Quality Changes the World

Truck Crane
STC500S3

Safety, Operation and Maintenance Manual

 STC500S3

STC500S3 Truck Crane

Operation and Maintenance Manual

WARNING
Read and follow the safety precautions and instructions in this manual and on the
machine decals. Failure to do can cause serious injury, death or property damage.
Keep this manual with the machine for reading and future reference.
STC500S3

SANY Group
SANY Mobile Cranes Co.,Ltd.
Sany Industry Town,
Economic and Technological Development Zone,
Changsha, Hunan, China
410100

http://www.sanygroup.com

Tel: 0086-21-20271802

Fax: 0086-21-20271702

WARNING
© 2010 by Sany Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as
described herein. All information included within this publication was accurate
at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes no
liability. For more information, contact Sany Group.
 Table of Contents
STC500S3

Table of Contents

1 Introduction
1.1 Overview................................................................................................................... 1-3
1.2 Your Documentation Package................................................................................... 1-5
1.2.1 Recommendations on using the documentation.............................................. 1-5
1.2.2 Documentation storage.................................................................................... 1-5
1.2.3 Operation manual organization........................................................................ 1-6
1.3 Your Sany Machine.................................................................................................. 1-8
1.3.1 Breaking in a new machine.............................................................................. 1-8
1.3.2 Machine information......................................................................................... 1-8
1.3.3 Table for serial number and distributor info.................................................... 1-13
1.4 Contact Information................................................................................................. 1-13
1.5 Conversion Table..................................................................................................... 1-14

2 Safety
2.1 Special Notice........................................................................................................... 2-3
2.1.1 Safety Equipment............................................................................................. 2-7
2.1.2 Special Announcement . .................................................................................. 2-7
2.2 Basic Rules............................................................................................................... 2-8
2.2.1 Safety Precautions........................................................................................... 2-8
2.2.2 Road and Traffic Regulations ........................................................................ 2-10
2.2.3 Breaking-in New Vehicle Rule ....................................................................... 2-11
2.3 Precautions before Operation ................................................................................ 2-13
2.3.1 Requirements for Correct Crane Operation .................................................. 2-13
2.3.2 Requirements for Operators .......................................................................... 2-14
2.3.3 Requirements to the Signalman..................................................................... 2-18
2.3.4 Requirements for Owner or Relevant Authorized Personnel . ....................... 2-21
2.3.5 Requirement for Ambient Temperature and Altitude....................................... 2-23
2.3.6 Check before Operation................................................................................. 2-24
2.3.7 Using Plan...................................................................................................... 2-25
2.3.7.1 Working Site.......................................................................................... 2-26
2.3.7.2 Operation at Night................................................................................. 2-28
2.3.7.3 Security Checks..................................................................................... 2-28
2.3.8 Keep all Footings and Shoes Clean............................................................... 2-28

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2.3.9 Safely Climbing onto and Descending from the Machine............................... 2-29
2.3.10 Anticipate Accident Situation........................................................................ 2-29
2.4 Precautions for Operation....................................................................................... 2-30
2.4.1 Working Site Requirement.............................................................................. 2-30
2.4.2 Complete Machine Support............................................................................ 2-30
2.4.3 Rules for Operation........................................................................................ 2-34
2.4.3.1 Rules for Operation (General)............................................................... 2-36
2.4.3.2 Cautions for Working at Heights............................................................ 2-54
2.4.3.3 Be Careful when Working under the Crane........................................... 2-54
2.4.4 Other Precautions for Lift Work...................................................................... 2-55
2.4.4.1 Crane being Connected to Ground........................................................ 2-55
2.4.4.2 Load Connected to the Ground............................................................. 2-57
2.4.4.3 Load Welding Works.............................................................................. 2-57
2.4.4.4 Rules for Operation (Weather).............................................................. 2-58
2.4.4.5 Rules for Operation (Power Lines, Radio Waves)................................. 2-61
2.4.4.6 Rules for Special Operation................................................................... 2-64
2.4.5 Examples of Aftermath Caused by Misuse..................................................... 2-65
2.5 After Operation ....................................................................................................... 2-67
2.5.1 After Operation, Stow the Machine . .............................................................. 2-67
2.5.2 Cautions for Refilling the Fuel ....................................................................... 2-67
2.5.3 Cautions for Adjusting Tire Pressure ............................................................. 2-68
2.5.4 Have Authorized Personnel to Replace or Maintain the Tire.......................... 2-68
2.6 Rules for Transportation and Towing....................................................................... 2-69
2.7 Rules for Inspection and Maintenance.................................................................... 2-73
2.7.1 Do not Adjust or Disassemble the Hydraulic Equipment................................ 2-73
2.7.2 Do not Modify the Machine............................................................................. 2-73
2.7.3 When an Irregularity is Detected.................................................................... 2-73
2.7.4 Inspect and Maintain at Regular Intervals...................................................... 2-74
2.7.5 Become Familiar with Procedures for Inspection and Maintenance............... 2-74
2.7.6 Provide Effective Ventilation........................................................................... 2-75
2.7.7 Cautions for Washing the Machine................................................................. 2-75
2.7.8 Inspect and Maintain the Machine on Level Ground...................................... 2-76
2.7.9 Start Inspection or Maintenance after the Machine has Cooled down........... 2-76
2.7.10 Beware of High-pressure Oils ..................................................................... 2-77
2.7.11 Use Two People for Inspection and Maintenance with the Engine Running
................................................................................................................................ 2-77
2.7.12 Beware of Overhead Obstacles and Footing .............................................. 2-78
2.7.13 Do not Allow Tools and Parts to Drop........................................................... 2-78

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2.7.14 Beware of Oil Smears................................................................................... 2-78

2.7.15 Beware of Dust............................................................................................. 2-78
2.7.16 About Starting Engine with Booster Cables................................................. 2-79
2.7.17 Disconnect the Battery Cable before Inspecting and Maintaining the Electrical
System..................................................................................................................... 2-80
2.7.18 Careful Handling Wire Ropes....................................................................... 2-80
2.7.19 Use Genuine Parts only................................................................................ 2-80
2.7.20 Use Specified Oils........................................................................................ 2-81
2.7.21 Verification after Maintenance...................................................................... 2-81
2.8 Possible Hazards.................................................................................................... 2-82
2.8.1 Mechanical Hazards....................................................................................... 2-82
2.8.2 Burn................................................................................................................ 2-82
2.8.3 Safety in Utilizing Electric Energy................................................................... 2-83
2.8.3.1 After Electric Shock Treatment Measures to the Crane......................... 2-83
2.8.3.2 Precaution on Battery............................................................................ 2-84
2.8.4 Welding in the Right Way .............................................................................. 2-85
2.8.5 Fire................................................................................................................. 2-86
2.8.5.1 Prevent Fire........................................................................................... 2-86
2.8.5.2 Illumination............................................................................................ 2-87
2.8.5.3 Use of Fire Extinguisher........................................................................ 2-87
2.8.6 Waste Disposal............................................................................................... 2-88
2.9 Safety Devices........................................................................................................ 2-89
2.9.1 LMB................................................................................................................ 2-89
2.9.2 3-ring Protector............................................................................................... 2-90
2.9.3 System Master Switch.................................................................................... 2-90
2.9.4 Hydraulic Filter Warning Light ....................................................................... 2-90
2.10 Safety Symbols..................................................................................................... 2-91

3 System Functions
3.1 Terminology............................................................................................................... 3-3
3.2 General Description................................................................................................. 3-12
3.3 Boom System.......................................................................................................... 3-13
3.3.1 Telescoping Mechanism................................................................................. 3-14
3.3.2 Boom.............................................................................................................. 3-16
3.3.3 Jib................................................................................................................... 3-17
3.3.4 Boom Nose Pulley.......................................................................................... 3-18

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3.4 Turntable Assembly................................................................................................. 3-19

3.4.1 Hoisting System.............................................................................................. 3-20
3.4.2 Swing System................................................................................................. 3-21
3.4.3 Counterweight................................................................................................ 3-22
3.5 Outrigger System.................................................................................................... 3-23
3.5.1 Outrigger Control............................................................................................ 3-24
3.5.2 Outrigger Control Lever.................................................................................. 3-25
3.6 Superstructure Operator's Cab................................................................................ 3-28
3.6.1 Instruction on Control Panel........................................................................... 3-30
3.7 Hydraulic System.................................................................................................... 3-37
3.7.1 Hydraulic Pumping Plant................................................................................ 3-37
3.7.2 Hydraulic System on Chassis......................................................................... 3-38
3.7.3 Hydraulic System on Superstructure............................................................. 3-39
3.8 Electrical System..................................................................................................... 3-41
3.8.1 Electrical Equipments inside the Cab............................................................. 3-41
3.8.1.1 Inner Structure of Operator's Cab......................................................... 3-41
3.8.2 Safety Device................................................................................................. 3-42
3.8.2.1 Moment Limiter...................................................................................... 3-42
3.8.2.2 3-ring Protector...................................................................................... 3-48
3.8.2.3 Master Switch of the System................................................................. 3-49
3.8.2.4 Height Limiter........................................................................................ 3-49
3.8.2.5 Overload Warning and Limitation.......................................................... 3-50
3.8.2.6 Overwinding Warning and Limitation..................................................... 3-50
3.8.2.7 Overlowering Warning and Limitation.................................................... 3-50
3.8.2.8 "Zero Angle" Warning and Limitation..................................................... 3-51
3.8.2.9 "Max.Angle" Warning and Limitation..................................................... 3-51
3.8.2.10 Tri-color Warning Lamp....................................................................... 3-51
3.8.2.11 Limitation on Loaded Telescoping....................................................... 3-51
3.8.3 Equipments inside the Cab............................................................................. 3-52
3.8.4 Instrument Panel inside the Cab.................................................................... 3-53
3.8.4.1 Instruments............................................................................................ 3-53
3.8.4.2 Switch.................................................................................................... 3-55
3.8.4.3 Advance Warning Indicator Lamp.......................................................... 3-64
3.8.5 Warm Air Device and Air-conditioner System................................................. 3-71
3.8.5.1 Warm Air Device and Air-conditioner System on Chassis .................... 3-71
3.8.5.2 Warm Air Device and Air-conditioner System on Superstructure.......... 3-74
3.9 Chassis.................................................................................................................... 3-82
3.9.1 Power System................................................................................................ 3-83
3.9.1.1 Engine................................................................................................... 3-84

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3.9.1.2 Engine Suspension................................................................................ 3-85

3.9.1.3 Fuel Supply System............................................................................... 3-86
3.9.1.4 Air Intake System................................................................................... 3-87
3.9.1.5 Exhaust System..................................................................................... 3-88
3.9.1.6 Cooling System..................................................................................... 3-89
3.9.2 Transmission System..................................................................................... 3-90
3.9.2.1 Clutch & Operating Device.................................................................... 3-91
3.9.2.2 Transmission & Operating Device......................................................... 3-92
3.9.2.3 Power Takeoff Device............................................................................ 3-97
3.9.2.4 Drive Shaft............................................................................................. 3-98
3.9.3 Steering System............................................................................................. 3-99
3.9.3.1 Steering Drive Mechanism.................................................................. 3-100
3.9.3.2 Steering Pipeline................................................................................. 3-101
3.9.4 Traveling System.......................................................................................... 3-102
3.9.4.1 Suspension.......................................................................................... 3-103
3.9.4.2 Steering Axle....................................................................................... 3-104
3.9.4.3 Drive Axle............................................................................................ 3-105
3.9.5 Brake System............................................................................................... 3-106
3.9.6 Driver's Cab.................................................................................................. 3-108

4 Operation
4.1 Traveling Operation................................................................................................... 4-3
4.1.1 Before Traveling............................................................................................... 4-3
4.1.1.1 Preparation and Check before Dispatching a Machine........................... 4-3
4.1.1.2 Driver's Seat Adjustment......................................................................... 4-7
4.1.1.3 Check when Machine Starts.................................................................... 4-9
4.1.2 During Traveling............................................................................................. 4-10
4.1.2.1 Engine Start........................................................................................... 4-10
4.1.2.2 Start....................................................................................................... 4-13
4.1.2.3 Gearshift................................................................................................ 4-15
4.1.2.4 Steering Operation................................................................................ 4-17
4.1.2.5 Brake Operation.................................................................................... 4-18
4.1.2.6 Operation of Air Conditioner.................................................................. 4-22
4.1.3 After Traveling................................................................................................. 4-27
4.1.3.1 Engine Shutdown.................................................................................. 4-27
4.1.3.2 Closing and Locking the Door............................................................... 4-29
4.2 Operation before Lifting .......................................................................................... 4-30
4.2.1 Oil Level Check (Hydraulic Oil Tank).............................................................. 4-30

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4.2.2 Operation of Power Takeoff Device................................................................ 4-32

4.2.2.1 Precautions for the Use of Power Takeoff Device................................. 4-32
4.2.2.2 Activating Power Takeoff Device............................................................ 4-32
4.2.2.3 Deactivating Power Takeoff Device....................................................... 4-37
4.2.3 Operation of Outrigger.................................................................................... 4-40
4.2.3.1 Precautions for the Operation of Outrigger............................................ 4-40
4.2.3.2 Instruction on Outrigger Control Lever.................................................. 4-42
4.2.3.3 Operation Steps of Outrigger................................................................. 4-43
4.2.4 Locking up and Releasing the Locking Device on Turntable.......................... 4-57
4.2.5 Getting into Crane Operator’s Cab................................................................. 4-58
4.2.5.1 Opening and Closing the Door.............................................................. 4-58
4.2.5.2 Adjusting the Seat Position.................................................................... 4-61
4.2.5.3 Starting the Power................................................................................. 4-62
4.2.5.4 Throttle Operation.................................................................................. 4-63
4.2.6 Use of Performance Label.............................................................................. 4-64
4.2.6.1 Location of Lifting Height Curve/Rated Lifting Capacity Table............... 4-64
4.2.6.2 Use of Load Radius/Lifting Height Chart............................................... 4-65
4.2.6.3 Rated Lifting Capacity Table.................................................................. 4-67
4.2.6.4 Use of Rated Lifting Capacity Table and Lifting Height Curve............... 4-72
4.3 Lifting Operation...................................................................................................... 4-74
4.3.1 Removing the Main Hook Block..................................................................... 4-74
4.3.1.1 Precaution for the Use of Main Hook Block........................................... 4-74
4.3.1.2 Removing the Main Hook Block............................................................ 4-75
4.3.2 Operation of Hoisting Mechanism.................................................................. 4-78
4.3.2.1 Precautions for the Use of Hoisting Mechanism.................................... 4-78
4.3.2.2 Operation of Main Hoist......................................................................... 4-79
4.3.2.3 Auxiliary Hoist........................................................................................ 4-84
4.3.2.4 Winch Drum Monitor Mirror................................................................... 4-86
4.3.3 Operation of Boom......................................................................................... 4-87
4.3.3.1 Telescoping Operation of Boom............................................................ 4-87
4.3.3.2 Luffing Operation of Boom..................................................................... 4-90
4.3.3.3 Swing Operation of Boom...................................................................... 4-92
4.3.4 Removing and Stowing the Single Top........................................................... 4-95
4.3.4.1 Precaution for the Use of Single Top..................................................... 4-95
4.3.4.2 Removing the Single Top....................................................................... 4-96
4.3.4.3 Stowing the Single Top.......................................................................... 4-99
4.3.5 Operation of Jib............................................................................................ 4-100
4.3.5.1 Precaution for Spreading the Jib......................................................... 4-100
4.3.5.2 Spreading the Jib................................................................................. 4-101

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4.3.5.3 Spreading the Folding Jib.................................................................... 4-104

4.3.5.4 Adjusting the Jib Offset Angle.............................................................. 4-107
4.3.5.5 Stowing the Folding Jib....................................................................... 4-109
4.3.5.6 Stowing the Jib.....................................................................................4-111
4.3.5.7 The Mounting and Stowing Order of Jib.............................................. 4-114
4.3.6 Removing and Stowing Auxiliary Hook Block............................................... 4-115
4.3.6.1 Precautions for the Use of Auxiliary Hook Block................................. 4-115
4.3.6.2 Removing Auxiliary Hook Block........................................................... 4-115
4.3.6.3 Stowing Auxiliary Hook Block.............................................................. 4-117
4.3.7 Reeving Wire Rope...................................................................................... 4-119
4.3.7.1 Standard Number of Parts of Line....................................................... 4-119
4.3.7.2 Reeving Steps..................................................................................... 4-120
4.3.7.3 Precaution for Reeving Wire Rope...................................................... 4-123
4.4 After Operation...................................................................................................... 4-125
4.4.1 Retracting Hook Block and Boom................................................................. 4-125
4.4.2 Locking Turntable......................................................................................... 4-131
4.4.3 Shutting down the Equipments in Operator's Cab........................................ 4-132
4.4.4 Retracting Outriggers................................................................................... 4-134
4.4.5 Shutting down the Power Takeoff Device and Engine.................................. 4-134
4.5 Operation of Accessories...................................................................................... 4-135
4.5.1 Operation of Air Conditioner inside the Cab................................................. 4-135
4.5.1.1 Operation of Air Conditioner................................................................ 4-135
4.5.1.2 Operation of Warm Air Heating System............................................... 4-141
4.6 Operation in Cold Weather.................................................................................... 4-142
4.6.1 Operation Instruction.................................................................................... 4-142
4.6.2 Fuel and Lubricant........................................................................................ 4-142
4.6.3 Coolant of Cooling System........................................................................... 4-142
4.6.4 Battery.......................................................................................................... 4-143
4.6.5 After Each Workday...................................................................................... 4-143
4.6.6 After Cold Season......................................................................................... 4-143
4.7 Long-term Storage................................................................................................ 4-144
4.7.1 Before Storage............................................................................................. 4-144
4.7.2 During Storage............................................................................................. 4-145
4.7.3 After Storage................................................................................................. 4-145
4.8 Transporting the Machine...................................................................................... 4-146
4.8.1 Lifting the Machine....................................................................................... 4-146
4.8.2 Packing List.................................................................................................. 4-149
4.8.3 Spare Parts List............................................................................................ 4-150
4.8.4 Attached Tools List........................................................................................ 4-151

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Table of Contents
STC500S3

5 Maintenance
5.1 Maintenance of Chassis............................................................................................ 5-3
5.1.1 Basic Maintenance........................................................................................... 5-3
5.1.1.1 Chassis Inspection.................................................................................. 5-3
5.1.1.2 Breaking-in of New Truck........................................................................ 5-5
5.1.1.3 Chassis Maintenance.............................................................................. 5-6
5.1.2 Daily Inspection and Maintenance.................................................................... 5-8
5.1.2.1 Hydraulic Oil............................................................................................ 5-9
5.1.2.2 Engine Oil.............................................................................................. 5-14
5.1.2.3 Gearbox Oil........................................................................................... 5-20
5.1.2.4 Differential Oil........................................................................................ 5-21
5.1.2.5 Cooling Fluid.......................................................................................... 5-22
5.1.2.6 Fuel........................................................................................................ 5-25
5.1.2.7 Clutch Brake Fluid................................................................................. 5-28
5.1.2.8 Drain of Water Accumulated in Air Reservoir......................................... 5-29
5.1.2.9 Inspection of Lighting System................................................................ 5-29
5.1.2.10 Air Pressure and Inflation.................................................................... 5-30
5.1.2.11 Steering Mechanism............................................................................ 5-30
5.1.2.12 Working Condition of Exhaust Brake................................................... 5-32
5.1.2.13 Foot Brake Inspection.......................................................................... 5-33
5.1.2.14 Inspection of Clutch............................................................................. 5-34
5.1.2.15 Battery................................................................................................. 5-35
5.1.2.16 Daily Inspection of Buffer Block........................................................... 5-40
5.1.2.17 Tire Pressure....................................................................................... 5-41
5.1.2 Regular Maintenance..................................................................................... 5-42
5.1.2.1 Maintenance Cycle................................................................................ 5-42
5.1.2.2 Different Classes for Maintenance Items . ............................................ 5-43
5.1.2.3 First Class Maintenance ....................................................................... 5-50
5.1.2.4 Second Class Maintenance . ................................................................ 5-51
5.1.2.5 Third Class Maintenance . .................................................................... 5-53
5.1.3 Regular Maintenance for Power System........................................................ 5-54
5.1.3.1 Maintenance Norms of Engine.............................................................. 5-54
5.1.3.2 Fuel Filter and Oil-water Separator....................................................... 5-56
5.1.3.3 Engine Oil Filter..................................................................................... 5-59
5.1.3.4 Air Filter................................................................................................. 5-60
5.1.4 Regular Maintenance for Traveling System.................................................... 5-62
5.1.4.1 Axle........................................................................................................ 5-62
5.1.4.2 Wheel & Tire.......................................................................................... 5-65

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5.1.4.3 Wheel Replacement.............................................................................. 5-69

5.1.4.4 Steel Plate Spring.................................................................................. 5-72
5.1.4.5 Adjustment of Toe-in.............................................................................. 5-73
5.1.5 Maintenance for Steering System.................................................................. 5-75
5.1.5.1 Steering Gear........................................................................................ 5-75
5.1.5.2 Steering Oil Pump................................................................................. 5-80
5.1.6 Maintenance for Transmission System........................................................... 5-83
5.1.6.1 Clutch.................................................................................................... 5-83
5.1.6.2 Gearbox................................................................................................. 5-85
5.1.6.3 Power Takeoff Device............................................................................ 5-87
5.1.6.4 Drive Shaft............................................................................................. 5-88
5.1.7 Regular Maintenance for Brake System......................................................... 5-90
5.1.7.1 Brake..................................................................................................... 5-90
5.1.7.2 Air Drier.................................................................................................. 5-92
5.1.8 Maintenance for Air Conditioner..................................................................... 5-93
5.1.9 Lubricating of Chassis.................................................................................... 5-95
5.1.9.1 Precaution for Lubricating of Chassis................................................... 5-95`
5.1.9.2 Lubricating Location and Method of Chassis......................................... 5-96
5.2 Maintenance for Superstructure............................................................................ 5-101
5.2.1 Regular Maintenance................................................................................... 5-101
5.2.1.1 Daily Maintenance............................................................................... 5-101
5.2.1.2 Weekly Maintenance........................................................................... 5-102
5.2.1.3 Monthly Maintenance.......................................................................... 5-103
5.2.1.4 Yearly Maintenance............................................................................. 5-104
5.2.2 Routine Check for Key Parts........................................................................ 5-106
5.2.3 Adjustment, Cleaning and Replacement of Parts......................................... 5-108
5.2.3.1 Replacement of Wire Rope................................................................. 5-108
5.2.3.2 Hook Block Replacement.................................................................... 5-115
5.2.3.3 Adjustment for Telescoping Rope of Boom.......................................... 5-116
5.2.3.4 Adjustment for 3-ring Protector............................................................ 5-118
5.2.4 Regular Maintenance for Winch Reducer and Swing Mechanism............... 5-120
5.2.5 Regular Maintenance for Swing Support...................................................... 5-122
5.2.6 Regular Maintenance for Boom.................................................................... 5-123
5.2.7 Regular Maintenance for Key Kinematic Pair............................................... 5-124
5.2.8 Lubrication of Superstructure....................................................................... 5-125
5.2.8.1 Lubricating Location............................................................................ 5-125
5.2.8.2 Lubricating Method of Superstructure................................................. 5-127
5.3 Recommended Oil and Grease............................................................................. 5-128

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6 Troubleshooting
6.1 Common Faults and Troubleshooting of Superstructure........................................... 6-3
6.1.1 Mechanical System.......................................................................................... 6-3
6.1.2 Hydraulic System.............................................................................................. 6-4
6.1.3 Electrical System.............................................................................................. 6-9
6.2 Common Faults and Troubleshooting of Chassis.................................................... 6-11
6.2.1 Mechanical System........................................................................................ 6-11
6.2.1.1 Engine................................................................................................... 6-11
6.2.1.2 Traveling System................................................................................... 6-11
6.2.1.3 Steering System.................................................................................... 6-13
6.2.1.4 Transmission System............................................................................ 6-16
6.2.1.5 Brake System........................................................................................ 6-24
6.2.2 Hydraulic System............................................................................................ 6-27
6.2.3 Electrical System............................................................................................ 6-28
6.2.3.1 Battery................................................................................................... 6-28
6.2.3.2 Electrical Instrument and Sensor on Chassis........................................ 6-33
6.2.3.3 Auxiliary Electrical Parts of Chassis Electrical System.......................... 6-43
6.2.3.4 Chassis Electrical Circuit....................................................................... 6-57
6.3 Schematic Diagrams of Complete Vehicle.............................................................. 6-60
6.3.1 Schematic Diagram of Brake System............................................................. 6-60
6.3.2 Schematic Diagram of Hydraulic System....................................................... 6-61
6.3.3 Schematic Diagram of Electrical System........................................................ 6-62
6.3.3.1 Schematic Diagram of Electrical System on Superstructure................. 6-62
6.3.3.2 Schematic Diagram of Electrical System on Chassis............................ 6-63

7 Specifications
7.1 Basic Specifications.................................................................................................. 7-3
7.1.1 Outline and Dimensions of Complete Vehicle.................................................. 7-3
7.1.2 Outline and Dimensions of Chassis.................................................................. 7-4
7.2 Technical Parameters of Complete Vehicle............................................................... 7-5
7.3 Performance Parameters of Main Parts.................................................................... 7-7
7.3.1 Performance Parameters of Main Parts on Superstructure.............................. 7-7
7.3.2 Performance Parameters of Main Parts on Chassis........................................ 7-9

X
 Introduction
STC500S3

Introduction

1 Introduction
1.1 Overview...................................................................................................................1-3
1.2 Your Documentation Package...................................................................................1-5
1.3 Your Sany Machine...................................................................................................1-8
1.4 Contact Information.................................................................................................1-13
1.5 Conversion Table.....................................................................................................1-14

1-1
Introduction
STC500S3

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1-2
 Introduction
STC500S3

1 INTRODUCTION

1.1 Overview

● SANY built truck cranes offer high-quality

performance and five star-grade after-sales
service.

● SANY built truck cranes are widely used

throughout the woldwide industry for various
applications.

● SANY is a leading manufacturer of

construction equipment worldwide.

This operator’s manual provides Introduction,

S a f e t y, S y s t e m F u n c t i o n s , O p e r a t i o n ,
Maintenance, Troubleshooting and
Specifications. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.

Items addressed in this manual are designed

to help you:
Fig.1-1.1
• Understand the structure and performance
of the truck crane.

• Reduce improper operation and point out

possible hazardous situations.

• Increase equipment efficiency during

operation.

• Prolong the service life of equipment.

• Reduce maintenance costs.

1-3
Introduction
STC500S3

Always keep this manual nearby and have

all personnel involved with any job-related
procedures read it periodically.

If you sell the machine, be sure to give this

manual to the next owner.

