sounds like "clash" on descending
gradients or when changing vehicle speed
Adjust or replace the
jerkily. Noise fades away or decreases
gear.
during normal driving: meshing clearance of
gears too large.
Continuous noise during driving. The higher
Abnormal noise the speed is, the louder the noise is. But
Adjust or replace the
noise fades away or decreases during
bearings.
sliding: the bearings (on hub, main reducer
or differential) wear and loose.
Gear oil level too low or oil viscosity do not
Fill oil
meet requirements.
No noise during straight driving but noise
sounds during turning: clearance of
bearings on both sides of reducer too large. Adjust or replace
Differential gear or thrust bearing shim
wears.
Bearing installed too tightly. Meshing
Adjust
clearance too small.
Fill more oil to the
The oil level is too low.
Heat generation specified requirements.
Replace the lubricant to
The viscosity of lubricant doesn’t meet the
the specified
requirements.
requirements.
Oil seal becomes invalid. Replace the oil seal.
Chapter 7
Replace the
Axle journal is worn.
corresponding parts.
Drain the oil to the level
The oil level is too high.
as required.
Oil leakage Replace the sealing
The sealing gasket is damaged.
gasket.
The bolt is loose. Fasten the bolts.
Clean up to make it
The vent cap is blocked.
smooth.

7.2.5 Steering system
The hydraulic system has insufficient oil. Fill oil
The air is in the hydraulic system. Exhaust and check

Clean or replace the filter
The filter or pipeline is blocked due to
or pipeline, or replace
inferior cleanliness of the hydraulic oil.
the oil.
Steer heavily both left
The oil pump has insufficient pressure. Repair
and right.
There is serious leakage inside the steering Repair or replace the
gear. sealing ring.
Too wide or too narrow clearance occurs Replace the bearing and
due to damages of the kingpin, thrust adjusting shim to adjust
bearing and adjusting shim. the clearance.
The oil leakage is not of the same

seriousness at both sides of the piston Replace the sealing ring.
Left and right steering
inside the steering gear.
is uneven in force
The limit valve is adjusted improperly and
application. Readjust
opened prematurely.
The air is in each chamber. Exhaust the air.
The steering shaft is sometimes blocked. Check

There are some bubbles in the oil to result
Check and remove
in unstable direction.
One front wheel cannot return after braking
or the bearings of the two front wheels are Check and adjust
different in degree of tightness.
The vehicle runs out
The right and left tires have great differential
during driving. Fill the air.
pressure.
Chapter 7
Too wide or too narrow clearance occurs

possibly due to damages of the thrust
Replace and adjust
bearing adjusting shim of the steering
knuckle pin on one side.
The steerable wheels are unevenly worn. Adjust the toe-in.

Fill the oil pump with
The steering wheel is
The oil pump has insufficient oil supply. more oil or repair the oil
operated difficultly in
pump.

time of fast steering. The oil seal of steering gear is damaged or

Replace the oil seal
has reached wear limit, leading to inner
again.
leakage.
The air enters in. Exhaust the air.
The steering wheel is Check the clamping

The steering piston or valve is stagnated.
operated too easily stagnation.
and difficultly some The screw thrust bearing of steering gear is

Replace the bearing.
damaged.
times during fast
steering. The hydraulic oil is too dirty. Replace the oil.
The hydraulic system has air or insufficient Exhaust or add enough
oil. oil.
The driving link ball head pins have too wide
Adjust the clearance.
clearance.
The mounting screws of steering gear are Check and tighten the
loose. screws.
The wheels wobble.
Check and tighten the
The thrust rod bolts are loose.
wheels.
The left and right steer wheels are unequally
Fill the air.
inflated.
Check and tighten the
Wheels are loose.
wheels.
The mounting screws of the steering gear Check and tighten the
and power cylinder bracket are loose. screws.
The driving link ball head pins have too wide
The steering wheel has Check or replace
clearance.
too large free
The steering drive link is worn or Adjust the clearance or
clearance.
inappropriately adjusted. replace the link.
The drive pair in the steering gear is worn to
Adjust or repair
Chapter 7
result in wider clearance.

The joint part of the drive link has Check and add more
insufficient lubricating oil. lubricating oil.
Check and eliminate the

The steering wheel is The steering gear is stagnated inside.
clamping stagnation.
difficult to return.
Clean the distribution
The steering gear is stagnated inside. valve to eliminate the
clamping stagnation.

7.2.6 Brake system
Check the pressure in

During braking, the air pressure can not reach the air line system and
the requirements. ensure the pressure
The braking force is reaches 0.8 MPa.
insufficient. Check the air line joint

and valve tightness to
The brake system suffers from air leakage.
make sure there is no
leakage.
During braking, the braking force is not
Adjust
uniform left and right.
Braking deviation The left and right tires have different

Adjust
pressure.
The brake is locked. Remove and replace

The mandril of the wheel brake cylinder
The brake drum is Remove and replace
cannot return smoothly.
overheated with smoke
The brake clearance is too narrow and the
appearing. Check and adjust
brake is poor in cooling.
The brake master cylinder, the relay valve or Replace or repair the
the quick release valve is damaged. corresponding parts.
The 4-circuit protection valve is defective. Replace or repair

The brake does not Connect the pipelines
The brake pipelines suffer from air leakage.
react. again.
Replace the air dryer
The air dryer is defective. and drain all air
reservoirs once a day.
Adjust the brake pedal
The brake responds The brake pedal has an excessively long
travel to a proper
Chapter 7
slowly. travel.
position.

7.2.7 Tire
Adjust the tie rod of the

The steer wheels on front steer axle in the
both sides are direction of elongation
The toe-in is too small or negative.
abnormally and equally to have the toe-in
worn inside. value increased to the
specified value.
Adjust the tie rod of the
The steer wheels on front steer axle in the
both sides are direction of contraction
The toe-in is too large.
abnormally and equally to have the toe-in
worn outside. value decreased to the
specified value.
Adjust to have the
The steer axle and drive axle are not parallel
vehicle axles correctly
or the vehicle axles are dislocated.
positioned.
Steerable wheel on one Adjust the drag link of
side is worn inside, the front steer axle to
while the other side is When one steer axle is in the position of have the two front
worn outside. straight running, while the other front axle is steer axles
not. simultaneously in the
position of straight
running.
The wheel is out-of-round to result in tire Reassemble the wheel
standing wave. or replace it.
Check whether too
Serrated wear appears. much hardening
The uneven rotation of wheel results in tire
talcum powder and
standing wave.
Chapter 7
other objects are left in

the tire.
Adjust the interval of
The wheels are often in the state of braking or
the brake on this side
Wheels on one side are half braking.
to the normal value.
abnormally worn.
The specification or size of tire on this side
Replace
does not satisfy the requirements.

The drive axles are seriously not parallel. Adjust
During normal driving,

The transversal or longitudinal differential switch off the
lock switch is not switched off. And thus make transversal or
The drive wheels are
the drive axles be locked for a long time. longitudinal differential
abnormally worn.
locks.
The transversal or longitudinal differential
lock is defective. And thus make the drive Repair or replace
axles be locked for a long time.
Overload: The crane is loaded with excessive
Remove the weight
weight, which should not be carried during
and replace the wheel.
driving.
The tire is flat. Run at high speed for a long time. Replace
The tire is damaged externally. Replace
The tire tread has been worn deep to the

Replace
wear identifying limit.
Chapter 7

7.2.8 Hydraulic system
The system pressure is too low. Check and adjust
The steering gear leaks internally. Replace or repair

The steering wheel is
difficult to turn. The steering oil pump leaks internally. Replace or repair
The steering booster cylinder leaks internally

Replace or repair
or damages.
The pressure of the relief valve is improperly
Adjust
adjusted.
No movements
The relief valve has its spool stuck. Repair
The chassis control valve is defective. Repair
The chassis control valve leaks internally. Repair

The movement is slow.
The pressure of relief valve is set too low. Adjust
The vertical cylinder is

The two-way hydraulic lock is defective. Repair or replace
retracted inadvertently.
The piston rod of The two-way hydraulic lock is defective. Repair or replace
vertical cylinder is The cylinder leaks internally. Repair
extended inadvertently
The cylinder seal is defective. And this results
during a drive. Repair
in oil leakage.
The system pressure is The pressure of relief valve is set too low. Adjust
low. The oil pump has more leakage. Replace or repair
CAUTION
The hydraulic system fault must be eliminated by professionals assigned by the
manufacturer or professional maintenance personnel with considerable technical
Chapter 7
experience.