Continuing improvements in the design of this

machine can lead to changes in detail which
may not be covered in this manual. Always
consult your SANY distributor for the latest
available information on this machine or if
there are any questions regarding information
in this manual.

1-4
 Introduction
STC500S3

1.2 Your Documentation Package

The documentation for this machine includes

the following items:

• Safety, Operation & Maintenance Manual

(SOMM) —This manual is in the operator cab
seat pocket.

• Parts Book —This publication consists of

parts lists and matching drawings for ordering
spare parts as-needed. If it was not already
shipped with your machine, the parts book for
this machine is available directly from SANY.

1.2.1 Recommendations on using the

documentation

• This documentation applies only to this

machine and should not be used with any other
machines.

• To ensure that the documentation is always

complete and up to date:

• Keep all pages inside its binder (if shipped

loose leaf).

• Insert SANY replacement pages immediately

into the appropriate book and destroy old
versions of those pages.

1.2.2 Documentation storage

Always keep the operator manual and load

charts with the machine in the operator cab.

The parts book is best left shelved indoors and

should always be available to maintenance and
service personnel as needed.

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Introduction
STC500S3

1.2.3 Operation manual organization

The operator’s manual is designed for the use

and maintenance of this machine. Each section
of this manual provides information one must
be familiar with before operating this machine.
Keep this manual with the machine for any one
to reference at all times. Replace it immediately
if it is damaged or lost. Due to improvement
and updating of products, some information
may differ from your machine. If you have any
questions about the machine, contact a SANY
distributor before operating or repairing the
machine.

1. Introduction
This section provides an overview of what is
covered in the rest of this manual, including
machine labeling information and SANY
contact information.

2. Safety
This section covers basic safety information
relating to this equipment. Make sure you fully
understand all the precautions described in this
manual and the safety labels on the machine
before operating or maintaining this machine.
Failure to do so may result in serious injury
or death.

3. System functions
This section includes descriptions of systems
of control, indicating and operation. Study
and become familiar with each system before
performing any operation and maintenance on
the machine.

1-6
 Introduction
STC500S3

4. Operation
This section provides some basic operating
procedures for this truck crane. Study and
become familiar with all operating procedures
before performing any job functions with the
machine.

5. Maintenance
This section provides all general maintenance
and repair procedures. Detailed rebuild/
replacement/repair information is covered in
a separate shop manual. Study and become
familiar with all repair and maintenance
procedures before performing any repair or
maintenance operations.

6. Troubleshooting
This section provides some common faults
and faults diagnosis procedures on operation
system of such crane. Besides, troubleshooting
for mechanical, hydraulic and electrical systems
is also included.

7. Specifications
This section includes basic information of such
crane. Continuing improvements in the design
of this machine can lead to changes in part of
this information.

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Introduction
STC500S3

1.3 Your Sany Machine

1.3.1 Breaking in a new machine

Your machine has been thoroughly adjusted

and tested before shipment. However, initial
operation of the machine under severe
conditions can adversely affect the performance
of the machine and shorten the machine life.
Therefore, SANY recommends that you allow a
break-in period of 100 operating hours before
full scale operation.

During the break-in period:

• Let the machine warm up prior to any

operation.

• Avoid operating with severe loads and at high

speeds.

• Avoid sudden starts, fast movements and

stops.

• Always let the machine cool down at the end

of use before shutting down.

1.3.2 Machine information

The serial numbers and model numbers on

the components are the only numbers that
your SANY distributor will need when ordering
replacement parts or for requiring assistance.
Record this information in this manual for future
reference. Below are the locations of the data
plates.

1-8
 Introduction
STC500S3

1. Product identification plate

Product data plate
1) Product data plate

It is stamped on the left side of the operator’s

cab. See Fig.1-3.1.

Refer to Fig.1-3.2 for detailed information on

product data plate.

Fig.1-3.1 Location of product data plate

Fig.1-3.2 Product data plate

1-9
Introduction
STC500S3

2) Chassis data plate

Chassis Identification Number (VIN) is stamped

on the right side of data plate and frame (the
front of axle 1). See Fig.1-3.3 for position of
Chassis Identification Number on the frame.
Refer to Fig.1-3.4 for detailed information on
chassis data plate.
Right side of frame Chassis data plate

Fig.1-3.3 Location of chassis data plate

Fig.1-3.4 Chassis data plate

1-10
 Introduction
STC500S3

2. Engine identification plate

It is stamped on engine valve cover. See Fig.1-

3.5.

Model:

Power (kw):

Number:

Fig.1-3.5 Location of engine identification plate

3. Swing motor data plate

It is stamped on the top of swing motor. See

Fig.1-3.6.

Model:

ID Number:

Fig.1-3.6 Location of swing motor data plate

1-11
Introduction
STC500S3

4. Winch motor data plates

Each winch (W1 and W2) has its own data

plate, both of them are stamped on the top of
winch motor. See Fig.1-3.7.

Model:

ID Number: W1

ID Number: W2

Fig.1-3.7 Location of winch motor data plate

5. Hydraulic pump data plate

It is stamped on the side of pump. See Fig.1-

3.8.

Model:

ID Number:

Fig.1-3.8 Location of hydraulic pump data plate

1-12
 Introduction
STC500S3

1.3.3 Table for serial number and

distributor info

This location is for you to record information relating to your machine. It is advised that you keep
this manual with your machine at all times for reference.
Machine Serial No.

Engine Serial No.

Distributor Name:
Address:

Phone Numbers:

1.4 Contact Information

Thank you for purchasing a SANY machine. In

the event that you should need to contact us for
any reason, you can reach us as follows:

Our address:
S a n y I n d u s t r y To w n , E c o n o m i c a n d
Technological Development Zone, Changsha,
Hunan, China 410100
TEL: 0086-21-20271802
FAX: 0086-21-20271702
E-mail: sany@sany.com.cn
Service e-mail: sanyservice@sany.com.cn
Service Hotline: 0086-21-20271861

1-13
Introduction
STC500S3

1.5 Conversion Table

Length

millimeter, mm centimeter, cm meter, m inch, in, ” foot, ft, ’

1 1x10-1 1x10-3 3.93701x10-2 3.28084x10-3
1x10 1 1x10-2 3.93701x10-1 3.28084x10-2
1x103 1x102 1 3.9370x10 3.28084
-2
2.54x10 2.54 2.54x10 1 8.33333x10-2
3.048x102 3.048x10 3.048x10-1 1.2x10 1

mile, mi kilomile, km
1 1.60934
-1
6.21373x10 1

Area
square millimeter, square centimeter,
square meter, m2 square inch, in2 square foot, ft2
mm2 cm2
1 1x10-2 1x10-3 1.55x10-3 1.07639x10-5
1x102 1 1x10-2 1.55x10-1 1.07639x10-3
1x106 1x104 1 1.55x103 1.07639x10
2 -4
6.4516x10 6.4516 6.4516x10 1 6.94444x10-2
9.2903x104 9.2903x102 9.2903x10-2 1.44x102 1

Volume

cubic centimeter, cm3, cc cubic meter, m3 cubic inch, in3 cubic foot, ft3
1 1x10-6 6.10237x10-2 3.53147x10-5
1x106 1 6.10237x104 3.53147x10
-5
1.63871x10 1.63871x10 1 5.78704x104
2.83168x104 2.83168x10-2 1.728x103 1

Mass

gram, g kilogram, kg ounce, oz pound, lb metric ton, t short ton, s.t

1 1x10-3 3.5274x10-2 2.20462x10-3 1x10-6 1.10231x10-6
1x103 1 3.5274x10 2.20462 1x10-3 1.10231x10-3
2.83495x10 2.83495x10-2 1 6.25x10-2 2.83495x10-5 3.12494x10-5
4.53592x102 4.53592x10-1 1.6x10 1 4.53592x10-4 5x10-4
1x106 1x103 3.5274x104 2.20462x103 1 1.10231
5 2 4 3 -1
9.07185x10 9.07185x10 3.2x10 2x10 9.07185x10 1

1-14
 Introduction
STC500S3

Pressure

Pa KPa MPa Kgf/cm2 Lbf/ in2, psi

1 1x10-3 1x10-6 1.01972x10-5 1.45038x10-4
1x103 1 1x10-3 1.01972x10-2 1.45038x10-1
1x106 1x103 1 1.01972x10 1.45038x102
9.80665x104 9.80665x10 9.80665x10-2 1 1.42233x10
3 -3 -2
6.89476x10 6.89476 6.89476x10 7.03072x10 1

bar MPa Kgf/cm2

1 1x10-1 1.01972
1x10 1 1.01972x10
-1 -2
9.80665x10 9.80665x10 1

Torque

N-cm N-m Kgf-cm Kgf-m foot-pound, ft-lbf inch-pound, in-lbf

-2 -1 -3 -3
1 1x10 1.01972x10 1.01972x10 7.37562x10 8.85074x10-2
1x102 1 1.01972x10 1.01972x10-1 7.37562x10-1 8.85074
-2 -2 -2
9.80665 9.80665x10 1 1x10 7.23301x10 8.67961x10-1
9.80665x102 9.80665 1x102 1 7.23301 8.67961x10
2 -1
1.35582x10 1.35582 1.38255x10 1.38255x10 1 1.2x10
1.12985x10 1.12985x10-1 1.152513 1.15213x10-2 8.33333x10-2 1

N-m Kgf-m ft-lbf

1 1.01972x10-1 7.37562x10-1
9.80665 1 7.23301
-1
1.35582 1.38255x10 1

Centigrade-Fahrenheit

℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉ ℃
-90 -67.78 -40 -40 10 -12.22 60 15.56 110 43.33 160 71.11
-80 -67.22 -30 -34.44 20 -6.67 70 21.11 120 48.89 170 76.67
-70 -56.67 -20 -28.89 30 -1.11 80 26.67 130 54.44 180 82.22
-60 -51.11 -10 -23.33 40 -4.44 90 32.22 140 60 190 87.78
-50 -45.56 -0 -17.78 50 -10 100 37.78 150 65.56 200 93.33
Conversion equation: t℃ =5(T ℉ -32)/9, T ℉ =(9xt℃ +160)/5

1-15
Introduction
STC500S3

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STC500S3

Safety

2 Safety
2.1 Special Notice...........................................................................................................2-3
2.2 Basic Rules...............................................................................................................2-8
2.3 Precautions before Operation ................................................................................2-13
2.4 Precautions for Operation.......................................................................................2-30
2.5 After Operation .......................................................................................................2-67
2.6 Rules for Transportation and Towing.......................................................................2-69
2.7 Rules for Inspection and Maintenance....................................................................2-73
2.8 Possible Hazards....................................................................................................2-82
2.9 Safety Devices........................................................................................................2-89
2.10 Safety Symbols.....................................................................................................2-91

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Safety
STC500S3

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 Safety
STC500S3

2 SAFETY

2.1 Special Notice

Only the specially trained personnel can

operate the crane. And the manufacturer will
not be responsible for accidents caused by
untrained personnel.

Various safety equipment must be checked on

time to make sure that they can work properly.
Once the safety equipment works abnormally,
timely feedback should be given to the after-
sale service workers. The machine should
be stopped working in case of some serious
hidden trouble.

Fatal accidents can occur if the crane is not

operated properly.

Wrong crane operation would lead to fatal or

serious injury.

The crane must be operated by authorized

and professional trained personnel.

All the technical safety procedures and

the operation manuals are for the crane’s
designative purposes.

2-3
Safety
STC500S3

Designative purposes:

T h e c r a n e ’s d e s i g n a t i v e p u r p o s e s a r e
only limited to the vertical lifting and free
independent load with known barycenter.

Only a hook assembly accepted by SANY can

be tied to the hoisting wire rope, and the crane
must be operated within its capacity.

No matter the crane is with a load or not,

the machine can only be operated by the
corresponding navigation chart and operation
lift chart at hand. The crane must be operated
within its capacity under safety conditions
given in the operation and maintenance
manual.

Any other purposes and usages out of range

do not belong to the designative purposes.

Some designated functions require to be done

according to safety procedure, conditions,
preconditions, crane equipments and
operation procedures in the crane documents,
such as, operation and maitenance manual,
lift chart, and operation plan.

The manufacturer will not take any

responsibility if the damage or defects are
caused by non-destination or misuse. The
relevant risks will be taken on by the user
themselves.

2-4
 Safety
STC500S3

Non-designative purposes:

• Do not operate beyond crane configuration

lift chart.
• Do not operate beyond allowed radius and
swing range in the lift chart.
• The chosen load value does not match with
the actual crane configuration.
• LMB code is unconformable with the actual
crane configuration.
• Operate when LMB or hoisting limit switch
are disconnected.
• Increase the hoisting radius after LMB is
disconnected, such as dragging a load on the
cross.
• Use outrigger pressure shown as anti-
rollover safety function.
• Use unapproved equipments or accessories
for the crane.
• Use the crane in sports fields or recreation
areas especially jumping places.
• Travel on the road when conditions are not
allowed, such as axle load and size.
• Equipment is positioned at a place which
does not allow the crane to travel.
• Use level device, active outrigger, or support
cylinder to push, tow or lift a load.
• Push, pull or hoist a load through driving
swing mechanism, boom hoisting mechanism
or extending telescoping mechanism.
• Loosen the fastened up pieces by the crane.
• Do material handling works by the crane for
a long-lasting time.
• Release the crane suddenly (seizing or
tipping operation)
• Use the crane when the load is changed,
such as, lifting the container which is hanged
on the hook.

2-5
Safety
STC500S3

The crane can not be used in the following

cases:

• Load application through blowtorch incision,

unknown barycenter and fastened-up load
loose.
• Let personnel outside the cab follow the
crane by driving a car.
• Carry persons in the cab when traveling.
• Carry persons in/on crane equipments and
load (standing on the load).
• Carrypersons in/on containers(cherry picker)
without written permissions of relevant safety
board
• Carry a load on chassis.
• Operate through double hooks without
auxiliary equipments.
• Loading operation of the lengthen ed
materials.

All personnel involved in the machine usage,

operation, installation and maintenance must
read and work on it according to this operation
and maintenance manual.

2-6
 Safety
STC500S3

2.1.1 Safety equipment

Pay special attention to the safety equipment

inside and check their functions on time. Do
not operate the crane if the safety equipment
can not work or work unusually.

WARNING
Accessories and spare parts
Not using original accessories when
operating, the crane could result in
accidents and lead to death.

Crane parts will be destroyed.

• Only original accessories can be used to
operate the crane.
• Accessories not belonging to crane are
forbidden to be used.

Once the original accessories are modified,

such as disassemble parts, non-original
a c c e s s o r y, c r a n e l i c e n s e a n d f a c t o r y
guarantee will be invalid.
• Do not modify original parts.
• Do not disassemble original parts.
• Use SANY original accessories only.

2.1.2 Special announcement

Hunan SANY will not be responsible for the

injuries caused by neglect or operations that
do not meet relevant requirements.

The relief announcement also applies to the

injury caused by users themselves, such as
modifying the crane freely.

Please consult Hunan SANY when are to

operate in line with the safety operation
procedures.

2-7
Safety
STC500S3

2.2 Basic Rules

2.2.1 Safety precautions

Safety operation and maintenance are very

important to enable the crane to lift the goods
to a very high position. Anyone who will be
involved in the crane operation, operators,
chief of section, dispatchers etc. must
operate the machine according to the safety
procedures. If not, it will lead to injury or death,
and great loss to the crane and fortune.

The manual supplies much safety information

to remind the workers of dangerous operation
modes and maintenance procedures. Each
piece of safety information includes one safety
precaution sign and a prompt word to show
the serious degree.

The safety information given in the manual

is only the safety operation guidance for the
qualified operator. It is impossible for SANY to
foresee all possible dangers, so the operators
and the owner themselves will be responsible
for safety problems.

Some districts and local governments may

have more serious regulations for crane
operation. If these regulations conflict with
that of this manual, the stricter ones should be
followed.

2-8
 Safety
STC500S3

In this manual and the messages on machine,

the following signs are used to indicate the
degree of potential hazard.

Indicates an imminent
DANGER
hazard which, if not
avoided, will result in
serious injury or death.

WARNING Indicates a potentially

hazardous situation which,
if not avoided, could result
in injury or possibly death.

Indicates a possible
CAUTION
potential hazardous
situation which, if not
avoided, could result in
minor or major injury.

Indicates a situation which

NOTICE
can cause damage to
the machine, personal
property and/or the
environment, or cause
the equipment to operate
improperly.

This hazard alert symbol

appears with most hazard
alerts. It means attention,
become alert, your safety
is involved! Please read
and abide by the message
that follows the hazard
alert symbol.

2-9
Safety
STC500S3

2.2.2 Road and traffic regulations

SANY crane is designed and made according

to China road traffic safety regulations, also
obtains the performance and form license
awarded by relevant departments. Truck crane
traveling should be in accordance with national
relevant road traffic laws.

According to the requirements of the road

traffic law, the maximum single axle load is not
allowed to exceed 12 tons. If a single axle load
exceeds 12 tons, the aftermath will be taken
on by the users.

NOTICE

The operator’s cab is not allowed to carry

personnel when traveling.

WARNING

The operator’s view is not allowed to be

obstructed by the hook pulley when the
crane is traveling on a road. Otherwise,
serious traffic accident may occur.

2-10
 Safety
STC500S3

2.2.3 Breaking-in new vehicle rule

NOTICE

New truck crane has not been tested by

breaking–in operation.
The lifting capacity during breaking-
in period can not exceed 75% of the
maximum load.

Breaking-in is a very important stage to

guarantee that a vehicle can be used for a
long time. This stage will make each moving
part lap completely to prolong the service
life of the crane chassis, therefore, breaking-
in works must be done carefully. Make sure
that the vehicle is in a normal working status
before breaking-in.

2-11
Safety
STC500S3

Breaking-in precautions:
• Breaking-in trip for the new vehicle is
2000km.
• With a cold motor start, the engine speed
can only be increases when it reaches the
normal operating temperature.
• The vehicle should run on smooth roads
during the process of breaking-in.
• Sudden acceleration, braking must be
avoided. Smooth gear selection and clutch
operation must be maintained.
• It is a must to select a proper gear before
climbing up to prevent the motor running at an
idle speed.
• Check the engine oil pressure, the
temperature of coolant, gear box, rear
axle, wheel hubs, and brake drums. If the
temperature is too high, take immediate
corrective action.
• Torque the wheel nuts after the first 50km
traveling and after a wheel is changed.
• Check all bolts and nuts, especially the
cylinder cover bolts. Tighten the cylinder cover
nuts at the thermal condition after the vehicle
has traveled 300km.
• Each gear speed must be limited in the
2000km of breaking-in.
1st:5km/h; 2nd:5km/h; 3rd:10km/h;
4th:15km/h; 5th:25km/h; 6th:35km/h;
7th:50km/h; 8th:60km/h
• All-around maintenance must be adopted
for the vehicle after breaking-in. Go to the
designated maintenance stations of our
company to do the maintenance.

2-12
 Safety
STC500S3

2.3 Precautions before Operation

2.3.1 Requirements for correct crane

operation

• Proper crane operation is the basic

requirement for safety operation.
• The crane should be used under “Crane
operation conditions”.
• Abide by all documents contained in the
safety regulations.
• Always be aware of potential danger.
• Keep all safety equipment inspected,
maintained and ensure them in good working
status.
• Have qualified and authorized personnel do
all necessary maintenance, inspection and
repairs.

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Safety
STC500S3

2.3.2 Requirements for operators

1. The crane should only be operated by the

following personnel:
• Qualified crane operators who have passed
exams. The certification is needed.
• Trained personnel, such as apprentices,
who have learned for more than half a year
supervised by qualified personnel directly.
• Maintenance and testing personnel whose
duties are involved in crane operation.
• Labor safety inspector appointed by the
supervisor.
• Any other persons are forbidden to enter
the cab.

2. Crane operators should meet the following

requirements:
• Healthy;
• Eyesight (including corrected vision) is up to
or over 0.7, no color blindness.
• Hearing ability should meet the requirements
of working condition.

3. The following persons should not operate

the crane. See Fig.2-3.1
• Sot or drug addicts.
• Persons who take prescription medicine that
inhibit reaction time. No Alcohol No Drug No Medicine

Fig.2-3.1

2-14
 Safety
STC500S3

4. Crane operators must be familiar with the

following knowledge:
• Read the operation and maintenance
manual thoroughly to know the structure and
technical ability of each part before operation.
• Crane operation regulations and relevant
rules.
• Safety operation requirements.
• The performance of safety devices.
• Basic knowledge of the engine, electric and
hydraulic systems.
• Commanding signals.

5. Duties and Precautions for operators:

• Crane operators must check the crane
status and the emergency cut-off equipments
and whether there is any evident damage
before working.
• Operate the machine with all heart and soul.
• Stop the operation once there is any risks of
danger.
• Control, operate and adjust the crane to
make sure there is no danger to the personnel
and property in the vicinity.
Notice: 65% accidents that occur during crane
operation are caused by wrong operation.
• Crane operators must guarantee:
1) Set all control gears to the neutral position
or no load position before supplying power to
driving parts.
2) Set the control gear to the neutral or control
position and turn off the power before leaving
the control platform.
3) Before demounting the control unit to do
wireless control, unauthorized operation
should not be done.

2-15
Safety
STC500S3

• Crane operators must pay attention to the

load all the time when traveling. Also, attention
must be paid to the load grabbing device, if it
would lead to danger when traveling without
a load. The crane can only be moved under
the assistance of the commanders if crane
operators can not observe them clearly.
• Safety symbols must be shown to crane
operators if necessary.
• Make sure that the operation in the wind will
not exceed the factory setting limit. Retract the
boom bracket once the wind speed is over the
crane limit or operation is finished.
• If the load is attached to the hook manually,
the crane operator can only move the load
after receiving clear signals from the personnel
attaching the load, commanders or other
personnel appointed by the contractor. The
responsible party should keep correspondence
with the crane operators on signal before
they communicate with each other by signals.
Do not move load until operation personnel
confirm that the load has been fixed to the
hook properly.
• After starting the LMB, crane operator must
not lift overload weight through dragging or
raising the boom.
• The operator must prepare necessary
protective equipment. Do not wear loose
clothes, scarf, open outer-coat or with shirt
sleeve released, to avoid being grabbed into
moving parts.

2-16
 Safety
STC500S3

Personnel protective equipments include the

following items (see the following figure):
• Protecting gloves
• Hard hat
• Safety glasses
• Safety shoes
• Caution clothing
See Fig.2-3.2

Fig.2-3.2

WARNING

• Never wear loose fitting clothes and

decorative ornaments, which can easily
catch on control lever or other protruding
parts.
• Long hair outside safety hat may be
caught by machine. In this case, long hair
should be made into a bun to avoid being
entangled byu machine.
• Always wear safety hat and safety shoes.
In operation or maintenance of machine, if
the job requests, wear safety glasses, face
shield, gloves, ear protection and seat
belts.
• Check all protective devices for proper
functioning prior to operation.
• Never listen to radio or wear music
earphones when operating.

2-17
Safety
STC500S3

2.3.3 Requirements to the signalman

Signalman needs to be employed if the

operator can not see the conditions of the
working equipments (and the dangerous area).
Signalman can also be used in a very noisy
situation where normal communication is not
possible.

Main duties of the Signalman:

Capable of communicating with the operator
efficiently.
Assistant the operator to work efficiently.
Familiar with all signals and be responsible
and reliable;
The signalman must stand at a safe place
where he can see the whole working sites
and he can also be seen clearly by all working
personnel.
Easily identified signals must be used for
operators;
Standard command signals must be used,
except when other modes are agreed to be
used, such as, intercom, flag, radio, etc..

WARNING

Accidents could be caused by

misunderstanding the hand signals.
Two parties should agree with each other
on hand signals, and the signal given
should be correct and clear.

2-18
 Safety
STC500S3

Normal hand signals: See Fig.2-3.3

Hook lifting. With forearm

Prepare. With arm vertical, fingers Use auxiliary hook. Tap elbow vertical, fingers stretch naturally
stretch naturally, palm forward and with one hand: then use regular higher than the shoulder and
stationary. signals. rotate around the wrist as axle.

Instruct landing direction. Stop. Arm extended, fingers Emergency stop. Both arms
Fingers extended to point out the outstretch, palm down, extended, fingers outstretch,
location of the load should be command to one side levelly. palms down, command to both
landed to. sides levelly at the same time.

Fig.2-3.3

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Safety
STC500S3
Special hand signals: See Fig.2-3.4
Lift boom. Arm extended,
fingers closed, thumb pointing
upward, the forearm swing
upward.
Lift boom lightly: Place one
forearm before one side of
the chest, fingers outstretch
straightly with palm down and
stationary. The other hand’s
thumb, pointing toward the
palm of the front hand, moves
up and down, with fingers
closed.
Swing. One arm stretches forward straightly, fingers stretch out
naturally. The other arm swings repeatedly and levelly.
Fig.2-3.4
2-20
Lower boom. Arm extended,
fingers closed, thumb pointing Work over. Fingers of both
downward, the forearm swing hands stretched out, cross the
downward. hands in front of forehead.
Lower boom lightly. Place
one forearm before one side
of the chest, fingers outstretch
straightly with palm up and
stationary. The other hand’s Grab. Both the forearms are
thumb, pointing toward the placed before each side of the
palm of the front hand, moves chest, palm to palm, swing
up and down with fingers from both sides to the middle.
closed.
 Safety
STC500S3

2.3.4 Requirements for owner or

relevant authorized personnel

• Operate and maintain the crane after reading

and understanding the safety instructions.
Enough training is also required.
• Make sure that the operator is qualified to
do the job and able to execute corresponding
duty.
• Check the safety awareness of relevant
personnel on time. Crane operation should be
stopped if there is any incident which will affect
safety.
• Besides the inspections specified by
the manufacturer, relevant checks of the
crane should be done according to national
regulations.
• Make sure to do maintenance and repairs to
the truck crane in time.
• Report every accident that has led to serious
injuries and great damages to the truck crane
to the manufacturer.
• The manufacturer’s serviceman is allowed
to check the truck crane without limitation
according to production and inspection duty
and requirement.
• Make good using plan for the truck crane
carefully.

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Safety
STC500S3

Dispatch a Signal Person:

Posting a signal person for all operations is a

necessity. Always follow instructions especially
when:
1. Working near power lines.
2. The load is not in the view of the operator.
3. Passing narrow roads or when the
operator’s view is obscured.

The signal person and the crane operator

should contact each other using mobile
transceiver phones.

Call Work Site Meetings with Relevant

Personnel

If work related personnel do not communicate

with each other enough, accidents can occur.
Before starting the job, arrange a coordinative
meeting with site supervisor, rigger, signal
person, etc. to reach agreement on the
following issue:
1. Mass of load, hoisting height (see rated
load chart), loading and unloading locations,
work area of the machine, craning procedures,
rigging methods, etc.
2. Conditions of ground where crane is set.
Ensure there are no city-water and gas piping
buried.
3. Preventing overturning by use of outriggers
and block plates.
4. Agreement on signal conventions between
rigger and signal person.
5. Setting off-limit areas and providing
barricade.
6. Work position of all concerned workers.
7. Emergency liaison plan, contact personnel
and safety / health organization.