7.2.9 Electrical system
The bulbs are damaged. Replace
Repair and
The fuse is burnt out.
replace
The lights and signal
lamps do not light up. Poor grounding occurs. Repair
The lines are defective. Repair
The switch or relay is defective. Repair or replace
The control lights / The switch is defective. Replace

warning lights on the
instrument panel do not
light up.
Check the air line

The air pressure is lower than 0.55 MPa.
The warning light “Brake system.
pressure too low” is
The warning light is defective. Replace
constantly on.
Repair and
replace

The wipers do not work.
The electric motor is damaged. Replace
Repair and
replace
Chapter 7

The horn does not
sound. The relay is defective. Replace
The horn is defective. Replace
The buzzer does not Repair and

sound. replace

The buzzer is damaged. Replace
The generator drive belt is loose or broken. Repair or replace

The warning light
“Charging monitoring” is The generator is defective. Repair or replace
constantly on.
The coolant temperature exceeds the allowed

The warning light Check
maximum temperature of the engine.
“Engine coolant
temperature too high” is The temperature sensor is defective. Replace
constantly on.
The engine oil pressure is lower than the allowed

Check
The warning light minimum pressure.
“Engine oil pressure too The oil pressure sensor is defective. Replace
low” is constantly on.
The air pressure is lower than 0.55 MPa. Check
The control light

The parking brake hand lever is defective. Replace
“Parking brake
activated” is constantly The warning light “Brake pressure too low” is
Replace
on. defective.
The warning light “Door The door open detector switch is defective. Replace
opened” is constantly
on. The lines are defective. Repair
Chapter 7
The coolant in the expansion tank is little. Repair and add

The warning light
The switch “Engine coolant level too low” is
“Engine coolant level too Replace
defective.
low” is constantly on.
The warning light The engine is defective. Repair

“Engine defects” or the
warning light “Engine The lines are defective. Repair

error code displayed” is

constantly on.
Repair and
replace
The complete vehicle The ignition starter switch is defective. Repair or replace
has no power.
The battery master switch is defective. Replace
Repair and
replace
The ignition starter switch is defective. Repair or replace
The neutral gear switch is defective. Replace

The starting motor does
not act. The starting motor is defective. Repair or replace
The relay K17 is damaged. Replace
The engine ECU is defective. Repair or replace
The outrigger accelerator switch is defective. Replace

The outrigger
The button “PTO engaged” is damaged. Replace
accelerator is invalid.

Chapter 7
The accelerator pedal is defective. Replace

The accelerator is
The button “PTO engaged” is damaged. Replace
invalid.

7.2.10 Outrigger
The relief pressure of chassis multiple unit valve

Adjust
No movements is improperly adjusted.
The chassis multiple unit valve is defective. Repair
The chassis multiple unit valve leaks internally. Repair

The movement is slow. The relief pressure of chassis multiple unit valve
Adjust
is set too low.
The vertical cylinders The two-way hydraulic lock is defective. Repair
retract inadvertently
during lifting.
The two-way hydraulic lock is defective. Repair

The vertical cylinders
extend inadvertently The cylinder leaks internally. Repair
during driving.
The cylinder leaks outward. Repair
Chapter 7

Chapter 8 Appendix
Periodic Maintenance Records
8.1 Routine inspection and maintenance

— Superstructure
Interval Maintenance
Items Contents date / Remarks
Daily Weekly
Signature
Check the oil level
1. Oil level and pressure in the hydraulic oil ●
tank.
Check the filter for
2. Return-line filter blockage and ●
damage.
Check the mounting
bolts for tight fit.
●
Check the housing
●
Hydraulic
for deformation and
motor
cracks.
Check it for
abnormal noise and ●
vibration.

3. Hydraulic Check whether the
system Hydraulic cylinder
cylinder inadvertently ●
retracts during
lifting operation.
Proportional
valve block
Check the bolts for
tight fit.
●
Balance
●
Chapter 8
Check it for leaks.

valves
Pressure
gauge
Check the pointer
for functional work.
●

Daily Weekly
Signature
Check them for
leaks.
●
Check them for
proper seating.
●
Pipelines and Check the pipelines
fittings for cracks and ●
damage.
Check the pipe
clamps for correct ●
seating.
Check the hoisting
limit switch for ●
functional work.
Check the lowering
limit switch for ●
functional work.
Check the warning
devices for ●
functional work.
Check the
4. Safety indicators and
devices emergency stop
switch for functional
●
work.
Check the diameter
of level gauge
bubble and the ●
position of level
gauge.
Check the flexibility
of the angle ●
indicator.
5. Load moment limiter

Check it for
●
Chapter 8
functional work.
6. Wire rope
Check it for
damage.
●

Daily Weekly
Signature
Check it for proper
lubrication.
●
Check the boom
7. Boom and derricking

and derricking
cylinder shaft for
●
cylinder shafts proper lubrication.
Check and tighten
the chuck plate.
●
Check whether the
8. Hoist gear wire rope on the
drum winds
●
uniformly.
9. Slewing gear Check it for leaks. ●
Check the
10. Counterweight handler counterweight lifting ●
cylinders for leaks.
Chapter 8

— Chassis
Daily Weekly
Signature

Check the fuel reserve. ●
Check the engine oil
pressure.
●
1. Liquid level,
pressure and Check the engine oil level. ●
temperature Check the engine coolant
temperature.
●
Check the liquid level in the
expansion tank.
●
Check the AdBlue level. ●
Check it for tight fit and
damage.
●
Hydraulic pump

Check it for abnormal noise
and vibration.
●
Check the pipe fittings for
proper seating and leaks.
●
Hydraulic
cylinder
Examine it for functional

2. Hydraulic System
work. Make sure it does not

retract inadvertently during
●
crane operation.
Clean off the contamination
●
Hydraulic oil
on the tank.
●
tank
Check it for tight fit.

●
Pipelines and joints
Check them for tight fit.

Chapter 8
Check the pipelines for

cracks and damage.
●
Check the pipe clamp for tight
fit.
●
Daily Weekly
Signature
Check the engine system for
leaks.
●
Check the transmission and
axles for leaks.
●
3. Oil and water Check the antifreeze and
●
leakage anti-corrosive fluid in the
engine cooling system for
leaks.
Check the pipelines of the
fuel supply system for leaks.
●
Check the engine oil
pressure gauge.
●
Check the warning light
“charging monitoring” and ●
voltmeter.
Check the fuel gauge. ●
Check the water
thermometer.
●
Check the engine fault
warning light.
●
●
4. Safety Check the air pressure
indicators and
devices gauge.
Check the reversing display
system.
●
Check the service brake. ●
Check the parking brake ●
Observe the pressure
differential indicator on the ●
inlet pipeline.
Check the lights and signal
devices special for the ●
vehicle during driving.
Chapter 8
Check the steering

mechanism.
●
5. Steering
system Check the system for
functional work.
●
Daily Weekly
Signature

Check the wheel alignment. ●
Check the brake pressure. ●
Check the sealing
performance of air line.
●
6. Brake system Check the brake
performance.
●
Drain off the accumulated
water in the air reservoir.
●
Check the tire pressure. ●
Clean up the tire tread
surface.
●
7. Wheels / tires
Clean off the contamination
on the wheel rim.
●
Check the wheel rim for
cracks.
●
Check the wheel nuts. ●
8. Suspension
Check it for proper
connections.
●
●
system
Check the thrust rod support.
9. Transmission
Check the transmission
ventilation cap.
●
10. Drive axles
Check the ventilation plug of
drive axles.
●
11. Battery Check the voltage. ●
Chapter 8

8.2 Inspections and maintenances during break-in period
— Superstructure
Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Clean the filter element. 200 hours
1. Return-line filter Check the surface of the

filter element for 200 hours
damage.
Check whether the work
pressure of the system 200 hours
is in normal range.
Check the hydraulic
pump for functional 200 hours
work.
2. Hydraulic
system Check the hydraulic
200 hours
valves for leaks.
Check the pipe lines and
fittings for tight fit, leaks, 200 hours
deformation and cracks.
Replace the pilot oil filter
250 hours
element.
Replace the lubricating
500 hours
oil of the winch reducer.
Check the hoist winch
200 hours
3. Hoist gear for leaks.
Check whether the wire
rope on the drum winds 200 hours
uniformly.
Check whether the
4. Wire rope telescoping rope is in 200 hours
good state.
Check whether the
Chapter 8
slewing bearing is 200 hours

5. Slewing gear lubricated properly.
Clean the tooth surface
200 hours
of slewing bearing.

Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Check the pre-tightening
force of the mounting 200 hours
bolts for slewing bearing.
oil of the slewing 500 hours
reducer.
Check the slewing gear
200 hours
for leaks
Check the slewing
200 hours
clearance.
Check the lock plate bolt
at the derricking cylinder 200 hours
fulcrum pin for tight fit.
Check the derricking
6. Derricking gear 200 hours
cylinder for leaks.
Check the derricking
cylinder for abnormal 200 hours
noise and vibration.
Check the welding
7. Slewing table 200 hours
seams for cracks.
Check whether the
boom can extend or 200 hours
retract normally.
Check whether the
telescoping cylinder
200 hours
retracts inadvertently
8. Telescoping during crane operation.
system Check the pipe lines and
200 hours
fittings for tight fit.
Check the hoses for
deformation and 200 hours
Chapter 8
damage.
Check the telescoping
200 hours
cylinder for leaks.

Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Check the welding
200 hours
seams for cracks.
Adjust the clearance of
200 hours
9. Boom the slide blocks.
Check whether the
pulley block can rotate 200 hours
smoothly.
Check whether the
counterweight lifting
10. Counterweight cylinders move
200 hours
handler simultaneously. And
check whether the
mounting bolt for tight fit.
th
Check whether the 5
outrigger pressure high
200 hours
warning light is working
normally or not.
Check whether the
11. Outriggers
outriggers can extend or 200 hours
retract normally.
Adjust the tightness of
telescoping extension / 200 hours
retraction wire rope.
Check the hoisting limit
200 hours
switch
Check the lowering limit
200 hours
switch
Check the hoisting limit
12. Safety
switch for functional 200 hours
indicators and
work.
devices
Check the angle
indicator for functional 200 hours
Chapter 8
work.
Check the level gauge
200 hours
for functional work.

Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Check the load moment
limiter for functional 200 hours
work.
Chapter 8

— Chassis
Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Check the ventilation cap. 3 months 3000 km

1. Transmission
Replace the lubricating oil. 3 months 3000 km
Check whether the

kingpin of steer axle is 3 months 3000 km
lubricated properly.
Clean the ventilation
3 months 3000 km
holes.
2. Axles Check the connecting
bolts and clamps of
3 months 3000 km
steering trapezoid for tight
fit.
Adjust clearance of the
3 months 3000 km
brake shoe.
steering column universal 3 months 3000 km
joint.
universal joint bearing of 3 months 3000 km
propeller shaft.
sliding splines of propeller 3 months 3000 km
shaft.
3. Lubricating
grease Check and lubricate the
intermediate bearing of 3 months 3000 km
propeller shaft.
3 months 3000 km
angle drive device.
Check and lubricate the oil
3 months 3000 km
pump drive device.
Chapter 8

universal joint of oil pump 3 months 3000 km
propeller shaft.

Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
3 months 3000 km
rocker arm shaft.
Check and lubricate other
3 months 3000 km
lubricating points.
3 months 3000 km
kingpin of steer axle.
Check the wheel nuts for
3 months 3000 km
tight fit.
Check the nuts of
3 months 3000 km
propeller shaft for tight fit.
Check the nuts of
propeller shaft
3 months 3000 km
intermediate bearing for
tight fit.
Check the U-bolt for tight
3 months 3000 km
fit.
Check the mounting bolts
3 months 3000 km
of engine for tight fit.
3 months 3000 km
of transmission for tight fit.
4. Key fasteners
Check the thrust rod bolts
3 months 3000 km
and clamp nuts for tight fit.
Check the ball joint nuts
and clamp nuts of the
3 months 3000 km
steering drag rod for tight
fit.
Check the ball joint nuts
and clamp nuts of the
3 months 3000 km
steering booster cylinder
for tight fit.
Check the nuts of brake
3 months 3000 km
Chapter 8
chamber for tight fit.

3 months 3000 km
of the oil pump for tight fit.

Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
of the driver’s cab for tight 3 months 3000 km
fit.
Check the system for
3 months 3000 km
functional work.
Check and adjust the
3 months 3000 km
wheel toe-in.
Check the steering
3 months 3000 km
hydraulic circuit for leaks.
5. Steering Clean up the steering oil
system 3 months 3000 km
tank filter element.
Make sure that the work
pressure of the hydraulic 3 months 3000 km
system is in normal range.
Check the pipes and
fittings for tight fit, leaks, 3 months 3000 km
deformation and cracks.
Check the brake pressure. 3 months 3000 km
Check the sealing
performance of air line.
Check the brake
3 months 3000 km
performance.
Check the thrust rod. 3 months 3000 km
Check the balance
suspension and the 3 months 3000 km
7. Suspension support.
system
Check the leaf spring and
3 months 3000 km
the rubber spring.
Check the shock
3 months 3000 km
absorber.
Chapter 8
Check the flanged bolts

8. Propeller
shaft and nuts of propeller shaft 3 months 3000 km
for tight fit.

Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Check the propeller shaft.