2-22
 Safety
STC500S3

2.3.5 Requirement for ambient

temperature and altitude

This truck crane can operate under normal

ambient temperature. Commonly, it works
under an ambient temperature of -20°C~40°C
and an altitude less than 5000m. What should
be specially noted is that based on different
geographical situation, SANY provides truck
cranes that can work under low temperature,
normal temperature and high temperature.
The permitted minimum ambient temperature
for the truck crane that can work under low
temperature is -40°C, while the permitted
miximum temperature for the truck crane that
can work under high temperature is 60°C.

2-23
Safety
STC500S3

2.3.6 Check before operation

Inspection before operation

Ignoring routine inspections and maintenance

can shorten service life of the machine or even
lead to an accident.

Before operation and before taking over a

shift, carry out the preoperative inspection on
the chassis and the superstructure to ensure
that the crane is in normal state and free from
problems.

If any problem is found, report it to the

responsible person, remedy it before starting
operation.

Do Not Operate a Crane Being Inspected or

Serviced.

Never operate the crane while it is undergoing

inspection or maintenance work. Or it can
cause damage or an accident.

Post a “Do Not Operate” sign on the operator’s

cab door or some control lever. Do not try to
operate the crane until the sign is removed by
authorized personnel.

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 Safety
STC500S3

2.3.7 Using plan

The following conditions should be clear

before driving the crane to the working site:
• Type of operation;
• Operation site distance;
• Passing height on the way and road width;
• Electrical wire conditions over working site
(magnitude of voltage in detail see Table
2-3.1);
• Working limit from the surrounding buildings;
• Weight and dimensions of the load lifted;
• Lifting and descending height;
• Bearing capacity of the ground;

After gaining these detailed conditions, crane

operators can determine the installation of
necessary hoisting gears and master the
hoisting operation mode, such as lifting hook,
jib, support pat, and run road choice.

NOTICE

It will be difficult to finish the job correctly

if the operator does not master the
necessary hoisting mode. Therefore,
operators must prepare before working to
avoid accidents.

Table 2-3.1 Minimum distance between lifting boom, load etc. and living wire

Living wire pressure V(KV) <1 1~35 ≥60

The minimum distance(m) 1.5 3 0.01(V-50)+3

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Safety
STC500S3

2.3.7.1 Working site

1. Working ground solidness and bearing

capacity should be checked before working.
Each bearing position and pressure resistance
of the working ground should be examined
and checked if the supporting ground condition
is unclear. Steel boards and cross sleepers
should be used to expand the supporting area
to reduce the applied force to the ground if
the supporting ground pressure resistance is
not enough. Table 2-3.2 gives the pressure
resistance of all kinds of earth, only for your
reference.

WARNING

Operating on solid ground which can bear

all kinds of loads is the most important
requirement for a crane to operate safely.
Otherwise, the crane may tip over.

Table 2-3.2 Pressure resistance of all kinds of

earth

Unpressed debris 0 ～ 0.1

Dirt road, marsh ground, moorland 0
Flinty and grail ground 0.2
Mud ground 0
Soft ground 0.04
Natural Bonding clay soil
Hard ground 0.1
soil
Semisolid ground 0.2
Solid ground 0.4
Loose rock without efflorescence Pressed ground 1.5
in good condition Massive rock and grass ground 3.0

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 Safety
STC500S3

2. Keep Unauthorized Personnel Away from

the Work Area. See Fig.2-3.5
Unauthorized personnel or vehicles in the
work area can lead to collision accidents,
injury or even death.
Before operation, ensure that there are no
unauthorized personnel or obstacles within the
work area.
If the work area is located near heavy traffic, 禁止靠近！

arrange a control person to prevent vehicular

accidents.
Barricade the work area with appropriate ways
with either colored tape or rope. Fig.2-3.5

3. Always Know the Conditions of Work-site

Pay due attention to surrounding situations.
Before operation, inspect the work area,
check routs to the work area and remove any
obstacles and locations of other machines.
Note any changes in the surroundings or site
conditions as operation is in progress.

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Safety
STC500S3

2.3.7.2 Operation at night

See Fig.2-3.6
It is difficult to ensure sound footing, locate
n earby personnel and obstacles w h e n
operating in the dark. It will increase the
probability of an accident.

NOTICE
Fig.2-3.6
Turn on all work lamps when operating
at night. Remember to carry appropriate
portable lighting equipment to illuminate
the work areas additively.

2.3.7.3 Security checks

• The choice of the parking location can

guarantee the crane operation within the
smallest possible radius.
• Ground with sufficient bearing capacity.
• Keep enough distance with pits and slopes.
• Make sure there is no power cords within the
crane working area.
• No obstacles blocking necessary movements
of the crane.

2.3.8 Keep all footings and shoes clean

Water, oil or mud on soles of shoes, steps

or decks can lead to slip and fall mishaps or
cause accidental release of a control pedal.

NOTICE

Always remove water, oil, mud or snow

before operation and keep floor of
the operator ’s cab and shoes clean.
Never leave any parts or tools on the
passageway or the operator’s cab floor.

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 Safety
STC500S3

2.3.9 Safely climbing onto and

descending from the machine

Never jump onto or off the crane.

Never climb onto or descend from the crane

with objects in hand.

Only climb onto or descend from the crane

when it is completely at a standstill.

Do not use the steering wheel or control levers

as handrails.

Do use the handrails and steps, always

support your hands and feet firmly enough
(three point support); that is, one hand- two
feet or two hands-one foot.
See Fig.2-3.7 Fig.2-3.7

2.3.10 Anticipate accident situation

To handle possible accidents or fires, equip the

machine with a fist-aid kit and fire extinguisher.
Remember the locations of all safety items
and learn the way to use them.

An emergency contact person and emergency

liaison plan should be carefully prepared, and
all personnel related must be aware of the
details.

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Safety
STC500S3

2.4 Precautions for Operation

2.4.1 Working site requirement

Refer to 2.3.7.1 on page 2-28 for detailed

information.

2.4.2 Complete machine support

When extending outriggers, keep a safe

distance between the outriggers and scallop,
slope, trench, excavation ground, other
machines, etc.

WARNING
It is very important to support the crane
according to the lift chart to ensure safe
operation.
Always observe the adaptation among the
active outriggers to ensure normal force
transfer.
Supporting to the crane can only be done
when the outrigger is extended. Otherwise,
crane may tip over.

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 Safety
STC500S3

(a) The minimum distance A from a slope:

(seeing the following figure)
Outrigger pressure ≤ 12t, A=1m;
Outrigger pressure ＞ 12t, A=2m; A
See Fig.2-4.1

45°

Fig.2-4.1

(b) Safe distance B from a scallop: (see the

A>=2XT A>=1XT
following figure)
Loose and backfilling ground, B ≥ 2T (T is
depthof pit); A A
Solid ground, B ≥ T (T is depth of pit)
See Fig.2-4.2
T

T
Fig.2-4.2

(c) No matter what the ground condition is,

! ! !
the supporting ground must be horizontal. If
necessary, the user must make a horizontal
supporting surface and make sure it is not
supported on a cavity.
See Fig.2-4.3

Fig.2-4.3

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Safety
STC500S3

(d) The maximum gradient of the horizontal

surface around crane should not exceed
±0.5%. The stability of the supporting ground
should be checked at the time in the process
of crane working. See Fig.2-4.4

Fig.2-4.4
(e) If any factors of reducing stability appear
on the ground, the boom bracket must be
furled in time. Re-support it according to the
requirements after the factors are eliminated.
Main factors of reducing stability are:
Rain, snow and other water sources that
cause ground condition to change.
Ground sinking at one side of the outrigger.
Leakage of supporting cylinders.
Not checking if there is a barrier or not before
setting the outriggers.
Not observing the bubble tube on the chassis
when setting the outrigger to make sure the
working crane has been adjusted horizontal.
The swing support plane gradient should not
exceed over ±0.5%.

WARNING
Inclination of the crane would lead to
tipping.
If the crane is stopped at a slope, and the
boom bracket steers to the slope direction,
then the radius will increase. Swing
mechanism would not be able to carry the
crane superstructure, and the crane would
topple over in the extreme cases.
Do park the crane horizontally.
The front and rear wheels of the chassis
must leave the ground after setting the
outrigger. Then move each control handle
of the outrigger operation valve back to
the middle opposition.

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 Safety
STC500S3

WARNING

As force transfer can only be done through

the parking areas of the two sides, the
central area can not realize the maximum
supporting effect. If there is not enough
parking area in the center, this would lead
to wrong force transfer on the bottom
boom bars.
Connect the active outrigger with outrigger
seat through the fixed pin according to the
lift chart.
Tighten the fixed pin completely.
Extend the four active outriggers,
supporting cylinders and counterweight
part according to the lift chart.
Crane rollover could be caused if only the
active outrigger at the side of the load is
extended when the load is being swung or
placed.

WARNING
Extending the active outriggers incorrectly
would lead to crane rollover.
The load on the hook would lead to strain
and distortion of the wire rope, telescopic
arm, truss, and zipper. Load will be
released suddenly and once the load falls
from the wire rope of the hook, the boom
bracket will draw back quickly. This would
lead to tipping.
Despite the above situations, there are still
some cases in which the load steers to
the reverse direction. This would lead to
crane rollover. When the crane vertically
inclines to the vehicle body direction, this
would lead to crane rollover because of
the boom bracket and the counter weight
momentum.
Four active outriggers and supporting
cylinders must be extended out according
to the data of the lift chart seriously.

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Safety
STC500S3

2.4.3 Rules for operation

1. Set the Crane on Firm Level Ground

The machine should not be located on soft

ground, which can lead to sinking, sliding or
overturning, nor on the edge of a pit, bank or
slope.

If the ground conditions are doubtful, use

blocks or steel plates of sufficient strength and
size below the outrigger floats to disperse the
load.
See Fig.2-4.5 Fig.2-4.5

2. Set the Crane Level

×
If the crane is lifted, and the load is swung
over the side, the load radius will increase,
and the machine can overturn.
When setting the outriggers, level the machine
carefully using a level.
See Fig.2-4.6

Fig.2-4.6

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 Safety
STC500S3

3.Fully Extend the Outrigger

If the outriggers are not extended correctly,

the crane may become unstable, causing the
crane to overturn. As a general rule, always
extend the outrigger fully, even if the crane is
rated for operation with outriggers at middle
extension. If it is absolutely necessary to use
the outriggers at middle extension, make sure
the machine is within the rated limits.
See Fig.2-4.7
Fully Extend

Fig.2-4.7

4.Check the Outrigger Setting

Incorrect setting of the outriggers can

decrease the load lifting capacity of the
machine and result in overturning.

To avoid crane instability, make sure:

• The machine is absolutely level.
• All outrigger floats are stable and set firmly
on the ground or blocks.
• All tires are clear of the ground.
• The outriggers are secured with lock pins.

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Safety
STC500S3

2.4.3.1 Rules for operation (general)

1.Observe Working Conditions

Operating the crane under conditions (boom

length, outrigger beam length, load radius,
etc.) other than specified in the rated lifting
capacity chart can cause overturn, even when
not lifting a load.
Follow all instructions in the rated lifting
capacity chart.

2.Do not Exceed Rated Lifting Capacity

= +
Exceeding the rated lifting capacity will
overload the crane. Damage or toppling over
can result from this practice. See Fig.2-4.8
Weight of hook block
Check the rated lifting capacity chart before
operation to make sure that the lift is safe.
Rated lifting capacity Lifting capacity
Load lifting capacity of the crane varies
depending on boom length and load radius.
Do not exceed the lifting capacity in the chart. Fig.2-4.8

3.Use Safety Devices Correctly

Improper usage of safety devices, including

the overload cutout, can result in damages or
overturning of the crane.
Use all safety devices according to instructions
in the manual.

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 Safety
STC500S3

4.Do not Rely Exclusively on Safety Devices

A safety device is not a substitute for human

skill and judgment.
The overload cutout, for example, does not
warn the operator about conditions on the
ground, influences of wind, load being pulled
sideways, improperly adjusted devices, or
other possibly hazardous situations.

All safety devices are merely auxiliary

means to assist the operator to perform the
task at hand. Safe crane operation requires
the qualities of a good operator, such as
experience, skill, judgement and safety
awareness.

5.Do not Deactivate Any Safety Devices

Do not do any actions that impair normal

operation of the safety devices.

Intentionally deactivating any safety device

may lead to the inability to detect overloading
or over winding during operation and result in
a serious accident.

Make sure that all safety devices function

correctly before starting any operation.

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Safety
STC500S3

6.Before Lifting a Load

Ensure the following before attempting to pick

up a load:
1) The weight does not exceed the rated
lifting capacity.
2) The number of ropes conforms to the
standard in the rated lifting capacity chart.
3) A proper load handling device is used and
the load is securely rigged.
4) The hook block is located directly above
the center of gravity of the load.
5) The wire ropes runs are plumb so that the
load can be lifted vertically.
6) The safety latch on the hook works
properly.
7) The wire rope has no entanglement or
disorderly winding on the drum.

7.Rig the Load Securely

Improper rigging procedure can result in the

lifted load falling. Rig the load safely, paying
special attention to the following:
1) Know the mass, shape and center of
gravity, and utilize suitable load handling
devices and rigging hardware.
2) The load handling devices, including
chains, wire ropes and rigging hardware, must
be strong enough and be free from damage or
wear.
3) Rig the load so that it is suspended at a
point above its center of gravity. Or, the load
can overturn or become loose on the handling
device when it is raised. Wire ropes and
chains must not be twisted or crossed around
each other.
4) Never rig the load with a single wire ripe.
Rigging practices like this is very dangerous
because the load can rotate and untwist the
wire rope, reducing its strength.
5) When rigging a load with sharp corners,
place protective softeners at the load corners
to protect the wire ropes and the load against
damages.

2-38
 Safety
STC500S3

8.Take Boom Deflection into Account before

Lifting the Load

When a load is raised, the boom will deflect

downward, and thus increases the load radius.
Swaying of the load also generates a hazard Boom Deflection
to the personnel around the crane, and may
result in overloading.

If the load begins to sink when it is lifted clear

off the ground, lower the load back on the
ground.

When lifting a heavy load or using the Load Radius

extended boom, consider the possible
increase of the load radius.
Fig.2-4.9
See Fig.2-4.9

9.Only Lift Single Loads

Never lift two or more loads simultaneously

×
even if their total mass is within the rated lifting
capacity. Or, the loads may lose balance. It
is usually impossible to maintain complete
attention to multiple loads.
See Fig.2-4.10

Fig.2-4.10

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Safety
STC500S3

10.Operate According to Signals

If signals are not followed or if signals are not

properly given, accidents can occur.
Follow instructions of the signal person.
An emergency shut down signal must be
accepted whoever gives it.

11 . O n l y O p e r a t e t h e C r a n e f r o m t h e
Operator’s Cab
×
Operate the crane from the outside of the cab
through the cab window is strictly prohibited
and extremely dangerous.
See Fig.2-4.11

Fig.2-4.11

12.Check Safety within the Load Radius of the

Crane before Starting Operation

Person located close to the crane may be

caught between machine components or
between the counterweight and a fixed
obstacle. Before any swing motion, ensure
that there is no one nearby. Sound the horn to
warn all immediate personnel of crane startup.
During operations, fence off or barricade the
work area to prevent unauthorized persons
from approaching the machine.

2-40
 Safety
STC500S3

13.Be Careful When Raising the Load Clear of

the Ground

Stop lifting the load once the riffing is fully taut;

check if the load is suspended at a point just
above its center of gravity, and that the load
is not stuck to the ground or interfering with a
nearby body or structure.
Lift the load vertically. When the load clears
the ground, stop lifting work and suppress any
swaying; then check if the rigging is secure,
the load is in a stable position, and the crane
is not overloaded. Then, re-lift the load.

14.Do not Lift the Load Clear of the Ground by

Raising or Extending the Boom

Only lift a load clear of the ground by vertical

hoisting.
Raising or extending the boom to lift a load
clear of the ground will result in the swaying of
the load, posing a hazard.
If the boom is elevated to raise a load clear of
the ground, the crane will not be automatically
stopped even in case of an overload. An
overloaded crane can topple over or be
damaged.

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Safety
STC500S3

15.Move a Lifted Load Carefully

When the crane state becomes near the full

rating, the AML gives an intermittent alarm.
Operate the crane more carefully and slow the
speed of load-moving.
Take great care for over-loading in boom-
lowering operation which increases the load

×
radius.

16.Do not Lift an Unknown Load

Trying to uproot a tree or raise an object

buried or driven into the ground can severely
overload various components of the machine,
and causing the crane to topple over or be
damaged, Do not try to pull up poles or piles
driven into the ground, trees or any objects
frozen or buried in mud or sand.
Only lift objects free from all restraining forces.
See Fig.2-4.12

Fig.2-4.12

17.Avoid Overloading

A load within the rated lifting capacity can still

cause overloading the crane if swaying occurs.
Never trigger overloading while telescoping
out or lowering of the boom. These actions
enlarge the load radius and are destabilizing.

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 Safety
STC500S3

18.When Overloading Occurs

When overloading happens, do not attempt to

raise or lower the boom rapidly. This situation
is very dangerous as the machine can
readily overturn. Set the load on the ground
immediately by unwinding the wire rope off the
winch drum slowly and carefully.

19.Operate the Crane Carefully

Operating the control elements abruptly can

lead to an accident: a swaying load can hit an
object or damage the crane.
Operate all control levers and pedals steadily
and smoothly.

20.Never Make Inadvertent Swing

When the front jack is not used, lifting

capacities in the over-front area are inferior to
those in the over-rear and over-side area. The
crane may topple over if inadvertently swung
to the over-front area with a load lifted in the
rear or side area. Depending on boom length,
boom angle and outrigger extension, even the
unloaded crane may tip over from inadvertent
swing.
Before operation, confirm the lifting capacity
by the rated lifting capacity chart. If there is
an inferior capacity area, put signal corns or
ropes for swing restriction to avoid swing into
such a perilous area.

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Safety
STC500S3

×
21.Swing the Crane Carefully

If the swing speed is too high, substantial

centrifugal force is applied to a load, leading
to an increased load radius. As a result, the
crane may become overloaded and overturn.
Stopping a swing abruptly can result in a load
to sway posing a hazard to nearby personnel
and possibly leading to boom failure.
Swing all loads slowly. Stop any swing
carefully.
Be extremely careful when working with an
extended boom. See Fig.2-4.13 Fig.2-4.13

22.Be Careful during Complex Operation

During complex operation, actions of the crane

will be slower. When switching from a complex
operation to a simple one, action of the crane
will become faster. When executing a complex
operation, don’t change speed immediately.
Do not try any complex operation until
the operator is fully familiar with the crane
operation.

2-44
 Safety
STC500S3

×
23.Avoid Contact with Obstacles

When moving a load, be sure that the load or

any part of the crane does not contact with
nearby structures or other objects.
While working on a site where potential
obstacles are present, arrange a signal
person and only move the load while following
instructions. See Fig.2-4.14

Fig.2-4.14

24.Operate the Crane with Correct Boom

When the boom configuration is irregular for

purpose of maintenance or inspection, do not
attempt to lift a load.
Check if all the boom sections are telescoping
in the correct sequence during operation. The
rated lifting capacity chart has been developed
based on the assumption that the boom
sections are telescoped in the right sequence.

25.Never Extend the Boom Excessively

An excessively extended boom will reduce

the rated lifting capacity and also can result
in over swing of the load or lower working
efficiency.
During crane operation, keep the length of the
boom as short as possible.

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Safety
STC500S3

26.Be Cautious When the Boom Is at Maximum

Permissible Angle

When boom is raised to max. Permissible

angle, there exists minimum horizontal
clearance between the boom and the load.
A swaying load may hit the jib or boom, and
result in damage.
Carefully handle the load so that it does not
strike the jib or boom.

27.Be Cautious in Demolition Work

It is very dangerous to lift components or

parts of a structure undergoing demolition if
the mass and center of gravity are not known.
Before operating, ascertain the mass and
center of gravity of the loads, and only then
can the lift procedure be taken.

28.Carefully Lift a Load in Water

While handling a load in water, it is important

not to lift the load out “all at once” when it
appears above the water. The load may be
impregnated with water and heavier than
expected. Allow the load to drain while lifting it
slowly.
A load is raised out of water, even when
fully drained, weighs more than it did when
submerged because of buoyancy effects.
Lift the load carefully so as not to cause
overloading.

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 Safety
STC500S3

29.Carefully Handle Wide Loads

Be careful while lifting a wide load. The

load can swing and hit a rigging person, the
machine itself or a nearby structure.
Utilize tethers tied to either or both ends of the
load to control the position and/or movement
of the load. See Fig.2-4.15

Fig.2-4.15

30.Never Over Wind the Hook Block

×
When the boom is extended or lowered, the
hook block is wound up.
Usually, over winding the hook block will
result in the anti-two block device to rip and
the winch automatically stops. However, if
the device is damaged or the automatic stop
function has been deactivated, the hook block
can affect the boom head.
Always be aware of the position of the hook
block. If the hook block comes to the boom
head, wind off the wire rope to lower the hook
block and avoid contact. See Fig.2-4.16
Fig.2-4.16

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Safety
STC500S3

31.Know the Number of Wire Rope Parts

If the number of the part lines is more than

specified for the boom length, the hoist line
may become too short. As a result, the line
can unwind off the winch drum causing the
wire rope to be damaged or broken.
While lowering a very light load or a bare hook
block, the rope will unwind off the winch drum
at a faster rate. The rope may then become
improperly rewound.
Utilize the proper number of part lines
appropriate to the boom length.

32.Wire Rope Must Be Wound on the Drum

Properly

Lifting a load with the wire rope improperly

wound on the winch drum can cause damage
of the wire rope Not only reduce service life of
the rope, but also possibly breaking wires and
strands which can result in ultimate failure.
After reeving or replacement of the wire rope,
ensure that the line is seated in the sheaves
and on the winch drum properly.

33.Never Unwind the Wire Rope

If the entire rope is unwound from the winch

drum, the frictional anchoring force will not
be enough to support a load. The rope will
become damaged or break.
Three winds of rope, at least, must always be
left on the winch drum. This condition applies
particularly when a load must be lowered
below ground level, such as, a trench or
excavation. See Fig.2-4.17

Fig.2-4.17

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34.Never Leave a Load Suspended

Never leave a load in a hoisted position. If the

crane is equipped with the drum lock device,
actuate the winch brake and the drum lock to
hold the load safely. Use working procedures
which minimize the duration a load is left

×
suspended.

35.Only Use the Crane for Approved

Applications

The crane is designed to lift a freely

suspended vertical load. Do not try to lift
persons or push/pull a load with the boom.
See Fig.2-4.18

Fig.2-4.18

36.Never Anchor the Machine

Never try to hold down the crane frame or

×
outrigger or contrary side to the lifted load by
wire rope.
Such practice might result in crane damage or
an accident. See Fig.2-4.19

Fig.2-4.19

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×
37.Never Add Counterweight

Assembling a counterweight other than those

specified can damage the crane or cause it to
overturn to the rear due to decreased rearward
stability.
Do not assemble or place a counterweight or
equivalent other than those specified.
See Fig.2-4.20

Fig.2-4.20
38.Never Position Any Part of Your Body Out
of the Window on the Boom Side

Letting any part of your body out from the

window on the boom side can lead to be
caught between the moving boom and the
window frame.
Serious injuries or death can result from this
dangerous action.
If the window is equipped with a confining
guard, do not remove it.

39.Never Look Away from the Load While

Operating the Crane
×
When operating the crane, looking away from
the load, chatting or performing any other
action that can detract from awareness, is very
dangerous.
During operation, pay all attention to the load
and the signal person.
See Fig.2-4.21

Fig.2-4.21

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×
40.Never Pass a Load over Any person

Passing a load over a person is forbidden

because it is very dangerous.
Never allow anyone be enter the area below
the boom or the load.
See Fig.2-4.22

Fig.2-4.22

×
41.Never Pull a Load Sideways, Never Lift a
Load Obliquely, Never Drag a Load

Pulling a load sideways, lifting a load obliquely

or trying to drag a load is very dangerous.
Such practices can damage the jib, boom or
swing mechanism, and lead to overturning of
the crane.
Never try to draw in a load that is located
outside the load radius. To deal with such
loads, move the crane to the vicinity of the
loads and lift them vertically one by one.
Fig.2-4.23
See Fig.2-4.23

42.Never Leave the Operator’s Cab When a

Load Is Suspended

Before leaving the operator’s cab, be sure to:

Lower the load to the ground.
Fully retract the boom and stow it.
Actuate all brakes.
Put all control levers in their neutral positions.
Shut off the engine, and remove the starter
key.
Lock the crane operator’s cab door.

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43.Do not Allow Anyone to Ride On the Crane,

Except In the Operator’s Seat

If any persons other than the operator (in the

operator’s seat) are on the machine, they must
be stationed inside the operator’s cab.

Persons on the machine other than the

operator (in the operator’s seat) may fall or be
caught by a crane component or other objects.
Other persons cause distraction and can
disturb the attention and work of the operator.

44.Never Push or Pull an Object with the

×
boom

Do not use the boom to push or pull an object.

Do not use the boom to thrust up an object or
force the boom into object.
Use a machine designed to move an object,
like a fork lift truck or carryall.
Never use the crane in applications other than
specified.
See Fig.2-4.24
Fig.2-4.24

45.Be Careful while Using the Jib(1)

×
Never try to lift separate loads on both the
boom and jib at the same time.
Such actions can damage the jib or boom, or
overturn the machine.
See Fig.2-4.25

Fig.2-4.25

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46.Be Careful While Using the Jib(2)

Lifting a load on the boom with the jib mounted

should be avoided, if possible.
If conditions require such a practice, follow
the instructions given in the “Load Moment
Indicator” section of the manual and perform it
with extreme care and attention.
See Fig.2-4.26

Fig.2-4.26

47.Mount and Stow the Jib Correctly

×
Failure to obey the specified procedures for
mounting and stowing the jib can damage the
jib, or may cause the jib to drop.
Make sure that the jib is mounted and stowed
in the correct manner by referring to the “Jib”
section of the manual.
See Fig.2-4.27

Fig.2-4.27

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2.4.3.2 Cautions for working at heights

Working at heights is risky. To reduce the risk,

remove all obstacles and any spilled oil and
grease. Keep all footing areas clean and tidy.

To climb onto and descend from a position

of high elevation, face the machine directly.
Utilize the handrails and steps; always be
supported by at least three points of your
hands or feet.