Check the cross shaft and
shaft fork for tight fit,
damages and
deformations. Check the
3 months 3000 km
propeller shaft tubes for
deformations, damages
and cracks. Check
whether there is balance
block fell off.
Check the intermediate

bearing for damages and 3 months 3000 km
proper seating.

connection.
Check the bolts of thrust
3 months 3000 km
rod for correct connection.
Check the thrust rod ball
3 months 3000 km
cup.
Check the steering rod
3 months 3000 km
9. Wheel ball end.
alignment
(only applied Check the rocker arm
3 months 3000 km
for all-wheel bearing.
steer
products) Check the steering
3 months 3000 km
coupling fork.
Check the ball end of
3 months 3000 km
trapezoidal mechanism.
Adjust the neutral position
3 months 3000 km
of the steering wheel.
Chapter 8
Check the toe-in of each

3 months 3000 km
steer axle.

Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
10. Steer drive
axle
11.Drive axle
(Non-steer)
12. Return-line Replace the hydraulic oil
3 months 3000 km
filter filter element.
Chapter 8

8.3 Monthly inspection and maintenance
— Superstructure
Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Check the level and quality of
1 month 100 hours
gear oil in slewing reducer.
1. Slewing Check whether the slewing
1 month 100 hours
gear bearing is lubricated properly.
Clean the tooth surface of
1 month 100 hours
slewing bearing.
Check the level and quality of
2. Hoist gear gear oil in the main (auxiliary) 1 month 100 hours
winches.
Check and add the
3.Cable reel lubricating grease in the 1 month 100 hours
cable reel pulley.
Chapter 8

— Chassis
Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Check the oil level in
1 month 1500 km
transmission.
1. Oil level
Check the gear oil level in
1 month 1500 km
drive axle.
universal joint of steering 1 month 1500 km
column.
universal joint bearing of 1 month 1500 km
propeller shaft.
sliding splines of propeller 1 month 1500 km
shaft.
intermediate bearing of 1 month 1500 km
2. Lubricating
propeller shaft.
grease
1 month 1500 km
angle drive device.
Check and lubricate the oil
1 month 1500 km
pump drive device.
universal joint of oil pump 1 month 1500 km
propeller shaft.
1 month 1500 km
rocker arm shaft.
1 month 1500 km
kingpin of steer axle.
Check the wheel nuts for tight
1 month 1500 km
fit.
3. Tightening
Check the nuts of propeller
torque of 1 month 1500 km
shaft for tight fit.
Chapter 8
key
Check the nuts of propeller
fasteners
shaft intermediate bearing for 1 month 1500 km
tight fit.

Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Check the U-bolt for tight fit. 1 month 1500 km

Check the bolts and clamp
1 month 1500 km
nuts of thrust rod for tight fit.
clamp nuts of the steering 1 month 1500 km
drag rod for tight fit.
clamp nuts of the steering 1 month 1500 km
booster cylinder for tight fit.
Check the nuts of brake
1 month 1500 km
chamber for tight fit.
Check the mounting bolts of
1 month 1500 km
the oil pump for tight fit.
Chapter 8

8.4 Quarterly inspection and maintenance
— Superstructure
Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Check the quality of
1. Hydraulic oil 3 month 200 hours
the hydraulic oil.
Check the wire rope for
3 month 200 hours
good state.
2. Wire rope
Check the lubrication
3 month 200 hours
status.
Check and add gear
3. Hoist winch 3 month 200 hours
oil.
4. Slewing Check and add gear
3 month 200 hours
reducer oil.
Check whether the
counterweight lifting
cylinders can
5. Counterweight extend/retract
3 month 200 hours
handler simultaneously. And
check whether the
mounting bolt for tight
fit.
Check the filter
element and drain the 3 month 200 hours
sediment.
Check the surface of
the filter element for 3 month 200 hours
damage.
Chapter 8

— Chassis
Interval
Maintenance
Calendar Mileages /
signature
month Service hours
3000 km /
Replace the engine oil. 3 months
250 hours
1. Engine Replace the engine oil 3000 km /
3 months
and its filter element. 250 hours
peripheral Replace the fuel 3000 km /
3 months
systems coarse filter element. 250 hours
Clean the air filter 3000 km /
3 months
element. 250 hours
Check the mounting
bolts of engine for tight 3 months 5000 km
fit.
Check the mounting
2. Key
bolts of transmission 3 months 5000 km
fasteners
for tight fit.
Check the mounting
bolts of the driver’s cab 3 months 5000 km
for tight fit.
3. Wheels / Check the tires for
3 months 5000 km
tires abrasion.
Check the electrolyte
4. Battery 3 months 5000 km
level.
Chapter 8

8.5 Semi-annually inspection and maintenance
— Superstructure
Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
1. Return-line Replace the hydraulic oil
6 months 500 hours
filter filter element.
Tighten the mounting
2. Slewing 6 months 500 hours
bolts.
reducer
Replace the gear oil 6 months 500 hours
Tighten the mounting

6 months 500 hours
3. Winch bolts.
reducer Replace the gear oil of
6 months 500 hours
main (auxiliary) winches.
Check the pipe and cable
of A/C for proper 6 months 500 hours
4. Air
connections.
conditioning
Check the heating and
6 months 500 hours
cooling effect.
Check the counterweight
5.Counterweight lifting cylinders and its 6 months 500 hours
main body for cracks
Check the welding seams
6 months 500 hours
for cracks.
6. Slewing table Check the slewing table
for deformation and 6 months 500 hours
cracks.
6 months 500 hours
for cracks.
Check the boom for
6 months 500 hours
deformation.
7. Boom
Check the pulleys and
6 months 500 hours
Chapter 8
rollers for damage.

Lubricate the slide blocks
6 months 500 hours
and adjust their clearance.

Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
6 months 500 hours
for cracks.
Check the boom for
8. Jib 6 months 500 hours
cracks and deformation.
Check the pulleys for
6 months 500 hours
damage.
Check the pulley for
6 months 500 hours
damage.
Check the bearing for
9. Hook 6 months 500 hours
damage.
Check the hook for
6 months 500 hours
damage.
Adjust the length
10.Cable reel 6 months 500 hours
detection value.
Chapter 8

— Chassis
Interval (whichever
comes first) Maintenance
Items Contents Mileages date / Remarks
Calendar
/ Service signature
month
hours
Check the hydraulic oil
6 months 5000 km
quality.
Check the gear oil
1. Oil quality 6 months 5000 km
quality of transmission.
Check the gear oil
6 months 5000 km
quality of axles.
Check it for proper
6 months 5000 km
Diesel engine
seating
Replace the engine oil. 6 months 5000 km
Replace the oil filter

6 months 5000 km
element.
Check the water tank
for proper seating, and
Water cooling
check the water pipe

6 months 5000 km
for tight fit, aging,
damage and
2. Engine deformation.
and its Clean the surface of
6 months 5000 km
peripheral water tank radiator.
control Check the intercooler
system for proper seating, and
check the intercooling
Intercooling
6 months 5000 km
pipe for tight fit, aging,
damage and
deformation.
Clean the surface of
6 months 5000 km
intercooler.
Check it for proper
Fuel supply
6 months 5000 km
system
seating.
Chapter 8
Drain off and clean the

6 months 5000 km
fuel coarse filter.

Interval (whichever
Calendar
/ Service signature
month
hours
Air intake
system
Replace the air filter

6 months 5000 km
element.
Exhaust
system
Check it for proper

6 months 5000 km
seating.
Replace the air dryer

element.
Replace the filter
4.Steering system element of steering oil 3 months 3000 km
tank.
connection.
Check the bolts of
thrust rod for correct 6 months 5000 km
connection.
Check the thrust rod
6 months 5000 km
ball cup.
Check the steering rod
6 months 5000 km
5. Wheel alignment ball end.
(only applied for Check the rocker arm

6 months 5000 km
all-wheel steer bearing.
products) Check the steering
6 months 5000 km
coupling fork.
Check the ball end of
trapezoidal 6 months 5000 km
mechanism.
Check the steering
6 months 5000 km
wheel.
Chapter 8
Check the toe-in of

6 months 5000 km
each steer axle.

Interval (whichever
Calendar
/ Service signature
month
hours
Clean the ventilation
6 months 5000 km
holes.
6. Axles
Check the welding
6 months 5000 km
seam of axle housing.
Transpose the wheels. 6 months 5000 km
7. Wheels Check the valve
6 months 5000 km
mouth.
Check the key welding
8. Chassis frame 6 months 5000 km
seams.
Check the pulley assy.
6 months 5000 km
for wear.
Check fixing bolts of
9. Outrigger horizontal cylinders for 6 months 5000 km
tight fit.
Check the wire rope for
6 months 5000 km
tightening.
Replace the hydraulic
10.Return-line filter 6 months 500 hours
oil filter element.
Chapter 8

— Superstructure
Interval (whichever
Maintenance
comes first)
Calendar Service
signature
month hours
Telescoping Check and lubricate the slide
9 months 750 hours
system blocks.
— Chassis
Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Check the connecting cable
9 months 7500 km
for good connection.
Check the terminal post for
Battery 9 months 7500 km
rust and corrosion.
Check the battery electrolyte
9 months 7500 km
for leaks.
Chapter 8