Be cautious not to slip. When non-slip strips

are provided on the crane, walk on them.

Use safety equipment such as safety belts

ties, platforms and lanyards as the situation
requires.

2.4.3.3 Be careful when working under the

crane

When working under the crane with the jack

cylinders extended, put supports and wood
blocks beneath the outriggers to support the
machine securely. Never work under the crane
unless the crane is securely and positively
supported.

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2.4.4 Other precautions for lift work

2.4.4.1 Crane being connected to ground

DANGER

Electric shock can cause the risk of fatal

injury.
Crane’s improper grounding will lead to
the danger of the electric shock.
Do properly ground the crane.
In the following circumstances, the crane
must be connected to the ground before
operating.
Coming close to a transmitter (radio,
television signal transmitter and wireless,
etc.).
Coming close to the high-frequency
switching station
Strength of thunder or potential thunder
could be significant.
Cranes carry static electricity, especially
when equipped with the multi-function
support blocks, or the support blocks
are placed on insulated material (such as
planks).

WARNING

Electrical shock may cause a fatal injury.

Crane’s improper grounding may lead to
electrical shock.
The connection between the crane and the
ground must be correct.
If a smaller grounding resistance can be
achieved, connect the chassis ground to
the frequency-band ground. This approach
should be given priority.

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DANGER

Electric shock can cause the risk of fatal

injury.
Crane’s improper grounding will lead to
the danger of the electric shock.
To prevent the crane from creating static
electricity, the following configurations are
required:
• Inserting a conductive ground rod with a
length of about 2m into the ground
• An electric cable with a cross-section of
at least 16 mm2
• Crane ground connection or screw clip,
as used for welding
Comply with the following requirements:
• Be sure to use the staggered-form
grounding rod.
• Grounding resistance must be less than
0.5 ohm
• The connection between the crane and
the ground must be correct.
Connect one end of the grounding cable,
with a cross-section of at least 16 mm2 ,to
the grounding rod and the cranes frame.
Insert the grounding rod into ground at
least 1.5m.
Wet the soil around the grounding rod in
order to enhance its conductivity.

NOTICE

Ground resistance depends on the

composition of the soil material and the
grounding rod contact surface.

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2.4.4.2 Load connected to the ground

WARNING

Electrical shock may cause a fatal injury.

Load’s improper grounding may lead to
electrical shock.
Do properly connect the load to a ground.
Prevent the load from carrying static
electricity.
The connection between the load and the
ground must be secure.

In the following circumstances, connect

the crane to a ground before operating
when:Close to a transmitter (radio, television
signal transmitter and wireless, etc.)
• Close to a high-frequency switching station
• Strength of thunder or potential thunder
could be significant

Even when the crane has been grounded,

there still remains the possibility for the load
to carry static electricity. Especially when the
hook pulley block used is made of composite
materials and non-conductive fastening
devices (such as plastic or rough hemp rope).

2.4.4.3 Load welding works

WARNING

Load must be connected to a grounding

rod.
If welding work is required on the load,
pressure lugs must be installed on the
parts to be welded to prevent the lifting
rope, superstructure and the chassis from
being conductive.
Damage to control components due to
heat.

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2.4.4.4 Rules for operation (weather)

1. Stop Operation When Visibility is Impaired.

During bad weather (like rain, snow or fog),

×
stop all operation and stow the crane. Wait
until visibility improves before restarting
operation.

2. Stop Operation When Strong Winds are

Present.
In strong winds, a lifted load will begin
swaying, raising a danger to working
personnel and nearby structures and also
possibly damaging the boom or toppling over
of the crane. See Fig.2-4.28
The effect of cross wind on crane stability is
directly proportional to length of the boom and
size of the load. Fig.2-4.28
When the wind speed exceeds 20 mph., stop
all crane operation and stow the crane.
When the boom is substantially extended or
a large-sized load is hoisted, stop operation
even if the wind speed is less than 20 mph if
any danger may exist.
The following Table 2-4.1 lists wind speed
ranges and the ground conditions for each
range. Note that the wind speeds here are
those at a point 30ft above open level ground.

Table 2-4.1

Wind speed (m/s) Ground conditions

5.5~8 Dust is raised, paper whirls up, and small branches sway.
8~10.8 Shrubs with leaves start swaying. Wave crests are apparent in ponds or swamps.
10.8~13.9 Tree branches move. Power lines whistle. It is difficult to open an umbrella.
13.9~17.2 Whole trees sway. It is difficult to walk against the wind.

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×
3. Stop All Operation If there is Any Possibility
of Lightning

Lightning can not only damage the crane but

also hurt the operator and working personnel.
If lightning is expected or forecast, stop
operation, stow the boom and leave the crane.

See Fig.2-4.29

If the crane is struck by lightning:

Stay in the cab and do not attempt to move
outside.

Warn people around not to get near the crane.

Then, check the entire crane carefully and
have any damaged components repaired.

Fig.2-4.29

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4. Cautions in Cold Weather

1) Snow or ice on the machine should be

cleared before operation; it is especially
important to eliminate any accumulation on the
boom, as it could fall and hurt people when the
boom is moved.

2) Never let bare skin be in contact with the

crane’s metallic parts when the temperature is
below freezing. Skin can freeze to the metallic
surface, if any moisture is present.

3) Warm up the machine enough. Then,

inspect that the machine is functioning
c o r r e c t l y. R e m o v e i c e a n d d r y c r a n e
components as required.

4) After beginning operation, run the crane

slowly until oils fully circulates through all
crane parts.

5) Before hoisting, ensure that the load is not

frozen to the ground or any other objects.
Attempting to lift a load frozen to the ground
can lead to severe overloading and is very
dangerous.

6) If possible, stow the crane indoors so that

the tires will not be frozen onto the ground,
Remove mud from the undercarriage.

7) Maintain the battery. Use oils and fuel rated

for cold weather.

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2.4.4.5 Rules for operation (power lines,

radio waves)

1. Prevent Electric Shock Accidents

Being too close to power lines can lead to

electric shock accidents. If it is required to
work near power lines or distribution lines,
implement the following preventive measures:

1) Negotiate with the power company

concerned to produce a relevant safety plan.
2) Wording personnel is required to wear
approved insulating shoes.
3) Keep the machine and load beyond the
required distance (stipulated by national of
local laws and regulations) and away from
power lines.
4) Arrange a full-time signal person to
make sure that the machine or load does
not approach power lines or unauthorized
personnel do not enter the work area.
5) Personnel on the ground must not directly
touch the crane or load. When necessary to
control the lifted load, use dry fiber ropes as
tethers to prevent the load from swaying or
rotating.
6) Never place a load below or near power
lines.
7) Operate the machine slowly with the
greatest care and attention.

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2. If an electric shock accident happens, do

not panic. Follow the following instructions:

1) Contact the power company to cut off the

power and obtain instructions for emergency
action.
2) Direct all personnel around the crane to
leave the site. Strictly control the site and keep
everybody away from the electrified crane and
load.
3) The operator should keep calm and
cautiously move the crane and load away
from the power lines to the required stand-off
distance, and only then can he leave the cab.
4) If the crane is damaged and/or disabled,
stay in the operator’s seat until the power is
cut off. If this is possible, jump directly from the
operator’s cab as far as possible. Do not touch
any parts of the crane that may be electrified
and can cause shock.
5) After the accident, contact an authorized
SANY distributor or dealer to report the
accident and discuss the measures, and
inspection and repairs needed.
See Fig.2-4.30

× Required safety distance

Fig.2-4.30

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STC500S3

×
3. Be Careful about High-power Radio Waves

In areas near sources of high-power radio

or TV station transmitters, a current can be
induced in the machine. Electrified crane parts
can be caused. Moreover, electronic devices
like the overload cutout may be damaged.
If necessary, discharge any induced voltage
through grounding the hook block and only
then start rigging.
See Fig.2-4.31
Fig.2-4.31

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2.4.4.6 Rules for special operation

1. Be Cautious in Multi-Crane Operation

Lifting a load with two or more cranes can be
dangerous. During these operations, loads are
lifted at points but not directly above the center
of gravity and there is possibility of the load
falling, the crane tipping, or the boom failing.

In multi-crane lifting work, be absolutely

careful, and fallow to the following instructions:
1) Meet personnel concerned to determine
the proper working procedure and lift strategy.
2) Post a work leader, and follow instructions.
3) Equip every person related with an
appropriate communications device.
4) Set each machine level on firm ground with
the outriggers fully extended.
5) The machines used must have the same
performance, features and enough capacity
for handling the load. Ensure that the cranes
have the same settings for the boom length,
boom angle and number of rope parts.
6) Lift the load so that the wire rope(s) of
every crane are only subjected to vertical line
pulls.
7) Attempt to rig the load so that all the
machines are loaded equally.
8) Only use the winches and boom to move
the load. Swing operations must be avoided.
Never perform hoisting, elevating, telescoping
of the boom, or swing at the same time.
9) To prevent the cranes from overloading,
operate the separate cranes simultaneously. Fig.2-4.32
See Fig.2-4.32

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2.4.5 Examples of aftermath caused by

×
misuse

Crane misuse could lead to:

• Injury and/or death.
• Serious damage to the crane;
• Hooked goods being destroyed;
• Great damage to the crane, quality guarantee
being invalid.

The following operations are prohibited:

• Changing crane structure in any-form without
the manufacturer’ written agreement
• Any operation that affects safety.
• Standing under hooked loads or hooked Fig.2-4.33
loads crossing over personnels head.
See Fig.2-4.33

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×
• Loosen the fixed load with hook or swing
mechanism.
• Pull load crosswise or drag hooked load on
the ground Proper lift chart is not fallowed.
• Caring personnel on hook or load.
• Drag transversely (swing or travel) the
hooked load which is still on the ground.
• Stopping suddenly and swing too fast while
lifting.
See Fig.2-4.34 and Fig.2-4.35

Fig.2-4.34

×
Fig.2-4.35

• Lift a load on the rugged ground without

adjusting the outriggers to the horizontal level.
• Improper load binding;
• Sudden loosening of the load lifted slantways
or the lifted load.
×
• Winch wire ropes are in disorder;
• Collide with bridge, ceiling and high pressure
wire etc.
• Overload.
See Fig.2-4.36

Fig.2-4.36

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2.5 After Operation

2.5.1 After operation, stow the machine

DO NOT leave the machine unattended. Once

×
operation is complete, stow the machine.

2.5.2 Cautions for refilling the fuel

Fuel and other oils are flammable and

dangerous.
Deal with combustibles very carefully.

While refueling, follow the instructions below:

1. Stop the engine.
2.Refuel the machine outdoors in a well-
ventilated area and use a grounding cable.
3. NO SMOKING. Keep sources of flames or
sparks away from the fuel and vapors.
4. Wear the necessary protective gear.
5. Do not exceed fuel tank rated capacity.
See Fig.2-5.1 Fig.2-5.1

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2.5.3 Cautions for adjusting tire

pressure

When adjusting tire pressure, do not stand

facing the side of the tire. The tire may burst
or wheel parts can fly off and cause injury or
even death.
Place a tire cage over the wheel and stay
behind the tire treads.
See Fig.2-5.2

Fig.2-5.2

2.5.4 Have authorized personnel to

replace or maintain the tire

Replace and maintain the tire with special

tools and skill;
Improper method or tools may lead to
accident;
As for detailed information about the
replacement or maintenance of tire, contact
our authorized SANY dealers, agencies, or
consult properly trained personnel.

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2.6 Rules for Transportation and

Towing

1. Observe All Vehicles Regulations.

Requirements for Travel on Public Roads;

Some national and local laws for the travel of
crane vehicles on public roads exist. Before
traveling on roads, do research on relevant
requirements, and strictly follow all the rules.

2. Traveling in Road Travel Configuration of

the Crane.

An unfixed hook, block, boom, or extended

outriggers cause terrible hazards during
traveling. Before traveling, stow the hook block
and other components in position and lock all
components. Configure the crane for traveling
according to relevant section in this manual.

3. Do not Travel with Any Cargo on the

Machine.

Carrying cargo on a traveling crane may

lead to a fall or spill. Transport cargo with a
specifically designed support vehicle.

4. Be Aware of Overhead Obstacles.

Pay attention to overhead clearance when

passing under electrical wires, railway and Distance
highway bridges, or when passing through a
tunnel.

If the crane has to travel below overhead

bridges or through a tunnel, check the
clearances in advance, BEFORE entry.
See Fig.2-6.1
Fig.2-6.1

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5. Inspection before Travel

Make sure that the following is met before

traveling;

If any irregularity in the fallowing, report it to

the responsible person, solve the problem and
then proceed.

1) Control elements and instruments are

functioning normally.
2) Hydraulic and pneumatic pressures are
correct. There is no air or oil leakage.
3) The fuel, lubricant, cooliant, hydraulic oil,
and brake fluid levels are adequate.
4) The tries are free from too much wear,
damage and cracks. Tire pressure is at a
normal level.
5) There are no loose wheel nuts.
6) The braking devices, including parking
brake and foot brake ,are functioning normally.
7) The lighting system and direction indicators
illuminate correctly.
8) The rear view mirrors are not damaged.
9) Exhaust gas color is normal.
10) There are no abnormal noises.

6. Observe the Riding Capacity.

Non-observance of the passenger restrictions

not only often violates the law, but also can
result in an accident. Only if the operator’s cab
is equipped with an auxiliary seat, the crane
can accommodate two people.

If an auxiliary seat is not provided, do not

allow anyone other than the operator to ride in
the cab.

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7. Always Fasten the Seat Belt.

When traveling with the machine, always

fasten the seat belt, Be careful not to twist the
belt.

8.Before starting, Be Aware of Conditions

Around the Machine

Before the start of travel, make sure that

there are no personnel or obstacles in the
immediate vicinity of the machine. Sound the
horn to signal the start of movement.

9. Drive Safely.

Always keep a safe stopping distance from the

other vehicles ahead.

Turning the steering wheel too sharply can

overturn the crane.

Do not drive abruptly. For instance; sharp

speed or steering, sudden starts and extreme
braking.

10. Arrange a Signal Person if Visibility Is

Limited.

When traveling around a narrow passage, tight

corner or location, where operator‘s visibility is
limited, or especially when backing up, always
post a signal person to prevent any mishap.

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11. Be Aware of Road-Surface Conditions.

Snow, ice, rain, mud and rock slides, loose

pavement ect.

12. Load and Unload the Machine Safely.

The machine can be displaced off a

transporter by improper loading and unloading
procedures. The following instructions must
be observed and extreme care must be taken
when loading and unloading the crane on a
transporter.

Make sure that the transporter is of sufficient

load capacity to carry the crane.

1) The transporter is on firm enough and level

ground, actuate the parking brake and chock
the wheels.
2) Make use of gangplanks of sufficient length,
width and load bearing strength. Be sure that
they provide a gentle slope from ground up to
the transporter deck.

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2.7 Rules for Inspection and

Maintenance

2.7.1 Do not adjust or disassemble the

hydraulic equipment

The hydraulic equipment, including safety

valve and pneumatic equipment, have been
inspected strictly and adjusted carefully before
its shipment from the factory.

Disassembly and inappropriate adjustment

of the hydraulic or pneumatic equipment can
result in danger and functional failures.

To disassemble or adjust them, contact an

authorized Sany distributor or dealer.

2.7.2 Do not modify the machine

Unauthorized modification may influence the

crane performance, safety and strength. It can
result in damage or toppling over.

Never modify any part of the machine.

2.7.3 When an irregularity is detected

An unforeseen irregularity can cause a very

serious failure or accident.

If an irregularity is detected in the process of

inspection, find out the reason, adjust,repair or
replace and then maintain the component in
question to correct specifications by a factory
authorized personnel.

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2.7.4 Inspect and maintain at regular

intervals

Careless inspection or maintenance work

makes it impossible to detect faults at an early
stage.

To ensure timely fault prevention and early

detection of potential problems, inspection
and maintenance work must be carried out
at specified intervals by factory authorized
personnel.

2.7.5 Become familiar with procedures

for inspection and maintenance

Improper inspection and maintenance

procedures can cause damage to the
machine, injury or even death.

Strictly follow the instructions in the manual on

inspection and maintenance. No inspection or
maintenance work is allowed to done until the
instructions are thoroughly understood.

When inspection or maintenance work is

complicated, consult an authorized SANY
distributor or dealer.

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2.7.6 Provide effective ventilation

Make sure that inspection and maintenance

work are carried out in a well ventilated area,
or it can lead to toxic poisoning.

Be careful while handling fuel, wash, oil and

paint.

Provide a means of effective ventilation when

the engine is started in an enclosed space.
Connect a hose from the exhausts to vent
the fumes outdoors. Open all doors and
windows to let fresh air in. Install a ventilator
as required.

2.7.7 Cautions for washing the machine

Wet footing can result in slipping and falling.

Wear non-slip shoes.

When washing the crane with high-pressure

steam, the jet can penetrate skin or flying mud
can cause eye injury. Wear suitable protective
gear during washing.

Do not direct water to any electrical quipment.

Discharge and/or short-circuits can cause
damage.

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2.7.8 Inspect and maintain the machine

on level ground

To inspect the crane properly, it is a must

for the crane to be park on level ground and
be properly secured or the crane may start
moving .

Remember to park the machine on firm flat

ground, activate the parking brake and chock
the tires.

2.7.9 Start inspection or maintenance

after the machine has cooled down

When the machine is in operation, many

machine components become very hot and
can cause burns.

These components include the engine, engine

cooling system, muffler, radiator, hydraulic oil,
reducer, hydraulic equipment and hydraulic
piping.

Before starting inspection and maintenance,

these components and areas must be cool.

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2.7.10 Beware of high-pressure oils

Pressurized fuel or hydraulic oils that contact

the skin or eyes can cause serious injury.

1) To avoid such danger:

Release internal pressure by fallowing
procedures.

2 ) To c h e c k f o r l e a k a g e , a l w a y s w e a r
protective goggles and gloves and the use
a piece of wood or cardboard as a monitor.
Keep unprotected hands away from all leaking
components. Seek medical care immediately
if high pressure oil cuts into the skin or affects
the eyes by accident.

2.7.11 Use two people for inspection

and maintenance with the engine
running

If it is necessary to carry out an inspection

or maintenance with the engine running,
arrange two people: one in the operator’s
cab, to shut down the engine down instantly if
necessary, the other to perform the inspection
or maintenance. During inspection and
maintenance, make sure that all personnel in
the work area are safe.

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2.7.12 Beware of overhead obstacles

and footing

Beware of overhead obstacles and footing.

The hook block, boom, or jib or slip can be
harmful. Loose footing can cause a slip and
fall off of the machine. Walk on the traction
strips if provided.

2.7.13 Do not allow tools and parts to

drop

Be careful not to drop objects in to the

inspection hole while working through an
inspection hole. It can damage and result in
malfunction of the crane.

Never keep unnecessary objects in open

pockets.

Recollect any objects or tools that have

dropped into the crane by accident.

2.7.14 Beware of oil smears

Oil smears on the lining; clutch and brake

disks can decrease braking effectiveness.

Always keep them free from oil accumulation.

2.7.15 Beware of dust

Do not inhale dust during inspection or

maintenance. To check or maintain brakes and
linings, use a vacuum cleaner to remove dust.
Do not use compressed air because it will
scatter dust into the air.

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STC500S3

2.7.16 About starting engine with

booster cables

The use of inappropriate booster cables to

start the engine can cause the explosion of the
battery or the damage of the machine.

Always wear protective goggles when starting

the engine using booster cables. To carry out
the procedure, two persons are needed. One
must sit in the operator’s cab. The procedure
includes:
1. Use an assist vehicle with a battery rated
for 24V. Do not use a 12V or 48V supply.
2. Set the starter key of the dead vehicle and
assist vehicle to “OFF” position.
3. Connect the booster cables in this order:
① “+”terminal of the battery on the dead
vehicle.
② “+”terminal of the battery on the assist
vehicle.
2
Booster cable 1
③ “-”terminal of the battery on the assist 3
vehicle.
④ A portion of the frame or engine block of the
dead vehicle, apart from its battery.
4. Start the engine of the assist vehicle.
5. Start the engine of the dead vehicle. Service vehicle battery Disabled vehicle battery
6. Once the engine of the dead vehicle has
started, disconnect the booster cables in the Booster cable
4 Frame
order of ③，② and ① .
See Fig.2-7.1 Fig.2-7.1

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STC500S3

2.7.17 Disconnect the battery cable

before inspecting and maintaining the
electrical system

Do not inspect or maintain the electrical

system until the battery cable is disconnected.
It may cause the wiring to be short-circuited
which will possibly damage the electrical and
electronic system.

Disconnect the battery cable from the minus

terminal (ground side) of the battery before
carrying out any inspection and maintenance
work on electrical system.

2.7.18 Careful handling wire ropes

Careless handling of wire ropes can shorten

their service life, or even cause them to fail.
Must observe all instructions in this manual to
handle wire ropes properly.

2.7.19 Use genuine parts only

Use of parts not approved by the factory

can result in failures in safety and functional
systems.

To replace components, observe the parts

list and use only the specified genuine items
approved by the factory.

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STC500S3

2.7.20 Use specified oils

It is a must to use recommended brands or

grades of oils and greases when adding or
replacing oils.

Mixing different brands may change properties

of the oil or grease, due to chemical reactions.
This would be harmful to the machines
components and void any warranties.

When using oil or grease of a brand not

matched to the same with that in the crane,
remove all of the remaining oil or grease first,
and then refill.

2.7.21 Verification after maintenance

It is essential to verify whether all components

and mechanisms function properly after any
maintenance work.

Ensure that the maintained components are

working normally, that there is no oil leakage
and loosen bolts.

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STC500S3

2.8 Possible Hazards

2.8.1 Mechanical hazards

×
DANGER

Accidental motion of the crane or

contacting a moving part can lead to
personal injury and even death.

When it is necessary to inspect or maintain the

machine while running, do not approach any
moving parts like the boom, elevating cylinder,
fan, fan belt etc.
Keep hands and clothes away from moving
parts. See Fig.2-8.1 Fig.2-8.1

2.8.2 Burn

DANGER

Never loosen the radiator cap while the

cooling system of the engine is hot.
Doing so will cause severe burns.

First, wait until the radiator is cooled down.

Then, loosen the cap slowly, while facing away
from the cap. STOP and wait to proceed if
there is any internal pressure.
See Fig.2-8.2 Fig.2-8.2

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STC500S3

2.8.3 Safety in utilizing electric energy

DANGER

Be very careful operating around any

wires. An appropriate safe distance must
be kept from all wires otherwise, all
personnel on, or near, the crane will face
a fatal danger. When a high voltage spark
(a “high-pressure funnel area”) accurs
on, or around, the equipment, the voltage
will be reduced as decentralization. There
remains great danger close to the funnel
area. If you step across the different
voltage areas (step voltage), the current
will flow through the body causing injury
and/or death.

2.8.3.1 After electric shock treatment

measures to the crane

• Do not leave the cab.

• If conditions allow, drive the crane out of the
danger area.
• Warn others not to come near or touch the
crane.
• Inform, then wait for, the proper personnel to
cut off the power supply.

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STC500S3

2.8.3.2 Precaution on battery

1. Prevent Battery Explosion

• Battery gas can explode.
• Prevent any sparks or open flame from
coming close to the top of the battery.
• Never should a metal object be placed
across the terminals to check the battery
voltage, a voltmeter or hydrometer should be
used.
• Do not charge a frozen battery. An explosion
can accrue. The battery should first be
warmed up to 16 ° C.
• Battery electrolyte is volatile and poisonous.
Blindness and burns are possible if one is
exposed. Read and fallow all safety warnings
on the battery decals.
• When checking the electrolyte level, always
wear an appropriate safety shield and clothing.

2. Be Cautious About Battery Fluid

The battery fluid includes dilute sulfuric acid.
If battery fluid enters eyes, it can cause
blindness. If the fluid contacts skin, the skin
will be burned.
Always wear protective goggles, gloves and
long-sleeved clothes when handling the
battery.
If battery fluid contacts your eyes or skin,
wash them with a great quantity of fresh water
and turn to medical care instantly.

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STC500S3

2.8.4 Welding in the right way

Welding process must be correct to prevent

damage to the electronic control devices and
bearings. When a machine equipped with
electronic control devices is being welded, the
user should follow the following these steps:
• Shut down the engine, set the engine switch
to OFF position.
• Remove the battery negative cable.
• Note: Do not take the earth points of the
electrical parts (electronic control module or
electronic control module sensor) or electronic
parts as the ground for the welding machine.
• Clamping the part, which are going to be
welded, with the ground clamp close as
possible to the the welding point to ensure
the current does not flow through any of the
bearings. This procedure can reduce the
possibility of damaging other components
such as; transmission bearings, hydraulic
components, electrical parts, and other
machinery parts.
• Prevent the wireing harness from touching
the welding debris and flying objects
generated in the process of welding.
• Weld materials together according to the
standard welding procedures.

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STC500S3

2.8.5 Fire

2.8.5.1 Prevent fire

To p r e v e n t f i r e d u r i n g i n s p e c t i o n a n d
maintenance requiring potentially flammable
substances, observe the following instructions.
1. Use non-flammable cleaning liquids to
clean parts and components.

×
2. Store fuel and oil away from any flame in a
suitable container.
3. Do not allow flames or sparks to be near
any combustible substance.
4. Do not smoke.
5. Always store a fire extinguisher in the
operator’s cab.
6. When checking fuel, oils and battery liquid,
use an explosion-proof lamp.
7. During grinding or welding, keep flammable
substances far away from flying sparks or
molten metal.
See Fig.2-8.3
Fig.2-8.3

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2.8.5.2 Illumination

Provide proper illumination before starting

inspection and maintenance. Do not use
the exposed flame of a match or lighter for
illumination, a fire accident may happen. The
gas emitted from open lead storage batteries
can explode.

Use explosion-preventive illuminating devices

when checking fuel and battery liquid level.

2.8.5.3 Use of fire extinguisher

There euqips a 1kg portable powder fire

extinguisher on the right side of the driver’s
cab back. Before operating the crane, do read
the instruction stamped on the extinguisher
and understand how to use it in case of
emergency.

WARNING

The following precautions must be

observed in order to deal with unexpected
fire:
Make sure that the extinguisher is
available in your cab. Read the instruction
decal of the extinguisher and understand
how to use it in case of emergency.
It should be inspected periodically, to
make sure it is in the guarantee period.
If extinguisher has expired, replace it
immediately.

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2.8.6 Waste disposal

Thriftless disposal of waste oils, used filters

and other petrochemical-related products will
result in environmental contamination.

Prepare a proper vessel before releasing

waste oils from the crane. Do not discharge
waste oils on the ground, into rivers, lakes or
marshes.

Abide by all governing environmental rules

and regulations when disposing of oils, fuels,
brake fluid, coolant, solvents, filters, batteries
or other damaging substances.