— Chassis
Interval (whichever
Maintenance
comes first)
Calendar
Mileages signature
month
Replace the engine
1. Engine 12 months 10000 km
coolant.
2. Transmission Replace the gear oil. 12 months 10000 km

oil of hub reducer and 12 months 10000 km
3. Axles central reducer.
Lubricate the driven axle
12 months 10000 km
hub bearing.
4. High Replace the
temperature high-temperature hose at 12 months 10000 km
hose the air pump outlet.
Replace the coarse fuel
12 months 10000 km
filter element.
5. Fuel supply
Replace the fine fuel
system 12 months 10000 km
filter element.
Clean the fuel tank. 12 months 10000 km

Check it for proper
12 months 10000 km
6. Cooling seating.
system Check and clean the
12 months 10000 km
radiator.
7. Steering Replace the hydraulic
12 months 10000 km
system oil.
8. Clutch control Replace the clutch brake
12 months 10000 km
mechanism fluid.
9. Steer drive
axle
10. Drive axle
Chapter 8
(non-steer)

— Superstructure
Interval
Maintenance
Calendar Service
signature
month hours
Hydraulic
Replace the hydraulic oil. 18 months 1500 hours
system
— Chassis
Interval
Maintenance
Calendar
Mileages signature
month
Outrigger Check whether the
telescoping outrigger spreads L and W 18 months 15000 km
system satisfy the requirements.
Chapter 8

— Superstructure
Interval
(whichever comes first) Maintenance
Items Contents Mileages / date / Remarks
Calendar
Service signature
month
hours
1. Hydraulic
Replace the hose. 24 months /
hose
2. Slewing Check the slewing
24 months /
gear clearance.
— Chassis
Interval
Maintenance
Calendar
Mileages signature
month
Replace the brake hose. 24 months 20000 km
Replace the fuel hose. 24 months 20000 km
Replace the water hose of
24 months 20000 km
engine.
Replace the intercooler
1.Hoses and 24 months 20000 km
hose of engine.
shock
Replace the air intake
pads 24 months 20000 km
hose of engine.
Replace the shock pad of.
24 months 20000 km
engine
Replace the shock pad of
24 months 20000 km
radiator
Chapter 8

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Zoomlion Heavy Industry Science & Technology Co.,Ltd.

Edition 1 March 2020

Refers to a dangerous situation which, if you do not prevent, will cause

Refers to a possible dangerous situation which, if you do not prevent,

Refers to a possible dangerous situation which, if you do not prevent, may

Refers to a situation which, if you do not prevent, may cause property or

Safety Instructions ....................................................................................................................... II

Chapter 1 Crane Maintenance Instructions

1.1 Instructions to maintenance cycles ............................................................................... 1-1

Chapter 2 Maintenance Schedule

2.1 Routine inspection and maintenance............................................................................ 2-1

Chapter 3 Daily Inspect and Maintenance Guidelines

3.1 Inspection of liquid level, pressure and temperature ..................................................... 3-1

ZTC Series Truck Crane (25t~80t) III

IV ZTC Series Truck Crane (25t~80t)

5.1 Periodical inspection and maintenance ........................................................................ 5-1

ZTC Series Truck Crane (25t~80t) V

Table for oil medium capacities............................................................................................. 6-1

Chapter 7 Diagnosis and Troubleshooting for Common Failures

7.1 Electrical system, superstructure.................................................................................. 7-1

8.1 Routine inspection and maintenance............................................................................ 8-1

VI ZTC Series Truck Crane (25t~80t)

ZTC Series Truck Crane (25t~80t) VII

1.1 Instructions to maintenance cycles

1.2 User's responsibilities

1.3 Obligations of marketing service networks

ZTC Series Truck Crane（25t~80t） 1-1

1-2 ZTC Series Truck Crane（25t~80t）

2.1 Routine inspection and maintenance

ZTC Series Truck Crane（25t~80t） 2-1

2-2 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-3

2-4 ZTC Series Truck Crane（25t~80t）

vibration. 3.2 for

Check it for leaks.

ZTC Series Truck Crane（25t~80t） 2-5

Check the pipelines for cracks and 3.2 for

2-6 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-7

2-8 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-9

2-10 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-11

2-12 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-13

functional work. maintenance

2-14 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-15

2-16 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-17

2-18 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-19

2-20 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-21

2-22 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-23

2-24 ZTC Series Truck Crane（25t~80t）

ZTC Series Truck Crane（25t~80t） 2-25