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STC500S3

2.9 Safety Devices

2.9.1 LMB

• Read the “LMB Manual” carefully and get

to know how to operate it proficiently before
hoisting operation.
• Although the LMB has been installed,
the driver still has the responsibility of safe
operation. Before any operation, the operator
must know about the load weight and the
relative distance from the crane to make sure
whether the load can be lifted or, another
appropriate lift condition can be chosen in
accordance to the hoisting characteristic
diagram.
• LMB is a very important safety device to this
machine, and definitely do not allow any lifting
of heavy objects when the LMB is turned off.
• The machine has an overload discharge
switch, namely a mandatory switch (on
the control panel’s LMB), if the vehicle is
overloaded, the user should be careful in
using this switch, SANY will not be responsible
for any injury caused by the misuse of the
mandatory switch.

WARNING

Incorrect LMB settings may lead to serious

vehicle damage or personal injury.

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STC500S3

2.9.2 3-ring protector

When the wire rope is wound on the reel

with three circles left, the 3-ring protector will
activate, and the hook will stopped lowering,
with overfall warning light on. At this moment,
warning will canceled when the lifting hook is
raised.

2.9.3 System master switch

This safety device is used to avoid

malfunctions caused by touching the control
handle accidentally.

Lifting operation can be realized through

master switch by a skilled operator.

2.9.4 Hydraulic filter warning light

When the hydraulic oil filter is blocked, warning

lights will come on. The crane operation must
be stopped, and the corresponding filter
elements must be cleaned or replaced.

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STC500S3

2.10 Safety Symbols

Some safety symbols are fixed on the crane.

These safety symbols give important notices
and precautions to ensure safety. This part will
display the location and content of the safety
symbols. All the explanations on the safety
symbols are extremely important to prevent
accidents. Understand and remember them
well.

Make sure that all the safety symbols are

clean and neat. Make sure they are clean
and readable.Any destroyed or missing safety
symbols must be replaced. New ones can be
obtained from the agents and distributors of
SANY or, SANY service department.

Safety symbols' position and content, see

Fig.2-10.1:

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STC500S3

Fig.2-10.1 Location of safety symbols

1: Caution for weight dropping

2: Caution for boom telescoping in/telescoping
out
3: No walking
4: Safety instruction 1
5: Safety instruction 2
6: Cautions for maintenance operation
7: Caution for swing lock
8: Caution for falling
9: Caution for winch reducer
10: Caution for winch rope
11: Caution for operation
12: No approach
13: Caution for outrigger
14: No entering
15: No smoking
16: Caution for overheat
17: Caution for locked outrigger tray
18: Caution for electrocution
19: Caution for engine cover

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STC500S3

1: Caution for weight dropping

See Fig.2-10.2

Fig.2-10.2

2: Caution for boom telescoping in/telescoping

out
See Fig.2-10.3

Fig.2-10.3

3: No walking
See Fig.2-10.4

Fig.2-10.4

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STC500S3

4: Safety instruction 1
See Fig.2-10.5

Fig.2-10.5

5: Safety instruction 2
See Fig.2-10.6

Fig.2-10.6

6: Cautions for maintenance operation

See Fig.2-10.7

Fig.2-10.7

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STC500S3

7: Caution for swing lock

See Fig.2-10.8

Fig.2-10.8

8: Caution for falling

See Fig.2-10.9

Fig.2-10.9

9: Caution for winch reducer

See Fig.2-10.10

Fig.2-10.10

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STC500S3

10: Caution for winch rope

See Fig.2-10.11

Fig.2-10.11

11: Caution for operation

See Fig.2-10.12

Fig.2-10.12

12: No approach
See Fig.2-10.13

Fig.2-10.13

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STC500S3

13: Caution for outrigger operation

See Fig.2-10.14

Fig.2-10.14

14: No entering
See Fig.2-10.15

Fig.2-10.15

15: No fire
See Fig.2-10.16

Fig.2-10.16

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STC500S3

16: Caution for overheat

See Fig.2-10.17

Fig.2-10.17

17: Caution for locked outrigger tray

See Fig.2-10.18

Fig.2-10.18

18: Caution for electrocution

See Fig.2-10.19

Fig.2-10.19

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STC500S3

19: Caution for engine cover

See Fig.2-10.20

Fig.2-10.20

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STC500S3

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STC500S3

System Functions

3 System Functions
3.1 Terminology................................................................................................................ 3-3
3.2 General Description.................................................................................................. 3-12
3.3 Boom System........................................................................................................... 3-13
3.4 Turntable Assembly.................................................................................................. 3-19
3.5 Outrigger System..................................................................................................... 3-23
3.6 Superstructure Operator's Cab................................................................................. 3-28
3.7 Hydraulic System..................................................................................................... 3-37
3.8 Electrical System...................................................................................................... 3-41
3.9 Chassis..................................................................................................................... 3-82

3-1
System Functions
STC500S3

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3-2
 System Functions
STC500S3

3 SYSTEM FUNCTIONS

3.1 Terminology

This section provides the meaning of some

important terms used in this manual.

The directional terms (front, rear, right and left)

used in this manual are defined with reference
to driver’s position when seated in the carrier
driver’s cab. Their definitions remain the
same even when the crane’s superstructure is
turned.

See 3-1.1 for basic position of truck crane

Right
Jib

Front Rear
Boom

Driver’s cab Left Operator’s cab

Fig.3-1.1 Basic position of truck crane

3-3
System Functions
STC500S3

Load radius, lifting height

Load radius refers to the horizontal distance
between the crane’s center of rotation and the
vertical center of the lifted load.
Lifting height is defined for each load radius
and refers to the vertical distance between
the ground and the bottom of the boom block
raised to its uppermost position.

Maximum lifting height

Maximum lifting height refers to the maximum
lifting height allowed.

See Fig.3-1.2 for basic information of truck

crane

Lifting height

Load radius
Center of rotation

Fig.3-1.2 Basic information of truck crane

3-4
 System Functions
STC500S3

Boom length, boom angle

Boom length refers to the distance from the
pivot pin at the foot of the boom to the center
axis of the sheave at the boom head.
Boom angle refers to the angle formed by the
boom’s centerline and the horizontal.

See Fig.3-1.3 for basic information of truck

crane

gth
len
om
Bo
Boom
angle

Fig.3-1.3 Basic information of truck crane

3-5
System Functions
STC500S3

Jib length, jib offset angle

Jib length refers to the center-to-center
distance as illustrated in the figure below.
Jib offset angle refers to the angle formed by
the centerline of a telescoped out jib and the
centerline of the boom.

See Fig.3-1.4 for basic information of truck

crane

Jib offset angle

Jib length

Fig.3-1.4 Basic information of truck crane

3-6
 System Functions
STC500S3

Rated lifting capacity

Rated lifting capacity refers to the maximum
allowable load for a particular boom length
and load radius.
The weight of load handling device such as
blocks, slings, etc., must be considered as
part of the load.

See Fig.3-1.5 for basic information of truck

crane

= +
Weight of hook block

Rated lifting capacity Lifting capacity

Fig.3-1.5 Basic information of truck crane

3-7
System Functions
STC500S3

Without load
Without load is used to indicate that no load is
being lifted on the hook block.

Over-front, over-rear, over-side

Over-front refers to the forward working
area of the carrier for which lifting capacities
have been rated and listed in the rated lifting
capacities table.
Over-rear corresponds to the rear working
area for which lifting capacities have been
rated and listed in the rated lifting capacities
table.
Over-side refers to the working area not
included in over-front and over-rear.

See Fig.3-1.6 for basic information of truck

crane

Over-side

Over-front Over-rear

Over-side

Fig.3-1.6 Basic information of truck crane

3-8
 System Functions
STC500S3

Stability section, strength section

Stability section refers to the section of the
rated lifting capacity table in which the major
factor for determining lifting capacity is the
stability of the crane.
Strength section refers to the section of the
rated lifting capacity table in which the major
factor for determining lifting capacity is the
structural strength of the crane.
In the rated lifting capacity table, the
capacities given above the blue line are those
determined based on structural strength, and
the capacities given below are determined
based on stability.

Over-front, over-side and over-rear

capacities
Over-front capacity refers to the rated lifting
capacity that can be lifting in the over-front
area.
Over-rear capacity refers to the rated lifting
capacity that can be lifting in the over-rear
area.
Over-side capacity refers to the rated lifting
capacity that can be lifting in the over-side
area.

360-degree capacity
360-degree capacity means that the lifting
capacities are the same regardless of the area
in which the load is lifted.

3-9
System Functions
STC500S3

Outrigger extension widths

Outrigger extension width refers to the
horizontal distance between the centers of
the right and left outrigger floats when the
outriggers are extended.

(1) Full extension width of outriggers <L1>

The distance between outriggers when thay
are fully extended.

(2) Middle extension width of outriggers <L2>

The distance between outriggers when they
are extended halfway.

(3) Minimum extension width of outriggers

<L3>
The distance between outriggers when they
are not extended.

3-10
 System Functions
STC500S3

Capacities with outriggers at full extension,

middle extension and minimum extension
(1) Capacities with outriggers at full extension
Lifting capacities specified for a crane
supported on fully extended outriggers.
(2) Capacities with outriggers at middle
extension
Lifting capacities specified for a crane
supported on outriggers extended halfway.
(3) Capacities with outriggers at minimum
extension
Lifting capacities specified for a crane
supported on outriggers not extended.

Raising load just clear of ground

This phrase is used to express the operation
where the load is hoisted up a few centimeters
above the ground and held at that position.

See Fig.3-1.7 for basic information of truck

crane

L3
L2
L1

Fig.3-1.7 Basic information of truck crane

3-11
System Functions
STC500S3

3.2 General Description

STC500S3 truck crane is mainly composed of

boom system, turntable assembly, operator’s
cab on superstructure, hydraulic system,
electrical system and chassis.

See Fig.3-2.1 for the machine general drawing

of STC500S3.

1 2 4 3 5 6

Fig.3-2.1 Machine general drawing of STC500S3

1-Boom system 2-Chassis 3-Electrical system 4-Hydraulic system
5-Operator’s cab on superstructure 6-Turntable assembly

Truck crane can be divided into chassis and

superstructure.

Superstructure is composed of boom

system, turntable assembly, hydraulic system
and electrical system on superstructure.
Superstructure is the working equipment of
truck crane, it is used for lifting weights.

Chassis is composed of hydraulic system and

electrical system on chassis. Chassis is used
for truck crane traveling and superstructure
supporting.

3-12
 System Functions
STC500S3

3.3 Boom System

Boom system is the crucial part of truck crane,

and the most important supporting structure
for the lifting operation.

Strength and rigidity of boom would have

direct impact on the performance of truck
crane.

See Fig.3-3.1 for component diagram of the

boom system on STC500S3.

Fig.3-3.1 Component diagram of the boom system on STC500S3

1-Telescoping mechanism 2-Boom 3-Jib 4-Boom nose pulley

3-13
System Functions
STC500S3

3.3.1 Telescoping mechanism

The telescoping mechanism of STC500S3

is composed of telescoping cylinder and
telescoping rope.

See Fig.3-3.2 for component diagram of the

telescoping mechanism on STC500S3.

6 5 4 3 2 1

7 8 9 10 11

Fig.3-3.2 Component diagram of the telescoping mechanism on STC500S3

1-1st boom section 2-Retracting rope for 4th boom section 3-2nd boom section 4-3rd boom section
5-4th boom section 6-5th boom section 7-Extending rope for 4th boom section
8-Extending rope for 5th boom section 9-Retracting rope for 5th boom section
10-Telescoping cylinder II 11-Telescoping cylinder I

3-14
 System Functions
STC500S3

Telescoping cylinder I is mounted on the end

of 2nd boom section through pin shaft. When
oil enters the non-rod chamber of telescoping
cylinder I, the cylinder extends forwards,
driving the 2nd boom section to extend.
Meanwhile, 3rd, 4th and 5th boom sections
assembled inside the 2nd boom section are
thus extended synchronously along with the
2nd bom section.

When telescoping cylinder II extends, it drives

the 3rd boom section to extend through the pin
shaft mounted on the end of 3rd boom section.
Synchronously, the telescoping rope reeved
through the head of telescoping cylinder II
drives the 4th boom section to extend; while
5th boom section is driven to extend through
the rope reeved through the end of 5th boom
section and the head of 4th boom section.

The principle for synchronous extending

goes the same with the one for synchronous
retracting in a reverse order.

3-15
System Functions
STC500S3

3.3.2 Boom

Boom is composed of basic boom, 2nd,

3rd, 4th and 5th boom sections. See Fig.3-
3.3 for component diagram of the boom on
STC500S3.

Fig.3-3.3 Component diagram of the boom on STC500S3

1-Rope press wheel 2-Rope support wheel 3-Pulley set 4-5th boom section
5-4th boom section 6-3rd boom secton 7-2nd boom section 8-1st boom section

3-16
 System Functions
STC500S3

3.3.3 Jib

Jib adpots truss combined solid structure. It

can make up the operation height and extend
the operation range of boom. Jib is mainly
composed of jib assembly and jib pedestal
assembly.

See Fig.3-3.4 for component diagram of the jib

on STC500S3.

1
8 6

2 4

Fig.3-3.4 Component diagram of the jib on STC500S3

1-Jib assembly 2-Connecting plate 3-Jib pedestal assembly 4-Supporting plate
5-Pulley subassembly 6-Folding jib 7-Supporting bracket for folding jib 8-Supporting bracket assembly

3-17
System Functions
STC500S3

3.3.4 Boom nose pulley

Boom nose pulley is mounted on the front

lower part of boom head, and it is a hoisting
system with single pulley. Commonly, boom
nose pulley conducts lifting operation through
the single number of parts of line of auxiliary
hook block. Boom nose pulley functions
to improve the lifting efficiency of boom.
However, due to the limitation from the single
wire rope, the lifting capacity of STC500S3 is
less or equals to 4t.

See Fig.3-3.5 for component diagram of the

boom nose pulley on STC500S3.

Fig.3-3.5 Component diagram of the boom nose pulley on STC500S3

1-Boom nose pulley bracket 2-Pulley subassembly

3-18
 System Functions
STC500S3

3.4 Turntable Assembly

See Fig.3-4.1 for component diagram of the

turntable assembly on STC500S3.

1 2

5
6

7
8

Fig.3-4.1 Component diagram of the turntable assembly on STC500S3

1-Hoisting system 2-Monitor mirror assembly on turntable 3-Balance weight 4-Machine shed
5-Turntable 6-Swing mechanism 7-Turntable lock up device 8-Luffing cylinder 9-Hook block

3-19
System Functions
STC500S3

3.4.1 Hoisting system

Hoisting system mainly consists of main/

auxiliary winch reducer, main/auxiliary hook
block and main/auxiliary wire rope. As shown
in Fig.3-4.2, hydraulic motor drives main winch
reducer to execute swing operation, and the
wire rope on main winch drives main hook
block to rise or lower through the fixed pulley
set beneath the boom head and the movable
pulley set on the main hook block. The change
of hydraulic motor’s rotation direction can be
done by changing its oil supply direction, which
enables main hook block to execute hoisting
operation. (Auxiliary hook block operates with
the same principle.)

3 6
5

7 8

Fig.3-4.2 Component diagram of the hoisting mechanism on STC500S3

1-Auxiliary winch reducer 2-Main winch reducer 3-Main hook block 4-Auxiliary hook block
5-Auxiliary wire rope 6-Main wire rope 7-Securing device for hook 8-Rope guard

3-20
 System Functions
STC500S3

3.4.2 Swing system

The crane superstructure executes swing

operation in the following way: hydraulic
swing motor drives swing reducer to swing,
and the pinion on the reducer output end
engages with the outter gear ring on swing
support. The outter gear ring on swing
support can not rotate for it is fixed on the
chassis pedestal ring with bolts. Therefore,
the swing reducer mounted on the base plate
of turntable is driven to execute 360° swing
operation together with the turntable by pinion.
The whole superstructure is driven to swing
through turntable.

Fig.3-4.3 Component diagram of the swing mechanism on STC500S3

1-Counterweight 2-Turntable 3-Swing reducer 4-Swing support

3-21
System Functions
STC500S3

3.4.3 Counterweight

When there is need to disassemble or

assemble the turntable, it is a must to remove
the counterweight prior to the turntable.
See Fig.3-4.4.

Fig.3-4.4 Counterweight
1-Tail box 2-Counterweight

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 System Functions
STC500S3

3.5 Outrigger System

The outrigger system supports, stabilizes and

level the truck chassis system during crane
operations.

The crane is equipped with 4 horizontal

outriggers, 4 vertical outriggers located at
left front, right front, left rear and right rear.
Basides, there is a front jack equipped under
the driver's cab. See Fig.3-5.1 for the diagram
of all the outriggers on the crane.

Fig.3-5.1 Diagram of all the outriggers on the crane

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System Functions
STC500S3

3.5.1 Outrigger control

The chassis outrigger circuit includes

chassis multi-port valve, outrigger cylinder
and hydraulic lock. The chassis multi-port
functions to extend/retract the 4 horizontal
outriggers cylinders along with the 5 vertical
outriggers cylinders on the chassis. Meanwhile,
the hydraulic lock is employed to prevent the
retraction of vertical outriggers during lifting
operation and the extending during traveling
and parking.

The control couplings for horizontal, vertical

cylinders (coupling 1, 2, 3, 4, 5) inside the
multi-port valve can be reset by hand, and the
spool can not reset automatically. However,
the telescoping operation control coupling 6
can be reset through spring, and the spool can
restore to the middle position after released.
As shown in Fig.3-5.2, the spool is connected
with the control lever of corresponding
outrigger.

Fig.3-5.2 Multi-port valve on the chassis

1-Control coupling for horizontal, vertical cylinder 1 2-Control coupling for horizontal, vertical cylinder 2
3-Control coupling for horizontal, vertical cylinder 3 4-Control coupling for horizontal, vertical cylinder 4
5-Control coupling for horizontal, vertical cylinder 5 6-Telescoping operation control coupling 6

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 System Functions
STC500S3

3.5.2 Outrigger control lever

The control levers for chassis multi-port valve

are equipped on both sides of the crane,
and they are connected to the main spool of
the multi-port valve, as shown in Fig.3-5.3
and Fig.3-5.4. One side of lever is directly
connected to the multi-port valve while the
lever on the other side is connected to the
valve through connecting rod.

Actually, the chassis multi-port valve mainly

functions to control the extending/retracting
of the horizontal and vertical cylinders, also,
it is used to prepare the crane for operation
and level it during crane operation. Beside the
multi-port valve, there equips a throttle control
lever.

Fig.3-5.3 Location of outrigger control lever

1-Outrigger control lever

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System Functions
STC500S3

1 2 3 4 5 6 7

Fig.3-5.4 Outrigger control lever and throttle control switch

1-Control lever for left front horizontal & vertical outriggers
2-Control lever for right front horizontal & vertical outriggers
3-Control lever for left rear horizontal & vertical outriggers
4-Control lever for right rear horizontal & vertical outriggers
5-Control lever for the front jack 6-Master control lever 7-Throttle control switch

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 System Functions
STC500S3

As shown in Fig.3-5.5, set the control lever

to the upper or lower position to maneuver
the horizontal outrigger or vertical outrigger.
With the completion of outrigger operation Upper position
(for horizontal outrigger)
(extending/retracting of horizontal/vertical
outriggers), do set the lever to the middle
position. Besides, do check whether the
levers are at the middle position before lifting
operation.
Middle position

As shown in Fig.3-5.6, set the master control

lever to the upper or lower position to retract
or extend outriggers. With the completion of Lower position
(for vertical outrigger)
outrigger operation (extending/retracting of
horizontal/vertical outrigger), do set the lever
to the middle position. Besides, do check Fig.3-5.5 Operation diagram of control lever
whether the lever is at the middle position
before lifting operation.

Note: The throttle control switch can be used

to control the operation (outrigger extending/
retracting) speed.

See chapter 4.2.3.3 starting from page 4-43 Upper position

(retracting outrigger)
to page 4-56 for detalied operation steps of
outrigger.

Middle position

(Master control lever)

Lower position
(extending outrigger)

Fig.3-5.6 Operation diagram of the master

control lever

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System Functions
STC500S3

3.6 Superstructure Operator's

Cab

Crane lifting operation is mastered by the

control levers inside the superstructure
operator’s cab. See Fig.3-6.1 for Component
diagram of the superstructure operator’s cab
on STC500S3.

Fig.3-6.1(1) Component diagram of the superstructure operator’s cab on STC500S3

1-Control panel 2-Crane operator’s cab 3-Control lever 4-Instrument desk assembly 5-Lamp bracket
6-Throttle pedal 7-Control device 8-Aluminum door handle

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 System Functions
STC500S3

Fig.3-6.1(2) Component diagram of the control device on STC500S3

1-Swing link 2-Push-and-pull rod 3-Protective device 4- Double force rod assembly
5-Control flexible shaft 6-Control lever 7-Swing link shaft

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System Functions
STC500S3

3.6.1 Instruction on control panel

Fig.3-6.2 Control panel illustration

1-Control panel

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 System Functions
STC500S3

S7 S10

H3 S8 S4
S2 S1
H2 H5 S9 S5

H1 H4 S6 S3

Fig.3-6.3 Arrangement diagram of the control panel on STC500S3

S1-Ignition key S2-Overload release switch
S3-Heater switch S4-Emergency switch
S5-Engine shutdown switch S6-Washer switch
S7-Work lamp switch S8-Instrument lamp switch
S9-Wiper switch S10-Master switch
H1-Power indicator lamp H2-Boom telescoping indicator lamp
H3-Overwinding indicator lamp H4-Overlowering indicator lamp
H5-Auxiliary winch operation indicator lamp

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System Functions
STC500S3

Function description of each switch:

1) Ignition key (S1)

Gear 0 represents cut-off and no-supply; I

represents power; II represents spare power
and III represents start. Insert key into ignition
key, rotate Gear I clockwise to energize the
whole system. Rotate key to Gear III to start
the engine. Each start should not exceed 5
seconds. If the engine still fails to start after
3~5 times' try, find out the cause and eliminate
it accordingly.
See Fig.3-6.4 Fig.3-6.4 Ignition key

2) Overload release switch (S2)

When crane is overloaded (the crane

moment exceeds 100% of the rated one), the
improper operations would be immediately
limited by moment limiter through operation
program (luffing up, hook lowering, swing are
permitted while luffing down, telescoping of
boom, hook rising are limited). Limitation for
overload can be cancelled through this switch.
With the activation of overload release key,
the overload warning information would be
dispalyed. This switch can only be applied in Fig.3-6.5 Overload release switch
some special occasions like machine repair or
adjustment. It can not be pressed during the
normal operation of truck crane. SANY will not
bear any responsibility for the damage caused
by improper use of this switch.
See Fig.3-6.5

3) Heater switch (S3)

Press this switch to active heater system.

See Fig.3-6.6

Fig.3-6.6 Heater switch

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STC500S3

4) Wiper switch (S9)

Set wiper switch to Gear I to operate the wiper

at low speed. The wiper operates at high
speed when the wiper switch is set to Gear II.
See Fig.3-6.7

Fig.3-6.7 Wiper switch

5) Engine shutdown switch (S5)

Press this switch to shutdown the engine.

See Fig.3-6.8

6) Washer switch (S6) Fig.3-6.8 Engine shutdown switch

With the activating of this switch, the washer

motor starts to operate with detergent sprayed.
See Fig.3-6.9

NOTICE
Operating wiper with no detergent in fine
weather may scratch the glass. Do operate
the wiper together with detergent. In
case of no detergent, do not operate the
wiper more than 5 seconds continuously.
Otherwise, the washer motor may be
burnt. Never use wiper without detergent.

Fig.3-6.9 Washer switch

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System Functions
STC500S3

7) Master switch (S10)

Activate this switch to set up pressure for

crane operation.
See Fig.3-6.10

Fig.3-6.10 Master switch

8) Emergency switch (S4)

When crane is under dangerous state (under

the state of overwinding, "Zero angle",
"Max. angle" and loaded telescoping), those
operations would be immediately limited
through the moment limiter.
Limitation for overwinding, operation under
Zero angle/Max. angle, loaded telescoping can
be cancelled through this switch. However, it
should be cautiously used.
See Fig.3-6.11

Fig.3-6.11 Emergency switch

9) Work lamp switch (S5)

Set work lamp switch to Gear I, work lamp

inside the cab will come on. Set it to Gear II,
work lamp on the boom along with the one
inside the cab will come on simultaneously.
See Fig.3-6.12

Fig.3-6.12 Work lamp switch

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 System Functions
STC500S3

10) Instrument lamp switch (S8)

Press this switch to light up all the background

lamps inside the rocker switch.
See Fig.3-6.13

Fig.3-6.13 Instrument lamp switch

11) Power indicator lamp (H1)

This lamp comes on when superstructure is

energized.
See Fig.3-6.14

Fig.3-6.14 Power indicator lamp

12) Overwinding indicator lamp (H3)

This lamp comes on with buzzer sounding

when the main or auxiliary winch is
overwound.
See Fig.3-6.15

Fig.3-6.15 Overwinding indicator lamp

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STC500S3

13) Overlowering indicator lamp (H4)

This lamp comes on with buzzer sounding

when the wire rope on main or auxiliary winch
is overlowered.
See Fig.3-6.16

Fig.3-6.16 Overlowering indicator lamp

14) Auxiliary winch operation indicator lamp

(H5)

This lamp is highlighted on when auxiliary

winch is under operation.
See Fig.3-6.17

Fig.3-6.17 Auxiliary winch operation indicator

lamp

15) Boom telescoping indicator lamp (H2)

This lamp comes on when boom is under

telescoping.
See Fig.3-6.18

Fig.3-6.18 Boom telescoping indicator lamp

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 System Functions
STC500S3

3.7 Hydraulic System

Truck crane hydraulic system is composed

of hydraulic pumping plant, chassis and
superstructure hydraulic system. Hydraulic
pumping plant is connected to superstructure
through center swing tower. Superstructure
hydraulic system operates other systems
through a multi-port valve and a swing reverse
valve.

3.7.1 Hydraulic pumping plant

Hydraulic system is a load feedback variable

system. The main oil pump is composed
of variable plunger pump and gear pump.
As shown in Fig.3-7.1, plunger pump
supplies power for all operations except
swing; while gear pump provides power for
chassis outrigger, the swing operation of
superstructure.

1 2 3 4 5

Fig.3-7.1 Component diagram of the hydraulic pipeline on STC500S3

1-Oil suction pipe of plunger pump 2-Oil suction pipe of gear pump 3-Hydraulic oil tank
4-Oil return pipe assembly 5-Center swing tower 6-Main oil pump assembly

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System Functions
STC500S3

3.7.2 Hydraulic system on chassis

Hydraulic system on chassis covers oil pump,

oil tank and chassis outrigger oil circuit.

Main oil pump sucks oil from chassis hydrauic

oil tank and then delivers pressure to each
actuator on superstructure and chassis.

Chassis outrigger oil circuit consists of

chassis multi-port valve, outrigger cylinder
a nd hydraulic lock. Chassis multi-p o r t
valve controls the extending/retracting of
4 horizontal and 5 vertical cylinders on the
chassis. Hydraulic lock can effectively prevent
that the vertical outrigger cylinder may retract
during hoisting and extend when traveling or
parked.

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 System Functions
STC500S3

3.7.3 Hydraulic system on

superstructure

Hydraulic system on superstructure covers

the systems of swing, luffing, telescoping and
main/auxiliary winch.

Swing operation is realized as follows: swing

motor drives the swing reducer to make the
turntable swing around the center.

Telescoping operation is executed as follows:

the telescoping cylinder drives 2nd, 3rd and
4th boom sections to telescope via the rope
arranging device.

Luffing operation is realized as follows: the

telescoping of luffing cylinder controls the
rising or lowering of boom.

Winching operation is executed as follows: the

winch motor drives the winch reducer to make
the rolling drum, wire rope and hook block rise
or lower.

Fig.3-7.2 Location of control lever

1-Control lever

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System Functions
STC500S3

Fig.3-7.3 Structure diagram of pull-rod type conytrol lever

1-Control lever for main winch 2-Control lever for auxiliary winch 3-Control lever for luffing operation
4-Control lever for telescoping operation 5-Control lever for swing operation
6-Swing right 7-Swing left 8-Telescope out 9-Telescope in 10-Luffing down 11-Luffing up
12-Lower auxiliary winch 13-Raise auxiliary winch 14-Lower main winch 15-Raise main winch

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 System Functions
STC500S3

3.8 Electrical System

3.8.1 Electrical equipments inside the

cab

3.8.1.1 Inner structure of operator's cab

Fig.3-8.1 Inner structure of operator’s cab

1-Roof wiper 2-Control panel 3-Moment limiter display screen 4-Front wiper

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System Functions
STC500S3

3.8.2 Safety device

3.8.2.1 Moment limiter

WARNING
Improper operation of moment limiter
could cause severe damage on the crane
or bodily injury.

SYML series moment limiter (LMB in short) is

composed of controller (SYMC), touch screen,
length/angle sensor, oil pressure sensor and
height limiter, etc.

Display interface includes 10 kinds of pages:

safety prompt page, main menu, information
page, password page, system function page,
length adjustment page, angle adjustment
page, idle load adjustment page, load
adjustment page and time setting page. The
default start page is safety prompt page. The
display keys are F1-F8 in sequence. Each key
is defined with different functions on different
pages, refer to definition of key function in
each page for operation.

F1 F2 F3 F4 F5 F6 F7 F8

3-42
 System Functions
STC500S3

1) Safety prompt page

The safety prompt page is shown on the
screen after start. It reminds the user to extend Safety Prompt
out all the outriggers before starting operation
to ensure operation safety.
See Fig.3-8.2
Truck crane can work only when
outriggers have been fully extended

Make sure outriggers have been

fully extended

Press YES to enter into Main Menu

Yes

Fig.3-8.2 Safety prompt page

2) Main menu SANY Truck Crane

See Fig.3-8.3 for information covered in the
Moment percentage :
main menu: Working condition:
hook block of boom

Moment percentage: display the actual value Magnification: 12

of moment in bar graph and percentage Boom length: 11.5m

Rated weight: 50.0t
values;
Actual weight: 50.0t
Display the boom length, angle, range, rated
Angle: 75°
weight, actual weight in real time;
Display the current working condition. Display
the current number of parts of line under the
Raduis:
working condition of boom;
Display faults & warning information as well as 5/20 07

the current time in real time.

Working Magni Infor Adjust Emer
Menu
See Fig.3-8.3 condition fication mation ment Mute gency

Fig.3-8.3 Main menu

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System Functions
STC500S3

3) Information page
Press F4 on main menu page to enter into Basic information
information page. This page displays sampling
Lower chamber pressure
information of several sensors along with Upper chamber pressure

information about setting of length and angle Sampling value of length

sensor. Sampling value of angle

Sampling value of lower chamber pressure

See Fig.3-8.4
Sampling value of upper chamber pressure

Total operating time

Base boom

Fully-extended boom

Large angle

Small angle

Back

Fig.3-8.4 Information page

4) Password page
Press F1 (menu) on main menu page to Type in password：
enter into password page. If the password is
correct, press confirm key to enter into system ******
function page. If the password is incorrect or
no password typed in, press confirm key two
times continuously to return to main menu.
See Fig.3-8.5

1 2 3 4 5 YES

Fig.3-8.5 Password page

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 System Functions
STC500S3

5) System function page

If the password is correct, press F8 (confirm)
to enter into system function page. System Function
System function page is mainly used to select
sub-page, including: length adjustment, Length adjustment
angle adjustment, idle load adjustment,
load adjustment and time setting. Press F2 Angle adjustment
(upwards) or F3 (downwards) to move the
cursor. Press F8 (confirm) to enter into the Idle load adjustment

selected page.
Load adjustment
Press F1 (return) to return to main menu.
See Fig.3-8.6
Time setting

Back Yes

Fig.3-8.6 System function page

Length Adjustment
6) Length adjustment page
See Fig.3-8.7 for its covered information. Retract the boom to the Min.Length

Type in base boom length 11.8m

Sampling value

Extend the boom to the Max.Length

Type in base boom length 40.5m

Sampling value

Select Tens Units Deci

Back Yes
mals

Fig.3-8.7 Length adjustment page

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System Functions
STC500S3

7) Angle adjustment page

Angle Adjustment
See Fig.3-8.8 for its covered information.
Adjust the boom angle to the Min. Angle

Type in Max. Angle 80

Sampling value

Adjust the boom angle to the Max. Angle

Type in Min. Angle 15

Sampling value

Select Tens Units Deci

Back Yes
mals

Fig.3-8.8 Angle adjustment

8) Idle load adjustment page Note: operate as followed

All operations should be conducted at an angle of 60

Select the data needs to be modified through

F2 (selected data will be displayed with
highlight). Confirm with F8 after modification. Boom, main hook_10.5m

Return to previous page through F1 if no Boom, main hook_14.5m

modification is needed or after confirming on Boom, main hook_18.3m

the modification.
Boom, main hook_22.1m
See Fig.3-8.9
Boom, main hook_25.9m

Boom, main hook_29.7m

Boom, main hook_32.5m

Load Angle Load

Back Select Yes

Fig.3-8.9 Idle load adjustment page

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 System Functions
STC500S3

9) Load adjustment page

Parameters covered including: boom main Load adjustment
hook, boom auxiliary hook, jib and load.
See Fig.3-8.10 Boom, main hook_5t

Boom, main hook_15t

Boom, main hook_20t

NOTICE Boom, main hook_2t

This machine is equipped with overload Jib 1 0°_2t

release switch to disable the protection
Load
f u n c t i o n f r o m m o m e n t l i m i t e r. T h i s
function must be applied with instruction
from service personnel appointed by our Back Select Hund
reds
Tens Units Yes

company. We takes no responsibility for

damages on the crane due to unauthorized
implementation of this function by the Fig.3-8.10 Load adjustment page
customer.

10) Time setting page

Time Settiing
Enter into the interface as shown in the
illustration on the right. Set the year, month,
Year
date, hour and minute in sequence. Press
confirm key to save or press the return key to Month
exit the page.
See Fig.3-8.11 Date

Hour

Minute

Back More Less Yes

Fig.3-8.11 Time setting page

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System Functions
STC500S3

3.8.2.2 3-ring protector

To prevent winch rope from being released

thoroughly, the operation of hook lowering will
be limited when there are about three loops
of wire rope left. This limit can be released
through hook rising.
See Fig.3-8.12

3-ring protector

Fig.3-8.12 Location of 3-ring protector

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 System Functions
STC500S3

3.8.2.3 Master switch of the system

This safety device is designed to prevent

malfunction due to the misuse of control lever.
The master switch S10 must be switched
on before starting the operation. It must
be switched off after operation and before
operator leaves the crane.
See Fig.3-8.13

Fig.3-8.13 Master switch

3.8.2.4 Height limiter

To prevent the confliction of hook block and

the pulley on boom head during hoisting.
The operation of hook rising will be restricted 1
once the hook reaches the specified height.
In this case, the limit can be released by hook
lowering or through the emergency switch S4.

See Fig.3-8.14 for the location of height limiter

See Fig.3-8.15 for emergency switch

2
3

Fig.3-8.14 Location of height limiter

1-Height limiter assembly 2-Round weight 3-Weight

Fig.3-8.15 Emergency switch

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System Functions
STC500S3

3.8.2.5 Overload warning and limitation

When the crane moment exceeds 100% of the

rated one, warning signal would be displayed
on the main menu with buzzer sounding at the
same time. The improper operations would
be immediately limited by moment limiter
through operation program (luffing up, hook
lowering are permitted while luffing down,
telescoping of boom, hook rising are limited).
With the activation of overload release key,
the overload warning information would be
dispalyed.

3.8.2.6 Overwinding warning and limitation

When the hook block is raised to a position

enables it to prop up the weight on height
limiter, warning signal would be displayed on
the main menu with buzzer sounding at the
same time. Then, the improper operations
would be immediately limited by moment
limiter through operation program (luffing up,
telescoping in of boom and hook lowering are
permitted while luffing down, telescoping out of
boom, and hook rising are limited). However,
those limitations can be released through
emergency switch.

3.8.2.7 Overlowering warning and limitation

When there are only 3 loops of hoist rope

left, warning signal would be displayed on the
main menu with buzzer sounding at the same
time. Then, the improper operations would be
immediately limited by moment limiter through
operation program (hook lowering is limited).

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 System Functions
STC500S3

3.8.2.8 "Zero angle" warning and limitation

When the angle of boom reaches the value

below 0, warning signal would be displayed
on the main menu with buzzer sounding at
the same time. Then, the improper operations
would be immediately limited by moment
limiter through operation program (luffing
down, telescoping of boom and hook lowering
are limited). However, those limitations can be
released through emergency switch.

3.8.2.9 "Max.angle" warning and limitation

When the angle of boom reaches the value

exceeding the specified Max.angle, warning
signal would be displayed on the main menu
with buzzer sounding at the same time.

3.8.2.10 Tri-color warning lamp

Tri-color warning lamp is equipped at the front

of crane operator's cab, commonly, it is used
to tell the lifting condition to the staff outside
the cab.

Green light: normal hoisting with moment

percentage less than 90%

Yellow light: to be overloaded with moment

percentage between 90%~100%

Red light: overloaded with momnet percentage

exceeding 100%

3.8.2.11 Limitation on loaded telescoping

When the crane moment reaches 30% of the

rated one, the improper operations would be
immediately limited by moment limiter through
operation program (telescoping of boom is
limited). This limitation can only be released
through emergency switch.

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System Functions
STC500S3

3.8.3 Equipments inside the cab

Equipments inside the cab include instrument

panel, control mechanism and driver's seat.

Instrument panel is mainly composed of

instruments, switches and indicator lamps.
See Fig.3-8.16

1 2 3 16 4

警告：严
禁高档起
CAUTION：
Forbid underway
in top grade
步！
！

警告：只
允许用四
CAUTION：A
LLOW TO
档取力操
BOOST 作！
BY FOURT
H GEAR ONLY！

5 6 7 8 9 10 11 12 13 14

15

Fig.3-8.16 Location of instrument and control mechanism

1-Engine speed indicator 2-Signal control lamp 3-Speedometer 4-Rocker switch set 5-5-coupling rocker switch
6-Left compound switch control lever 7-Clutch pedal 8-Steering wheel 9-Foot brake 10-Throttle pedal
11-Right compound switch control lever 12-Warm and cold air control switch 13-Radio
14-Cigar lighter 15-Transmission control lever 16-Hand brake

3-52
 System Functions
STC500S3

3.8.4 Instrument panel inside the cab

3.8.4.1 Instruments

Red zone
Yellow zone
Green zone
Green zone

Fig.3-8.17 Instruments
1-Engine speed indicator 2-Water temperature gauge 3-Fuel gauge 4-Speedometer

(1) Engine speed indicator

The tachometer indicates engine speed

(r / min), which means the engine’s number of
revolutions per minute; its signal is taken from
flywheel rotary speed sensor, and the lower
hop value is total running hours of the engine.
Engine speed within 1000 ~ 1600 r / min can
save fuel and prolong engine life.

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System Functions
STC500S3

(2) Water temperature gauge

It is used to indicate engine coolant

temperature. Once the key switch is set to
ON position, the gauge will work. Green zone
means the normal water temperature while
yellow area means advance warning water
temperature. When the pointer is at the red
zone, stop the machine as soon as possible to
add water for cooling.

(3) Fuel gauge

Fuel gauge is used to indicate the quantity

of oil in fuel tank, when the key switch is set
to the ON position, the gauge will work. The
region around 0 indicates oil will be exhausted
to remind the drivers to add clean fuel as soon
as possible.

(4) Speedometer

The indicated value on the speedometer

is the truck traveling speed (km/h), and the
accumulated mileage will be displayed on the
screen.

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 System Functions
STC500S3

3.8.4.2 Switch

(1) Key switch

The key switch is located under the right side

of steering wheel. It has four gears: namely
LOCK, ACC, ON and S.
See Fig.3-8.18

LOCK: When key switch is set at this position,

power is completely cut off. At the moment,
key can be pulled out or inserted into.

ACC: When engine is stopped, accessories

like radio recorder player, cigar lighter and
Fig.3-8.18 Key switch
wiper can be operated by setting key to ACC
position.

ON: When key is set to ON position, the whole

electrical system is energized.

S: abbreviation of the word START. Start the

engine by turning the key from the position ON
to S. Engine will automatically bounce back to
ON position after released. After engine start,
never turn the key to S position.

(2) Cigar lighter

When there is need to light a cigar, directly

press the cigar lighter inside, then release it
and wait about 10s. Resistance wire in the
front of the cigar lighter will pop out after
burned red. Then you can pull out the cigar
lighter and put it back.
See Fig.3-8.19

Fig.3-8.19 Cigar lighter

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System Functions
STC500S3

(3) Rocker switch

(a) Master power switch

With the activation of this switch, rocker

switch indicator lamp lights up and the whole
vehicle is energized. Do cut off the power
when conducting inspection or maintenance
operation on the vehicle circuit.
See Fig.3-8.20

NOTICE
Never shut off the master power switch
when engine is under operation.
Fig.3-8.20 Master power switch

(b) Power takeoff switch

Press this switch downwards to activate

t h e p o w e r t a k e o ff d e v i c e a n d l i g h t u p
the corresponding indicator lamp on the
instrument. Power takeoff device can be
deactivated with indicator lamp going off by
pressing this switch forwards.
See Fig.3-8.21

Fig.3-8.21 Power takeoff switch

(c) Power takeoff cancel switch

To cancel power takeoff, do firstly restore the

power takeoff switch to its original position.
Then, cancel power takeoff by pressing the
power takeoff cancel switch.
See Fig.3-8.22

Fig.3-8.22 Power takeoff cancel switch

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 System Functions
STC500S3

(d) Inter-wheel differential lock switch

When wheels slip or fall into pits, inter-wheel

differential lock can be employed to improve
the machine passing ability. When machine
is parked, the inter-wheel differential lock can
be engaged only after the disconnection of
clutch. This indicator lamp comes on after
the activation of inter-wheel differential lock
switch. It indicates inter-wheel differential lock
is under operation.

The vehicle can only travel in straight when

inter-wheel differential lock is applied. Remove Fig.3-8.23 Inter-wheel differential lock switch
the inter-wheel differential lock after the
machine has passed muddy roads. Never turn
the machine if the indicator lamp continues to
illuminate. Operator should stop the vehicle to
identify and eliminate the problem. Otherwise,
the gears on inter-wheel differential may be
seriously damaged.
See Fig.3-8.23

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System Functions
STC500S3

(e) Inter-axle differential lock switch

When wheels slip or fall into pits, inter-axle

differential lock can be employed to improve
the machine passing ability. When machine
is parked, the inter-axle differential lock can
be engaged only after the disconnection of
clutch. This indicator lamp comes on after the
activation of inter-axle differential lock switch.
It indicates inter-axle differential lock is under
operation.

The vehicle can only travel in straight when Fig.3-8.24 Inter-axle differential lock switch
inter-axle differential lock is applied. Remove
the inter-axle differential lock after the machine
has passed muddy roads. Never turn the
machine if the indicator lamp continues to
illuminate. Operator should stop the vehicle to
identify and eliminate the problem. Otherwise,
the gears on inter-axle differential may be
seriously damaged.
See Fig.3-8.24

(f) Gas-electric horn transfer switch

The electric horn is a default selection. It has

a low sound that suitable for use in urban. The
gas horn can be activated by pressing this
switch. Compared with electric horn, it has a
louder sound that suitable for use in field.
See Fig.3-8.25

Fig.3-8.25 Gas-electric horn transfer switch

3-58
 System Functions
STC500S3

(g) Rear fog lamp switch

Press this switch when the front fog lamp is

activated. At this moment, the rear fog lamp
along with its indicator lamp on the instrument
come on. When traveling in a foggy day, this
switch can be applied to aviod accident.
See Fig.3-8.26

Fig.3-8.26 Rear fog lamp switch

(h) Warning lamp switch

Press this switch when vehicle fails, when

traveling in thick fog or when emergency
happens on the road. With the activation
of this switch, the front, rear, left and right
steering signal lamps begin to flash to catch
the attention of other passers-by and vehicle
drivers.
See Fig.3-8.27

Fig.3-8.27 Warning lamp switch

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System Functions
STC500S3

(4) Combined switch

Right control lever on combined switch

Left control lever on combined switch

Fig.3-8.28 Combined switch

Combined switch is the combination of small

lamp, head lamp, right and left steering lamps,
ultra lamp, alternating lamp, wiper, washer
switch and exhaust brake switch, etc.
See Fig.3-8.28

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 System Functions
STC500S3

(a) Turning signal indicator lamp operation

Push the left control lever forward, the right Forward

turn lamp comes on;
See Fig.3-8.29

Left control lever on combined switch

Fig.3-8.29 Push left lever forward

Pull the left control lever backward, the left

turning signal indicator lamp comes on.
See Fig.3-8.30

Backward
Left control lever on combined switch

Fig.3-8.30 Pull left control lever backward

(b) Alternating lamp switch

The alternating lamp must be applied when

traveling at night. Turn on the headlamp, move
the control lever up and down to achieve the
the changeover between high-beam and low-
beam.

(c) Ultra lamp switch

Raise and lower the left control lever, lamp

comes on and goes out to alert the vehicles
ahead that you are to overtake. When the
machine is traveling normally, no matter how
other lamps are applied, turn on the ultra lamp
through ultra lamp switch.

(d) Lighting switch

Rotate the left control lever end of combined

switch towards the operator. Front, rear
outline lamps, outline lamp, license lamp and
instrument lamp come on firstly follwed by
headlamp.

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System Functions
STC500S3

(e) Exhaust brake switch

Exhaust brake switch is located on the right

lever of combined switch.

As shown in Fig.3-8.31, press the lever end

to activate the exhaust brake with its indicator Left control lever on combined switch
lamp on. Exhaust brake can be deactivated
with indicator lamp out by pressing the Fig.3-8.31 Press the left control lever end
exhaust brake switch down again.

EURO III engine exhaust brake is controlled

by ECU. Only when the following conditions
are met, can exhaust brake solenoid valve
operate:

Pressure is enough to operate the butterfly

valve; Do not press the clutch; Do not press
the throttle; At non-neutral gear; Engine speed
exceeds 1300rad/min.

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 System Functions
STC500S3

(f) Windshield wiper switch

Rotate the right lever end of combined switch

to activate wiper. Markers on wiper are:
HI: High speed LO: Low speed
OFF: Turn off INT: Interval

(g) Windshield sprayer switch

Press the button on the right control lever end

of combined switch to activate the sprayer.
Sprayer can be deactivated by pressing the
button again. Right control lever on combined switch
See Fig.3-8.32
Fig.3-8.32 Press the right control lever end

NOTICE

Operating the wiper alone in fine weather

may scratch the glass. It should be
used together with detergent. In case
of no detergent, it cannot be operated
continuously for more than 5 seconds.
Otherwise, washer motor may be
burned out. Never operate wiper without
detergent.

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System Functions
STC500S3

3.8.4.3 Advance warning indicator lamp

Signal lamp assembly

警告：严
禁高档起
CAUTION：Forbid
underway
in top grade
步！
！

警告：只
允许用四
CAUTION：A
LLOW TO 档取力操
BOOST
BY FOURT
作！
H GEAR
ONLY！

Fig.3-8.33 Signal lamp assembly

1-Charging indicator lamp 2-Engine oil pressure indicator lamp 3-Coolant fluid temperature indicator lamp
4-Low pressure indicator lamp 5-Reverse travel indicator lamp 6-Power indicator lamp
7-Preheat system start indicator lamp 8-Rear fog lamp indicator lamp 9-High beam indicator lamp
10-Unlocked door indicator lamp 11-Exhaust brake indicator lamp 12-Inter-axle differential lock indicator lamp
13-Fuel level indicator lamp 14-Inter-wheel differential lock indicator lamp 15-PTO indicator lamp
16-Engine fault indicator lamp 17-Parking brake indicator lamp 18-Coolant level indicator lamp

3-64
 System Functions
STC500S3

(a) Charging indicator lamp

The generator is under operation once suck

lamp extinguishes after the start of engine;
while the illumination of it means the non-
operation of generator.
See Fig.3-8.34

Fig.3-8.34 Charging indicator lamp

(b) Engine oil pressure indicator lamp

The indicator lamp comes on before engine

start and goes out after the engine has been
started. This indicates the engine oil is normal.
Operator should stop the machine immediately
to trouble shoot if the indicator lamp comes
on during traveling. Never activate the engine
when this lamp is on. Fig.3-8.35 Engine oil pressure indicator lamp
See Fig.3-8.35

(c) High beam indicator lamp

Turn head lamp to the distant light, the high

beam indicator lamp will light up.
See Fig.3-8.36

Fig.3-8.36 High beam indicator lamp

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System Functions
STC500S3

(d) Inter-axle differential lock indicator lamp

This indicator lamp comes on when the inter-

axle differential lock switch is on.
See Fig.3-8.37

Fig.3-8.37 Inter-axle differential lock indicator

lamp

(e) Inter-wheel differential lock indicator lamp

This indicator lamp comes on when the inter-

wheel differential lock switch is on.
See Fig.3-8.38

WARNING

Never turn vehicle or make travel it at high

speed when the inter-wheel differential
lock indicator lamp is on. In principle,
the inter-axle differential lock should
be engaged prior to the inter-wheel
Fig.3-8.38 Inter-wheel differential lock indicator
differential lock. And the differential lock
lamp
should be immdiately released after the
vahicle has passed the uneven road.

(f) Low pressure indicator lamp

When this indicator lamp comes on with

buzzer sounding, it reminds the operator not
to move the machine for the pressure in brake
system stays below the rated value. If this
lamp comes on with buzzer sounding without
stop, do check the brake system for any
leak of air. It is recommended to activate the
exhaust assistant brake when the machine is Fig.3-8.39 Low pressure indicator lamp
traveling along a long incline.
See Fig.3-8.39

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 System Functions
STC500S3

(g) Coolant fluid temperature indicator lamp

When coolant level can not reach the specified

value or the temperature exceeds 95 ° C,
the indicator lamp comes on with buzzer
sounding. It reminds operator that the engine
is in danger.
See Fig.3-8.40

NOTICE
Fig.3-8.40 Coolant fluid temperature indicator
Add coolant full if there is no enough;
lamp
or else, engine may be damaged due to
overheat caused by continuous traveling
without sufficient coolant.

(h) Parking brake indicator lamp

Lift up the parking brake when key switch is

at ON position. At this moment, this indicator
lamp comes on.
See Fig.3-8.41

Fig.3-8.41 Parking brake indicator lamp

(i) Rear fog lamp indicator lamp

This indicator lamp comes on when rear fog

lamp is activated.
See Fig.3-8.42

Fig.3-8.42 Rear fog lamp indicator lamp

3-67
System Functions
STC500S3

(j) Preheat system start indicator lamp

When this indicator lamp comes on, it

indicates the preheat system is heating the
inlet air for engine. The engine can only be
started after the indicator lamp has gone out.
(The automatic preheat system is an optional
accessory).
See Fig.3-8.43

Fig.3-8.43 Preheat system start indicator lamp

(k) PTO indicator lamp

This indicator lamp comes on when the power

take off switch is on.
See Fig.3-8.44

Fig.3-8.44 PTO indicator lamp

(l) Reverse travel indicator lamp

This indicator lamp comes on when the

machine is conducting reverse travel.
See Fig.3-8.45

Fig.3-8.45 Reverse travel indicator lamp

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 System Functions
STC500S3

(m) Power indicator lamp

This indicator lamp comes on when the key

switch is rotated to "ON" position.
See Fig.3-8.46

Fig.3-8.46 Power indicator lamp

(n) Unlocked door indicator lamp

If this lamp is highlight on after the engine has

been started, it indicates the cab door has not
been properly locked.
See Fig.3-8.47

Fig.3-8.47 Unlocked door indicator lamp

(o) Fuel level indicator lamp

This lamp comes on when there is no enough

fuel left in the tank.
See Fig.3-8.48

Fig.3-8.48 Fuel level indicator lamp

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System Functions
STC500S3

(p) Engine fault indicator lamp

This indicator lamp comes on if there exists

any fault on the engine and goes out till the
fault has been eliminated.
See Fig.3-8.49

Fig.3-8.49 Engine fault indicator lamp

(q) Exhaust brake indicator lamp

The exhaust brake indicator lamp comes on

with the activating of exhaust brake switch. It
indicates the exhaust brake is under operation.
See Fig.3-8.50

Fig.3-8.50 Exhaust brake indicator lamp

(r) Coolant level indicator lamp

This lamp comes on when engine coolant is

below the specified value.
See Fig.3-8.51

Fig.3-8.51 Coolant level indicator lamp

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 System Functions
STC500S3

3.8.5 Warm air device and air-

conditioner system

3.8.5.1 Warm air device and air-conditioner

system on chassis

警告：严
禁高档起
CAUTION：Forbid
underway
in top grade
步！
！

警告：只
允许用四
CAUTIO
N：ALL 档取力操
OW TO
BOOST
BY FOURTH
作！
GEAR ONLY！

Warm air and air-conditioner

switch assembly

Fig.3-8.52 Location of warm air and air-conditioner switch assembly

1
5

3 4

Fig.3-8.53 Warm air control switch assembly

1-Cooling/heating mode select knob 2-A/C power switch 3-Air delivery level control knob
4-Fresh air/recirculation slide switch 5-Air outlet control konb

3-71
System Functions
STC500S3

(1) Cooling/heating mode select knob

Rotate the konb clockwise to select heating

mode. Rotate the knob counterwise to select
cooling mode.

Fig.3-8.54 Cooling/heating mode select knob

(2) A/C power switch

Press this switch to activate cooling operation.

Fig.3-8.55 A/C power switch

(3) Air delivery level control knob

Rotate the knob to the corresponding gear to

reach the required amount of air delivery.

Fig.3-8.56 Air delivery level control knob

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 System Functions
STC500S3

(4) Fresh air/recirculation slide switch

Push the slider upwards to take in fresh air

and pull it downwards to activate recirculation.

Fig.3-8.57 Fresh air/recirculation slide switch

5) Air outlet control konb 2

Turn the knob to 1 position to activate the air

outlet for face; turn it to 2 position to activate
the air outlet for feet; turn it to 3 position to
activate the air outlet for defroster.

1 3

Fig.3-8.58 Air outlet control konb

1-Air outlet for face 2-Air outlet for feet
3-Air outlet for defroster

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System Functions
STC500S3

3.8.5.2 Warm air device and air-conditioner

system on superstructure

(1) Warm air device

Warm air for operator's cab is supplied by

the heater under the turntable. The heater is
connected to the evaporator behind the seat
through a rubber pipe, and the warm air goes
out from the outlet on the evaporator.

1 2

Fig.3-8.59 Location of warm air device

1-Evaporator 2-Heater

3-74
 System Functions
STC500S3

Fig.3-8.60 Component diagram of the warm air device on STC500S3

1-Evaporator 2-Rubber pipe 3-Heater 4-Oil tank 5-Water tank

3-75
System Functions
STC500S3

(2) Air-conditioner system

The air-conditioner system is composed of

evaporator, compressor and condenser, etc.

1
5
2

Fig.3-8.61 Component diagram of air-conditioner system

1-Turntable 2-Evaporator 3-Compressor 4-Condenser 5-Operator’s cab

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 System Functions
STC500S3

(3) Air-conditioner system control panel

Air-conditioner system control panel is

equipped on the evaporator at the back of
operator's seat. See Fig.3-8.62

AIR CONDITIONER
自动(Auto) 高速( High)

新风( Fresh) 中速( Middle)

冷风( Cool) 低速( Low)

南京协众汽车空调集团有限公司

Operator's seat

Fig.3-8.62 Location of air-conditioner system control panel

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System Functions
STC500S3

Fig.3-8.63 Air-conditioner system control panel

1-Display 2-Cooling operation indicator lamp 3-Fresh air indicator lamp 4-Power indicator lamp
5-Evaporator blower rotational speed indicator lamp (high speed)
6-Evaporator blower rotational speed indicator lamp (moderate speed)
7-Evaporator blower rotational speed indicator lamp (low speed) 8-Automatic control key for air delivery
9-Air delivery set key 10-Fresh air intake port control key 11-Cooling operation control key
12-Control key for temperature increase 13-Control key for temperature decrease 14-Power switch control key

3-78
 System Functions
STC500S3

a. Turn on/off air conditioner

Pressing the power switch control key "14" in

ON
Fig.3-8.63, can light up the power indicator
lamp for control panel, energize control panel,
display the temperature inside the cab on
the screen and activate the whole system OFF
at the same time. The control panel can be
deactivated by pressing this switch once
again.
Fig.3-8.64 Power switch control key

b. Set air delivery

Pressing air delivery set key "9" in Fig.3-8.63

once: low air flow with corresponding indicator
lamp on;
Pressing it once again: moderate air flow with
corresponding indicator lamp on;
Pressing it the third time: high air flow with
corresponding indicator lamp on;
Pressing it continuously: air flow goes in turn Fig.3-8.65 Air delivery set key
"low-moderate-high-low"

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System Functions
STC500S3

c. Temperature control

1. The temperature can be set with a

decrement of 1°C through the control key "13"
shown in Fig.3-8.63, and the set temperature
can be seen from the display. Then, after 3
seconds, the set value would automatically
change into the actual temperature inside the
cab.
Also, temperature can be set with an
increment of 1°C through the control key "12" Fig.3-8.66(1) Control key for temperature
shown in Fig.3-8.63. The temperature can be decrease
set between 16°C~27°C.

Fig.3-8.66(2) Control key for temperature

increase

2. With the activation of air delivery regulating

gear and when the set temperature stays
below the one inside the cab, pressing the
cooling operation control key "11" in Fig.3-8.63
can light up the cooling operation indicator
lamp. It means the cooling operation has been
activated. Then, the cooling operation can be
deactivated with indicator lamp going off by
pressing this key once again.
Fig.3-8.67 Cooling operation control key

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 System Functions
STC500S3

d. Automatic control key for air delivery

Air delivery is regulated automatically by

pressing the control key shown in the right
illustration "8" in Fig.3-8.63. Air delivery step
AUTO
into high flow mode automatically when the
temperature inside the cab stays 1.5°C higher
than the set one; it can also step into low flow
mode when the temperature inside the cab
stays 1.5°C lower than the set one.
Fig.3-8.68 Automatic control key for air
delivery

e. Fresh air intake port control key

This key is disabled.

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System Functions
STC500S3

3.9 Chassis

Chassis is composed of driver's cab and

hereof air-conditioner system, steering system,
traveling system, brake system, transmission
system and power system.
See Fig.3-9.1

1 4 2 3 6 5

Fig.3-9.1 Component diagram of the chassis on STC500S3

1-Driver’s cab 2-Steering system 3-Traveling system
4-Power system 5-Transmission system 6-Brake system

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 System Functions
STC500S3

3.9.1 Power system

Function of the power system is to give power

by fuel combustion.
See Fig.3-9.2

5
4

Fig.3-9.2 Power system

1-Engine suspension 2-Fuel supply system 3-Air intake system 4-Exhaust system 5-Cooling system

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System Functions
STC500S3

3.9.1.1 Engine

Dongfeng Cummins ISLe340 30 is adopted in

the engine of this series crane. See Fig.3-9.3

Technical parameters:
Rated power: 250kW/2100rpm;
Rated torque: 1425N.m/1200~1500rpm;

Engine function: A power mechanism that

transforms heat energy generated by fuel
combustion into mechanical power.

Fig.3-9.3 Engine

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 System Functions
STC500S3

3.9.1.2 Engine suspension

Functions of engine suspension system are as

follows:

a. Insulate vibration;
b. Support and position the engine;
c. Protect the engine;
d. Overcome and balance the counterforce
caused by torque output.

4
18

12
11
23
5

14

6 24 10

21
9
19 8
1

22
16 2
3 15
7 13

17 25

20

Fig.3-9.4 Engine suspension

1-Engine left front support bracket assembly 2-Engine right front support bracket assembly
3-Front suspension support bracket assembly 4-Engine left rear support bracket assembly
5-Engine right rear support bracket assembly 6-Rear suspension support bracket assembly
7-Washer 8-Washer 9-Washer 10-Washer 11-Washer 12-Washer 13-Engine
14-Engine rear suspension cushion 15-Nut 16-Bolt 17-Nut 18-Bolt 19-Bolt 20-Bolt 21-Nut 22-Nut
23-Bolt 24-Bolt 25-Engine suspension cushion

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System Functions
STC500S3

3.9.1.3 Fuel supply system

Functions of engine fuel supply system are as

follows:

To g u a r a n t e e p r o p e r s t a r t a n d n o r m a l
operation of the diesel engine, there must
be sufficient fuel continuously supplied to oil
spraying pump, and fuel supply system can
just realize this function. Permitted volume for
fuel tank is 300L. To avoid any power loss, fuel
in the fuel supply system should be prevented
from being heated.

15
4
8

14

18

17

16
9

3
11 6 1
7
2 13 10

12

Fig.3-9.5 Component diagram of the fuel supply system on STC500S3

1-Washer 2-Washer 3-Washer 4-Washer 5-Washer 6-Pipe connector 7-Fuel tank 8-Throat collar 9-Nut
10-Bolt 11-Nut 12-Bolt 13-Link bolt 14-Fuel intake adaptor 15-Return joint 16-Fuel return pipe
17-Diesel filter Fuel intake pipe 18-Engine Fuel intake pipe

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 System Functions
STC500S3

3.9.1.4 Air intake system

Air intake system functions to supply as much

clean air and as equally as possible to each
air cylinder.

1. Air filter
Air filter functions to filter foreign bodies or
dust from the air, and allow clean air into air
cylinder. Besides, air filter can effectively
reduce the air intake noise. Commonly, our
truck crane is equipped with paper-filter-
cartridge contained air filter.

2. Intercooler
The intercooler functions to cool down and
pressurize the air to an appropriate range.
Doing this can make the engine combustion
be conducted properly.

25
10

23
7
24
17 2

16
8
1 13
19
22
3
14
15 18
21
11
4

12
6

20

Fig.3-9.6 Air intake system

1-Intercooler air intake pipe bracket 2-Bracket 3-Washer 4-Washer 5-Washer 6-Air filter 7-T-type clip
8-T-type clip 9-T-type clip 10-T-type clip 11-Air intake rubber hose of air compressor 12-Nut 13-Bolt 14-Nut
15-Hose hoop 16-Rubber hose 17-Rubber cushion 18-U-type bolt 19-Air intake rubber hose of turbocharger
20-Air outtake rubber hose of air filter 21-Steel pipe bracket 22-Air intake steel pipe of turbocharger
23-Air outtake steel pipe of intercooler 24-Air intake steel pipe of intercooler 25-Rubber hose of intercooler

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System Functions
STC500S3

3.9.1.5 Exhaust system

Exhaust system is employed to discharge

the emission from air cylinder with less air
discharging resistance and lower noise.
See Fig.3-9.7

19

10

11

1
15
9
8
18
6
5

12 17
7
2
4 14
3 20 13
16

Fig.3-9.7 Exhaust system

1-Exhaust pipe 1 assembly 2-Exhaust pipe 2 assembly 3-Washer 4-Washer 5-Washer 6-Washer 7-Washer
8-Washer 9-Exhaust brake valve 10-Exhaust clip 11-Muffler 12-Nut 13-Bolt 14-Nut 15-Bolt 16-Nut
17-Metal hose assembly 18-U-type bolt 19-Exhaust tail pipe 20-Exhaust pipe bracket

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 System Functions
STC500S3

3.9.1.6 Cooling system

Cooling system functions to maintain the

engine within appropriate temperature range,
under any working condition.
See Fig.3-9.8

32

11
27 9

18
2 26
14 10
5

35 13 19

1
20 34 4
15 23 17
7
21 8
25
33
24 28
37 30
3
29 6
31
36
16
22

12

Fig.3-9.8 Cooling system

1-Radiator bracket 2-Radiator pull rod assembly 3-Wahser 4-Washer 5-Washer 6-T-tpye clip 7-T-tpye clip
8-Ball valve 9-Combined radiator 10-Wind guard hood 11-Throat collar 12-Warm-air connector
13-Water rubber hose-from auxiliary water tank to engine 14-Degassing rubber hose 15-Warm-air water pipe
16-Hoop 17-Radiator cushion 18-Water intake pipe of engine 19-Nut 20-Nut 21-Bolt 22-Bolt 23-Bolt 24-Bolt
25-Nut 26-Bolt 27-Hose hoop 28-Hose hoop 29-Connecting shaft of fan 30-Water intake steel pipe
31-Water intake rubber hose 32-Expansion water tank 33-Water intake rubber of engine 34-Warm-air water pipe
35-Water outtake rubber hose of engine 36-Water pipe bracket 37-Fan

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System Functions
STC500S3

3.9.2 Transmission system

Transmission system is a power transmission

device located between the engine and driving
wheels.
See Fig.3-9.9

Fig.3-9.9 Transmission system

1-Clutch&operating device 2-Transmission&operating device 3-Drive shaft device

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 System Functions
STC500S3

3.9.2.1 Clutch & operating device

Clutch is located behind the engine and in

front of transmission. As the starting point
of the transmission system, it’s directly
connected with engine.

Main function of the clutch: guarantee the

machine can start properly, guarantee the
transmission system to work smoothly during
gear shift, and avoid overload at the same
time.

11

16 21
1
14
5 18 19
3
13

12
15

8 22

7 20
2
17 6
4

10

Fig.3-9.10 Clutch & operating device

1-Washer 2-Washer 3-Clip sleeve 4-Washer 5-Oil pipe 2 of clutch booster cylinder
6-Pressure hose assembly of clutch 7-Clutch booster 8-Clutch release bearing 9-Driven plate assembly
10-Clutch pressure disc assembly 11-Clutch oil can 12-Pipe connector 13-Pipe connector
14-Pipe connector 15-Nut 16-Oil can bracket 17-Bolt 18-Nut 19-Nut 20-Bolt 21-Hose hoop
22-Oil pipe of clutch booster cylinder

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System Functions
STC500S3

3.9.2.2 Transmission & operating device

The main functions of transmission:

1) Change transmission ratio, enlarge tractive
force and speed range to meet different
working conditions;

2) Under the condition that the spinning

direction of engine crank shaft is unchanged,
enable the machine to travel in opposite
direction;

3) Use neutral gear to interrupt the power from

engine to drive wheels. Doing this can make
enable the engine to start properly and run at
idle speed;

4) Take the transmission as power output

device for superstructure.

16

28 27

26
29
25

17
5 18

11
15 19
1
2 4
21
10

20 3
12
23 13

22

24
8 7

9
14

Fig.3-9.11 Transmission & operating device

1-Gearshift flexible axle 2-Gear selector flexible axle 3-Flexible axle bracket 4-Operating lever on transmission
5-Mounting rack assembly 6-Wahsr 7-Washer 8-Transmission assembly 9-Controller 10-Gear selector pitman arm
11-Nut 12-Nut 13-Bolt 14-Bolt 15-Bolt 16-Bolt 17-Nut 18-Nut 19-Bolt 20-Nut 21-Bolt 22-Tapping bolt
23-Dust proof hood on operating lever(L) 24-Pressure loop of dust proof(L) 25-Sleeve 26-Presser
27-Adjusting slide block 28-Pressor 29-Elastic cross beam

3-92
 System Functions
STC500S3

FAST 9JS150TA-B 9-gear transmission by

Shanxi FAST Gear Co.,Ltd is adopted on this
series crane.

Fig.3-9.12 Outline drawing of 9JS150TA-B transmission

3-93
System Functions
STC500S3

9JS150TA-B 9-gear mechanical transmission

from Shanxi FAST Co.,Ltd. is characterized
with a combined structure of the main &
a uxiliary transmission case. The m a i n
transmission cases is equipped with
sychronizer while the auxiliary one is not.

(1) For gear position of transmission, see

Fig.3-9.13.

Fig.3-9.13 Gear position of FAST transmission

(2) See the following tables for speed ratio of

each gear.

Speed ratio for RT.11509C 9-gear transmission

Gear C 1 2 3 4 5 6 7 8
Speed ratio 12.66 8.38 6.22 4.57 3.40 2.46 1.83 1.34 1.00
Reverse 12.65

3-94
 System Functions
STC500S3

Shift mode of single H double-pole left control

gearbox

Single-H shift mechanism is adopted on

combined transmission. When transmission
shifts between lower gear (gear 1 to 4) and
higher gear (gear 5 to 8), it can be operated
directly with the change lever. When shifting
from lower (gear 1 to 4) to higher (gear 5 to 8)
or vice versa, the control lever and the high-
low gear shift switch need to be operated at
the same time.

When change lever shifts from gear 4 to

neutral and is ready to up shift, push the
change lever to open the range gear valve.
Then, release the change lever and allow it
bounce back to the neutral position of 5/6
gear. Finally, push the change lever to gear 5.

When change lever turns to the neutral from

gear 5 and is ready to down shift, push the
change lever to open the gear range valve.
Then, release the change lever and allow it
bounce back to the neutral position of 3/4
gear. Finally, push the change lever to gear 4.

3-95
System Functions
STC500S3

NOTICE

Release the parking brake before starting

the machine. When pressure increases
to the value suitable for parking brake
release, start the machine with gear C or 1
according to the road conditions.

clutch pedal (completely separate clutch),

and set change lever in place.
For machine stopping, set change lever to
the neutral position within the lower gear
zone.
For reversing, overcome the resistance
from reverse gear lock with a greater shift
force. Stop the machine firstly before
setting change lever in place. Doing this
can avoid damage to the internal parts.
When moving the change lever to the
reverse gear, the reverse indicator lamp
comes on with buzzer sounding at the
same time.
For shifting from lower to higher gears
(or vice versa), there should be a short
period's pause at neutral position. Firstly
shift the high-low shift switch to the higher
(or lower) position, then set the change
lever to the required gear.
For shifting from lower gear to higher gear
(or vice versa), never trip to manipulate.
Otherwise, the service life of vice-box
synchronizer will be seriously affected.

WARNING

When the machine goes downhill, shifting

from higher to lower gears or vice versa is
extremely prohibited.

3-96
 System Functions
STC500S3

3.9.2.3 Power takeoff device

To transform the power from transmission to

the superstructure, power takeoff device is
equipped on the lengthening drive shaft at the
end of FAST transmission.

When the power takeoff device doesn’t work,

it stays in neutral position. The transmission is
set to gear 4 when it is under operation.

Fig.3-9.14 Power takeoff device

1-Drive shaft assembly on power takeoff device 2-Oil pump bracket 3-Nut 4-Bolt 5-Washer
6-Washer 7-Bolt 8-Washer 9-Coupling bush

3-97
System Functions
STC500S3

3.9.2.4 Drive shaft

Drive shaft functions to transmit power,

improve critical speed and working reliability.

18
21
24
23
10
11 17
1
8
12 13 6
22

14

16
4
2
7

20
15

19

Fig.3-9.15 Drive shaft structure

1-Drive shaft 2-Drive shaft 3-Drive shaft 4-Drive shaft 5-Drive shaft 6-Washer 7-Washer 8-Washer
9-Spacer flange 10-Washer 11-Retainer ring 12-Bolt 13-Guard plate for drive shaft 14-Nut 15-Nut 16-Bolt
17-Bolt 18-Bolt 19-Bolt 20-Nut 21-Nut 22-Bolt 23-Bolt 24-Coupling flange on oil pump

3-98
 System Functions
STC500S3

3.9.3 Steering system

Steering system is used for keep and change

the traveling direction of the machine.

Fig.3-9.16 Steering system

1-Steering drive mechanism 2-Steering pipeline

3-99
System Functions
STC500S3

3.9.3.1 Steering drive mechanism

10

8
6
11
4 5

13
1

3
14
12

Fig.3-9.17 Steering drive mechanism

1-Steering intermediate drive shaft 2-Intermediate pitman arm & bracket assembly 3-Washer 4-Washer 5-Steering
gear assembly 6-Steering plumbing arm 7-Steering power cylinder assembly
8-Steering straight drag rod assembly 9-Intermediate connecting drag rod assembly
10-Steering straight drag rod assembly 11-Bolt 12-Nut 13-Bolt 14-Angle steering gear

3-100
 System Functions
STC500S3

3.9.3.2 Steering pipeline

11
13
12

1
14

15 7
10

2 9

8
3
5
6 4

Fig.3-9.18 Steering pipeline

1-Spiral cooling pipe assembly 2-Rubber pipe 3-Steel pipe assembly 4-Steel pipe assembly 5-Pipe joint
6-Pipe joint 7-Hose hoop 8-Rubber pipe 9-Rubber pipe 10-Oil intake joint of oil pump 11-Nut 12-Bolt
13-Power steering oil tank 14-Rubber pipe 15-Rubber pipe

3-101
System Functions
STC500S3

3.9.4 Traveling system

Traveling system is used to guarantee the

normal traveling, the correct traveling direction
and operation stability of the machine.

6
2
5

Fig.3-9.19 Traveling system

1-Front suspension 2-Rear suspension 3-Wheel&tire 4-Rear axle
5-Intermediate axle 6-2nd front axle 7-1st front axle

3-102
 System Functions
STC500S3

3.9.4.1 Suspension

Suspension indicates all the connecting drive

devices between frame and axles (or wheels).

Vertical, longitudinal and lateral reactions from

the ground all act on the wheels. Suspension
is thus used to transfer those reactions along
with the torques caused by them to the frame,
enabling the truck to run normally.

5
4

Fig.3-9.20 Component diagram of the suspension on STC500S3

1-Steel plate spring 2-Buffer block 3-Balance bracket 4-U-type bolt 5-Cover plate on leaf spring

3-103
System Functions
STC500S3

3.9.4.2 Steering axle

Steering axle can make the left and right

wheels at front end turn certain angle to
achieve steering.

Do correctly mount the wheels, so that the

machine can steer easily and stably. See
Fig.3-9.21

Fig.3-9.21 The assembly of axle 1 & 2

3-104
 System Functions
STC500S3

3.9.4.3 Drive axle

Drive axle is employed to transmit the engine

power from drive axle to drive wheels. Doing
this can decelerate the speed and increase
the torque.

1
2
5

3
4

Fig.3-9.22 The assembly of axle 3 & 4

1-Bolt, nut on axle 3 wheel 2-Axle 3 3-Brake chamber on axle 3 4-Axle 4
5-Brake chamber on axle 4 6-Bolt, nut on axle 4 wheel

3-105
System Functions
STC500S3

3.9.5 Brake system

Functions of brake system:

a. Provide safety measure for high-speed

traveling or steering;

b. Decelerate or stop the traveling machine

compulsively;

c. Stabilize the traveling speed when the

machine is traveling along the incline;

d. Remain the stopped machine still (even on

the incline).

Brake system is mainly composed of valves

& pipes, brake chamber, air cylinder, air
compressor and dryer, etc. See Fig.3-9.23(1)
and Fig.3-9.23(2)

3-106
 System Functions
STC500S3

Fig.3-9.23 (1) Component diagram of the brake system on STC500S3

1-Relay valve 2-Brake chamber 3-Double-controlled two-position 5-way valve 4-Solenoid air valve set
5-Clutch booster cylinder 6-Air compressor 7-Brake valve

11

10

8 9

Fig.3-9.23 (2) Component diagram of the brake system on STC500S3

8-Dryer 9-4-loop protective valve 10-Differential valve 11-Air reservoir

3-107
System Functions
STC500S3

3.9.6 Driver's cab

STC500S3 crane chassis utilizes specially

produced, full-width driver’s cab of SANY
Bodyworks Co., Ltd., which provides you nice
figure, comfortable driving and broad view.

Fig.3-9.24 Configuration of driver’s cab

3-108
 Operation
STC500S3

Operation

4 Operation
4.1 Traveling Operation................................................................................................... 4-3
4.2 Operation before Lifting .......................................................................................... 4-30
4.3 Lifting Operation...................................................................................................... 4-74
4.4 After Operation...................................................................................................... 4-125
4.5 Operation of Accessories...................................................................................... 4-135
4.6 Operation in Cold Weather.................................................................................... 4-142
4.7 Long-term Storage................................................................................................ 4-144
4.8 Transporting the Machine...................................................................................... 4-146

4-1
Operation
STC500S3

E
G
PA
K
AN
BL

4-2
 Operation
STC500S3

4 OPERATION

4.1 Traveling Operation

4.1.1 Before traveling

4.1.1.1 Preparation and check before

dispatching a machine

(1) Check if the tire pressure is normal

(0.88MPa for single tire and 0.81MPa for
double tires), if there is any damage on the
tires;

(2) Check if the engine coolant, engine oil and

fuel levels is sufficient;

(3) Drain water off from the air reservoir;

4-3
Operation
STC500S3

(4) Check if battery terminal posts are secure

and clean, if fluid level of the electrolyte is
sufficient;

WARNING

It is dangerous to charge a battery while

it is installed on the machine. Remove the
battery before charging it.
Stop the engine and turn the start switch
key to OFF position before checking or
handling the battery.
Wear goggles and rubber gloves when
handling the battery.
A loose terminal can result in improper
contact, which may cause sparks and
explosion.
Check that which terminal is positive
(+) and which one is negative (-) when
removing or installing the terminals.

a. Notice on battery check

• Make sure the level is 10~15mm above pole

plate and proportion over 1.28/cm3.

• Do keep battery clean and dry. If coonection

is found contaminated, loosen and clean it.
Besides, coat it with acidless and anti-acid
lubricating grease. Never coat oil port with
lubricating grease.

• Never place any tool onto battery.

• Conduct battery check once a week in

summer. Check the acid in electrolyte once
per month in other seasons except summer.
Add distilled water if necessay.

4-4
 Operation
STC500S3

b. Charging for battery

Measure electrolyte density with densimeter

once per month. Value displayed represents
the charging condition of battery, see Table
4-1.1. Conduct measurement half an hour
later after adding of distilled water under the
ideal temperature of 20℃ . Do properly charge
battery especially in cold season. Besides,
maintenance is in great need due to high
consumption of power.

Table 4-1.1

Proportion Charging condition

1.28 Well
1.20 Half charged, charge it timely
1.12 Uncharged, charge it immediately

4-5
Operation
STC500S3

(5) Check if there is any leakage of oil, water,

and gas;

(6) Check if all instruments, switches, lights,

signals, wipers are working properly;

(7) Check if each component of steering, and

brake system are flexible, safe, reliable; if
liquid level in steering fluid reservoir tank and
clutch cup is at normal level;

(8) Check if drive shaft bolts, U bolts, hub

bolts, wheel nuts are fastened reliably; if there
is any fracture or damage;

9) Check air filter maintenance indicator lamp,

if the indicator lamp shows red, filter should be
cleaned or filter cartridge should be replaced.
Dirt on bottom tray of air filter should also be
frequently cleared off.

4-6
 Operation
STC500S3

4.1.1.2 Driver's seat adjustment

NOTICE

It is necessary to adjust seat position

before operating or after changing
operator.
Adjust the seat so as to enable operator
to easily manipulate the control levers,
pedals and switches from the seat.

NOTICE
Before adjustment, handles should be
pulled in place to ensure full suspension.
After adjustment, reset handles to the
original position to ensure reliable self
lock of each part to avoid damage.

4-7
Operation
STC500S3

a) Forward/rearward adjustment
Pull up the front / rear position adjuster lever 5
under the seat. Move the seat back and forth
to the desired position and release the handle
to self-lock.

b) Seatback angle adjustment

Raise the backrest angle adjuster lever 1 to
the maximum position and adjust the backrest
to the desired position. Release the handle to
self-lock.

c) Height adjustment
Pull up handle 3, front part of cushion props
up automatically. Pull up handle 2, so does the
rear part. Operator can adjust the seat to the
desired height according to requirement.

d) Rigidness adjustment
Rotate rigidness adjuster lever, set preset
power to desired value according to road
condition and weight of operator.

Fig.4-1.1 Seat adjustment

1-Backrest angle adjuster lever 2-Rear part height (elevation angle) adjuster lever
3-Rear part height (elevation angle) adjuster lever 4-Rigidness adjuster lever
5-Front / rear adjuster lever

4-8
 Operation
STC500S3

4.1.1.3 Check when machine starts

(1) When the engine is at idle, the permitted

lowest oil pressure is 0.069 Mpa;

(2) Signal lights for air pressure and parking

brake should be out, and barometer pressure
should be above 0.55 MPa;

(3) Check if the power generator is working;

(4) Engine water temperature should be above

60 ℃ .

WARNING
Remove flammable materials from the
surrounding of battery, engine, muffler,
turbocharger, or other hot components.
The leak of oil or fuel may cause the
machine to catch on fire. Careful
inspection is necessary. Contact Sany
dealer if any fault of your machine must be
corrected.

4-9
Operation
STC500S3

4.1.2 During traveling

4.1.2.1 Engine start

Start the engine in the following sequence

after the check before dispatching. See
chapter 4.1.1.1 on page 4-3 for detailed check
before dispatching.

CAUTION

Before starting the engine, hand brake

must be set to the LOCK position.
Otherwise, with the increase of brake
system pressure, the original parking
brake will be released.

3 4

A
警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

A 6

2
1 5

Fig.4-1.2 Location of control devices for engine start inside the cab
1-Clutch pedal 2-Transmission control lever 3-Hand brake
4-Power takeoff control switch 5-Throttle pedal 6-Key switch

4-10
 Operation
STC500S3

(1) Depress clutch pedal "1" in Fig.4-1.2, set

the transmission control lever "2" in Fig.4-1.2
to neutral position, then release the pedal;
See Fig.4-1.3

Fig.4-1.3 Set transmission control lever to

neutral position

(2) Insert key into key switch "6" in Fig.4-1.2,

rotate it to ON position to connect the circuit;
See Fig.4-1.4

Fig.4-1.4 Turn key to ON position

(3) Press the OFF end of power takeoff control

switch "4" in Fig.4-1.2 to deactivate the power ON
takeoff device;
See Fig.4-1.5

OFF

Power takeoff switch on FAST transmission

Fig.4-1.5 Deactivate power takeoff device

4-11
Operation
STC500S3

(4) Depress clutch pedal "1" in Fig.4-1.2;

See Fig.4-1.6

(5) Lightly depress the throttle pedal "5" in Fig.4-1.6 Depress clutch pedal
Fig.4-1.2 (it is also ok if throttle pedal is not
depressed), turn the key from the position ON
to S to start the engine. Each start time cannot
exceed 5~8 seconds. If start fails once, the
next start shall be resumed after 1 minute.
If the start fails 3~5 times, stop starting the
engine to find out and eliminate the problem
as soon as possible.
See Fig.4-1.7

NOTICE

Run the engine at idle speed right after the

engine start, abrupt depressing the throttle Fig.4-1.7 Turn the key from the postion ON to
is extremely prohibited. S
For operation in winter, do run the engine
at idle for 15~20 minutes right after the
engine start.

NOTICE

Observe and listen carefully whether ab-

normal noise is present in machine. In
case of fault or abnormality, shut down
the machine immediately. Prior to further
operation, remove the fault and report to
upper level immediately.

4-12
 Operation
STC500S3

4.1.2.2 Start

(1) Push the hand brake "3" in Fig.4-1.2 Forwards Unlock

forwards to release the parking brake;
See Fig.4-1.8

Lock

Fig.4-1.8 Push hand brake forwards

(2) Depress clutch pedal "1" in Fig.4-1.2;

See Fig.4-1.9

Fig.4-1.9 Depress clutch pedal

4-13
Operation
STC500S3

(3) Set the transmission control lever "2" in

Fig.4-1.2 to Gear 1, slowly release clutch
pedal "1" in Fig.4-1.2, then slightly depress
throttle pedal "5" in Fig.4-1.2 to start the crane.
See Fig.4-1.10

NOTICE
Never start the crane in high gear. Starting
the crane in high gear will cause serious
damage to the crane.

Fig.4-1.10 Set transmission control lever to

Gear 1

WARNING: Forbid to start the crane in high gear!

Fig.4-1.11 Forbid start the crane in high gear

4-14
 Operation
STC500S3

4.1.2.3 Gearshift

1) Depress clutch pedal "1" in Fig.4-1.12 to

completely release the clutch;
See Fig.4-1.12

警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

2
1

Fig.4-1.12 Location of control devices for gearshift inside the cab

1-Clutch pedal 2-Transmission control lever

Fig.4-1.13 Clutch pedal

4-15
Operation
STC500S3

2) Set transmission control lever "2" in Fig.4-

1.12 to the desired position. Do set it in place,
and then release the clutch pedal "1" in Fig.4-
1.12;
See Fig.4-1.14

Fig.4-1.14 Set transmission control lever to

desired position

4-16
 Operation
STC500S3

4.1.2.4 Steering operation

Steering system is of mechanical, hydraulic-

servo operation. Operator can travel the
machine striaght or steer it through steering
wheel.
See Fig.4-1.15

Operator can steer the machine through

steering wheel when it is turning. Machine
turns left when steering wheel is turned left;
machine turns right when steering wheel is Fig.4-1.15 Steering wheel
turned right.

NOTICE

During steering, never steer the steering

wheel to the limit position and hold it there
for a long time.

4-17
Operation
STC500S3

4.1.2.5 Brake operation

The machine brake system includes: traveling

brake (foot brake), emergency and parking
brake (hand brake) and assistant brake
(engine exhaust brake).

(1) Traveling brake

Traveling brake is operated by foot pedal "1"

in Fig.4-1.16. Machine can be decelerated
through foot brake pedal during traveling.

警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

Fig.4-1.16 Location of control devices for brake operation inside the cab
1-Foot brake 2-Hand brake

4-18
 Operation
STC500S3

(2) Emergency and parking brake

Forwards Unlock
Hand brake is located on the right side of the
instrument gauges.

Emergency and parking brake can be

activated through hand brake "2" in Fig.4-
1.16. Setting the hand brake to LOCK position
shown in Fig.4-1.17 can activate the brake
operation.
Lock

CAUTION
Fig.4-1.17 Set hand brake to LOCK position
Before starting the engine, hand brake
must be set to the LOCK position.
Otherwise, with the increase of brake
system pressure, the original parking
brake will be released.

When machine is parking on the slope,

hand brake should be pulled backwards to
the LOCK position.

4-19
Operation
STC500S3

(3) Engine exhaust brake

Engine exhaust brake can be operated

through the combined switch beside steering
wheel. The exhaust brake control switch
is located on the left lever of the combined
switch "1" in Fig.4-1.18(1).

The exhaust brake is activated with indicator

lamp come on by pressing the control switch
"1" in Fig.4-1.18(2); it can also be stopped
with indicator lamp going out by pressing the
switch once again.

Fig.4-1.18 (1) Location of the left lever of combined switch

1-Left lever of combined switch

Left lever of combined switch

1

Fig.4-1.18 (2) Press exhaust brake control switch

1-Exhaust brake control switch

4-20
 Operation
STC500S3

NOTICE

When descending a long slope, exhaust

brake should be activated. Applying
exhaust brake on the snow, muddy roads
can effectively avoid sliding. It can also
be used to decelerate in advance when
traveling on bad roads. Besides, exhaust
brake can reduce the operation frequency
of main brake, reduce abrasion and heat
of the tires and wheels, extend lifetime,
reduce fuel consumption and improve
safety.

NOTICE

Never run the engine at a speed above

2200rpm.

When the gear box is set to neutral, it will

not achieve the role of auxiliary brake.
When gearbox is set to a lower gear, the
exhaust brake efficiency is much higher.

4-21
Operation
STC500S3

4.1.2.6 Operation of air conditioner

NOTICE
For cooling mode, do shut off the heating
valve. For heating, do activate it. Water
in warm-air pipeline must be drained
off along with the one in engine cooling
system in winter.

When activating the air conditioner, do

shut down the engine warm-air valve and
activate recirculation mode.

警告：严禁高
CAUTION：Forbid
档起步！
underway
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

1
5

3 4

Fig.4-1.19 Location of control devices for air conditioner operation inside the cab
1-Cooling/heating mode select knob 2-A/C power switch 3-Air delivery level control knob
4-Fresh air/recirculation slide switch 5-Air outlet control konb

4-22
 Operation
STC500S3

(1) Start air conditioning system

Steps to start the air conditioning system:

a. Start the engine as mentioned in chapter

4.1.2.1 on page 4-10;

b. Activate the A/C power switch “2“ in Fig.4-

1.19 as shown in Fig.4-1.20.

Fig.4-1.20 A/C power switch

c. Activate cooling mode by turning the cooling

/ heating mode selector knob “1“ in Fig.4-1.19
counter-clockwise, as shown in Fig.4-1.21.

Fig.4-1.21 Cooling/heating mode selector knob

d. Activate recirculation by pulling the fresh

air/recirculation slide switch "4" in Fig.4-1.19
downwards, as shown in Fig.4-1.22.

Fig.4-1.22 Fresh air/recirculation slide switch

4-23
Operation
STC500S3

e. Choose a proper wind speed as needed,

turn the air delivery level control knob “3“ in
Fig.4-1.19 to a required gear, as shown in
Fig.4-1.23. Gear 0 means off, gear 4 means
maximum wind speed.

Fig.4-1.23 Air delivery level control konb

f. Choose a proper wind direction as needed,

turn the air outlet control knob “5“ in Fig.4-1.19
to a required position, as shown in Fig.4-1.24.
Turn to position 1 to activate outlet for face;
turn to position 2 to activate outlet for feet; turn
to position 3 to activate outlet for windshield,
this is normally used for anti-fog and anti-frost.

Fig.4-1.24 Air outlet control konb

1-Outlet for feet 2-Outlet for face
3-Outlet for windshied

(2) Shut off air conditioning system

Steps to shut off the air conditioning system:

a. Press the A/C power switch “2“ in Fig.4-1.19

once again to shut off the air conditioner.

b. Shut down the engine as mentioned in

chapter 4.1.3.1 on page 4-27;

Fig.4-1.25 A/C power switch

4-24
 Operation
STC500S3

(3) Start warm air heating system

NOTICE
For cooling mode, do shut off the heating
valve. For heating, do activate it. Water
in warm-air pipeline must be drained
off along with the one in engine cooling
system in winter.

When activating the air conditioner, do

shut down the engine warm-air valve and
activate recirculation mode.

Steps to start the warm air heating system:

a. Start the engine as mentioned in chapter

4.1.2.1 on page 4-10;

b. Activate the engine heating valve; Fig.4-1.26 Fresh air/recirculation slide switch

c. Activate fresh air by pushing the fresh air/

recirculation slide switch upwards, as shown
in Fig.4-1.26.

d. Turn the cooling/heating mode select knob

as shown in Fig.4-1.27 clockwise to activate
heating system.

Fig.4-1.27 Cooling/heating mode selector knob

4-25
Operation
STC500S3

e. Turn the air delivery level control knob

as shown in Fig.4-1.28 to a proper gear as
needed.

Fig.4-1.28 Air delivery level control konb

f. Direct the warm air towards operator’s face

or feet by turning the air outlet control knob to
a required gear, as shown in Fig.4-1.29.

Fig.4-1.29 Air outlet control konb

1-Outlet for feet 2-Outlet for face
3-Outlet for windshied

4-26
 Operation
STC500S3

4.1.3 After traveling

4.1.3.1 Engine shutdown

A
警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

A 4

2
1

Fig.4-1.30 Location of control devices for engine shutdown inside the cab
1-Clutch pedal 2-Transmission control lever 3-Hand brake 4-Key switch

(1) Depress clutch pedal “1“ in Fig.4-1.30

completely to release the clutch. Set the
transmission control lever “2“ in Fig.4-1.30 to
neutral position;

Fig.4-1.31 Depress clutch pedal

4-27
Operation
STC500S3

Fig.4-1.32 Set transmission control lever to

neutral position

(2) Turn key switch ”4” in Fig.4-1.30 to LOCK

position when engine starts running at idle;

Fig.4-1.33 Turn key switch to LOCK position

Forwards Unlock
(3) Set the hand brake “3“ in Fig.4-1.30 to
LOCK position;

Lock

Fig.4-1.34 Set hand brake to LOCK position

4-28
 Operation
STC500S3

4.1.3.2 Closing and locking the door

As shown in Fig.4-1.35. Close the door, insert

key into the hole and rotate it counterclockwise
to lock the door.

CAUTION

Park your machine on a level ground

before unlocking the cab door. Place
stop blocks under wheels when park the
machine on a slope.
Do not expose your body or hand out of
the cab or lay your hand on the door frame
when unlocking the door. It may cause
injury.

Fig.4-1.35 Door handle and lock

4-29
Operation
STC500S3

4.2 Operation before Lifting

4.2.1 Oil level check (hydraulic oil tank)

Before starting the crane, do check the

hydraulic oil level with oil level gauge. See
Fig.4-2.1. The oil level gauge is equipped on
the side of hydraulic oil tank. Check if there is
sufficient oil according to the label of oil level
gauge. Add oil enough as specified.

CAUTION
Components and oil are still hot and can
cause burning after the engine has been
just shut down. Wait for them to cool down
before working on them.
When removing the cap for oil injection,
turn it slowly to release internal pressure
before removing it.

NOTICE

Oil pump may be damaged by sucked air

due to insufficient oil.

A direction
1 2

A direction

6 5 4 3

Fig.4-2.1 Location of oil level gauge

1-Air filter 2-Oil level gauge 3-Drain port 4-Return joint body
5-Stop valve 6-Stop valve

4-30
 Operation
STC500S3

Oil level marker line

Fig.4-2.2 Oil lever gauge

NOTICE

Refill the hydraulic oil till it is above the oil

level marker line when oil level falls below
the marker line under the state of retraced
cylinder.

4-31
Operation
STC500S3

4.2.2 Operation of power takeoff device

4.2.2.1 Precautions for the use of power

takeoff device

NOTICE
1) Before engaging the power takeoff
device, ensure all control levers inside
superstructure cab is at neutral position;

2) Do operate FAST power takeoff device

in Gear 4.

4.2.2.2 Activating power takeoff device

NOTICE
Before activating the power takeoff
device, ensure all control levers inside
superstructure cab are at neutral position.

3 4 7

A
警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

A 6

2
1 5

Fig.4-2.3 Location of control devices for power takeoff device operation inside the cab
1-Clutch pedal 2-Transmission control lever 3-Hand brake
4-Power takeoff control switch 5-Throttle pedal 6-Key switch 7-Power takeoff cancel switch

4-32
 Operation
STC500S3

Activate the FAST transmission power takeoff

device as per the following steps:
Forwards Unlock

a. Set hand brake “3” in Fig.4-2.3 to LOCK

position;

Lock

Fig.4-2.4 Set hand brake to LOCK position

b. Check whether the transmission control

lever "2" in Fig.4-2.3 is at neutral position and
the power takeoff control switch "4" in Fig.4-
2.3 is at OFF position. If not, do set the control
lever to neutral position and the power takeoff
control switch to OFF position;

Fig.4-2.5 Set transmission control lever to

neutral position

ON

OFF

Power takeoff switch on FAST transmission

Fig.4-2.6 Turn off the power takeoff control

switch

4-33
Operation
STC500S3

c. Insert the key into key switch "6" in Fig.4-

2.3 and turn it to "ON" position to energize the
whole system. Release the key after turning
it from the position"ON" to "S" to start the
engine. Do start the engine after preheat in
cold weather. See Fig.4-2.7;

Fig.4-2.7 Release the key after turning it from

“ON“ to “S“ position

d. Depress clutch pedal "1" in Fig.4-2.3

completely;

Fig.4-2.8 Depress clutch pedal

4-34
 Operation
STC500S3

e. Activate the power takeoff control switch "4"

in Fig.4-2.3 in the order shown in Fig.4-2.9 and
deactivate the power takeoff cancel switch "7"
in Fig.4-2.3 in the order shown in Fig.4-2.10;
Press here
Note: The button in the right illustration is used
to lock the switch on the position where it is
set, which can effectively avoid being touched
by mistake.

For example: With the ON end of switch Push the button in this direction
shown in Fig.4-2.6 is pressed, you should
push the button in the direction shown in the
right illustration to lock the switch on that Fig.4-2.9 Activate the power takeoff control
position, which can avoid the switch being switch
touched by mistake during operation. When
turning off the switch, you should firstly push
the button to release the switch and then press
the OFF end shown in Fig.4-2.6.

Press here

Push this button in this direction

Fig.4-2.10 Deactivate the power takeoff cancel

switch

4-35
Operation
STC500S3

f. Set transmission control lever "2" in Fig.4-

2.3 to Gear 4;

NOTICE

Do operate FAST power takeoff device in

Gear 4.

Fig.4-2.11 Set transmission control lever to

Gear 4

g. Slowly release clutch pedal "1" in Fig.4-2.3;

Fig.4-2.12 Release clutch pedal

4-36
 Operation
STC500S3

4.2.2.3 Deactivating power takeoff device

Deactivate the FAST transmission power

takeoff device as per the following steps:

a. Depress clucth pedal "1" in Fig.4-2.3

completely to release clucth. Set transmission
control lever "2" in Fig.4-2.3 to neutral position;

Fig.4-2.13 Depress clutch pedal

Fig.4-2.14 Set transmission control lever to

neutral position

4-37
Operation
STC500S3

b. Deactivate power takeoff control switch "4"

in Fig.4-2.3 in the order shown in Fig.4-2.15;

Press here

Push this button in this direction

Fig.4-2.15 Deactivate the power takeoff control

switch

c. Activate the power takeoff cancel switch "7"

in Fig.4-2.3 in the order shown in Fig.4-2.16,
and the indicator lamp goes out;
Press here

Push this button in this direction

Fig.4-2.16 Activate the power takeoff cancel

switch

4-38
 Operation
STC500S3

d. Release clutch pedal "1" in Fig.4-2.3;

Fig.4-2.17 Release clutch pedal

e. Turn key switch "6" in Fig.4-2.3 to LOCK

position to shut down the engine.

Fig.4-2.18 Turn key switch to LOCK position

4-39
Operation
STC500S3

4.2.3 Operation of outrigger

4.2.3.1 Precautions for the operation of

outrigger

Refer to Fig.4-2.19 for the location of outrigger

operation instruction label and outrigger
operation label.

1 2
Fig.4-2.19 Location of outrigger operation instruction label and outrigger operation label
1-Outrigger operation instruction label 2-Outrigger operation label

4-40
 Operation
STC500S3

Refer to Fig.4-2.20 and Fig. 4-2.21 for the

content of outrigger operation label.

Fig.4-2.20 Content of right outrigger operation label

Fig.4-2.21 Content of left outrigger operation label

4-41
Operation
STC500S3

4.2.3.2 Instruction on outrigger control

lever

See Fig.4-2.22 for the location of outrigger

control lever on the crane.

Fig.4-2.22 Location of outrigger control lever

1-Outrigger control lever

See Fig.4-2.23 for outrigger control lever and

throttle control switch

1 2 3 4 5 6 7

Fig.4-2.23 Outrigger control lever and throttle control switch

1-Control lever for left front horizontal & vertical outriggers
2-Control lever for right front horizontal & vertical outriggers
3-Control lever for left rear horizontal & vertical outriggers
4-Control lever for right rear horizontal & vertical outriggers
5-Control lever for the front jack 6-Master control lever 7-Throttle control switch

4-42
 Operation
STC500S3

4.2.3.3 Operation steps of outrigger

DANGER

1. Before operation, ensure there is no

person at the extension direction of
outrigger; otherwise, will result in serious
injury or death.
2. During operation, horizontal outriggers
should be fully extended, vertical
outriggers set up. Besides, extend front
jack till the outrigger tray can just touch
the ground. Never operate with outrigger
not set up.
3. It is a must to support the crane with
front jack when crane is operating at front
area.

WARNING

If the crane is set on inappropriate ground,

it is possible that the crane could overturn.
Always set the crane on firm ground.

1. Extend horizontal and vertical outriggers as

per the following steps:

a. Before operation, activate the power takeoff

device as mentioned in chapter 4.2.2.2 on
page 4-32;

b. Pull out the outrigger tray locking pin "1" in

Fig.4-2.24 before extending the outrigger;

NOTICE

Set the outrigger tray in position before Fig.4-2.24 Pull out the outrigger tray locking
operating outrigger cylinder. Otherwise it pin
may causes damage to outriggers. 1-Outrigger tray locking pin

4-43
Operation
STC500S3

c. Make sure all the control levers are at

neutral position before operation. Set the
Upper position
control levers (1, 3) for the left two horizontal (for horizontal outriggers)
outriggers to the upper position shown in
Fig.4-2.25.

Note: 1, 3 here refers to the control lever for Middle position

the left front and left rear horizontal outriggers. (1, 3)

WARNING Fig.4-2.25 Set the control lever for the left two
outriggers to the upper position
When operating horizontal outriggers, do
operate the two outriggers of the same
side synchronously. Operating the two
outriggers of different sides may cause
personnel injury or death.

NOTICE
Boom must be kept at the front of crane
when extending outriggers; Middle position
6 (Master control lever)

When extending outriggers, the horizontal Lower position

outriggers must be extended prior to the (extending outriggers)

vertical ones;
Fig.4-2.26 Set the master control lever to the
lower position

d. Set the master control lever 6 to the lower

position as shown in Fig.4-2.26. The left two
horizontal outriggers are thus extended as
shown in Fig.4-2.27.

Fig.4-2.27 The left two horizontal outriggers

are extended

4-44
 Operation
STC500S3

e. Set the control levers (2, 4) for the right

two horizontal outriggers to the upper position
shown in Fig.4-2.28. Upper position
(for horizontal outriggers)

Note: 2, 4 here refers to the control levers

for the right front and right rear horizontal
outriggers. Middle position

(2, 4)

Fig.4-2.28 Set the control lever for the right

two outriggers to the upper position

f. Set the master control lever 6 to the lower

position as shown in Fig.4-2.29. The right two
horizontal outriggers are thus extended as
shown in Fig.4-2.30.

Middle position
6 (Master control lever)

Lower position
(extending outriggers)

Fig.4-2.29 Set the master control lever to the

lower position

Fig.4-2.30 The right two horizontal outriggers

are extended

4-45
Operation
STC500S3

g. During outrigger extending, maneuvering

the throttle control switch "7" in Fig.4-2.23
can accelerate this operation. Throttle control
switch can restore to its original position
after released. It functions the same in the
operations of vertical outriggers and the front
jack.

Fig.4-2.31 Throttle control switch

h. After the four horizontal outriggers have

been extended, restore all the control levers Upper position
to the middle position, as shown in Fig.4-2.32 (for horizontal outriggers)

and Fig.4-2.33.

Note: 1, 2, 3, 4 here refers to the control levers

Middle position
for the left front, right front, left rear and right
(2, 4)
rear horizontal outriggers.

Fig.4-2.32 Restore the control levers for the

four vertical outriggers to the middle position

Middle position
6 (Master control lever)

Lower position
(extending outriggers)

Fig.4-2.33 Restore the master control lever to

the middle position

4-46
 Operation
STC500S3

i. Set the control levers 1, 2, 3, 4 to the lower

position shown in Fig.4-2.34.

Note: 1, 2, 3, 4 here refers to the control levers

for the left front, right front, left rear and right
rear vertical outriggers.
Middle position
(1, 2, 3, 4)
Lower position
(for vertical outriggers)

Fig.4-2.34 Set the control levers 1, 2, 3, 4 to

the lower position

j. Set the master control lever 6 to the lower

position shown in Fig.4-2.35. The four vertical
outriggers are thus extended as shown in
Fig.4-2.36.

Middle position
6 (Master control lever)

Lower position
(extending outriggers)

Fig.4-2.35 Set the master control lever 6 to the

lower position
NOTICE

Do let all the wheels away from the ground

and each outriggers firmly stands on the
ground.

NOTICE

It is extremely forbidden to operate

c y l i n d e r o f t h e l o a d e d o u t r i g g e r.
Otherwise, serious damage may occur.

Fig.4-2.36 The four vertical outriggers are

extended

4-47
Operation
STC500S3

k. After the four vertical outriggers have been

extended, restore all the control levers to the
middle position as shown in Fig.4-2.37 and
Fig.4-2.38.

Note: 1, 2, 3, 4 here refers to the control levers

for the left front, right front, left rear and right Middle position
rear vertical outriggers. (1, 2, 3, 4)
Lower position
(for vertical outriggers)

Fig.4-2.37 Restore the control levers for the

four vertical outriggers to the middle position

Middle position
6 (Master control lever)

Lower position
(extending outriggers)

Fig.4-2.38 Restore the master control lever to

the middle position

4-48
 Operation
STC500S3

l. After all the vertical outriggers have been

extended, extend the front jack with the steps
described in the "2. Extend the front jack" on
page 4-50, based on atucal condition.

WARNING

Do extend the front jack cylinder when

operating at front area.

m. Observe the level meter (see Fig.4-2.39 for

its location on the crane) after all the vertical
outriggers have been extended: the crane is
properly levelled when the air bubble in level
meter stays at the center, shown in Fig.4-2.40;
the side where the bubble tends towards is
lower than the other side. Level the crane if it
is not properly levelled.

Fig.4-2.39 Location of level meter

n. Retract the vertical outrigger of the higher

Air bubble
side till the air bubble moves to the center of
level meter.

o. Restore all the control levers to the middle

position see Fig.4-2.37 and Fig.4-2.38 on page
4-48, after the air bubble reaches the center of
level meter. The crane is thus levelled.

Fig.4-2.40 Air bubble stays at the center of

level meter

4-49
Operation
STC500S3

2. Extend the front jack as per the following

steps:

WARNING

Do extend the front jack cylinder when

operating at front area.

a. Extend the front jack after the horizontal

and vertical outriggers have been extended;

Middle position
(5)
b. Set the control lever 5 to the lower position
Lower position
shown in Fig.4-2.41. (for vertical outriggers)

Note: 5 here refers to the control lever for the Fig.4-2.41 Set the control lever 5 to the lower
front jack. position

c. Set the master control lever 6 to the lower

position shown in Fig.4-2.42. The front jack is
thus extended as shown in Fig.4-2.43 .

Middle position
6 (Master control lever)
NOTICE
Lower position
(extending outriggers)
Do extend the front jack to the position
where the outrigger tray can just touch the Fig.4-2.42 Set the master control lever 6 to the
ground. lower position

Fig.4-2.43 The front jack is extended

4-50
 Operation
STC500S3

d. After the front jack has been extended,

restore all the control levers to the middle
position as shown in Fig.4-2.44 and Fig.4-
2.45.

Note: 5 here refers to the control lever for the

front jack. Middle position
(5)
Lower position
(for vertical outriggers)

Fig.4-2.44 Restore the control lever 5 to the

middle position

Middle position
6 (Master control lever)

Lower position
(extending outriggers)

Fig.4-2.45 Restore the master control lever 6

to the middle position

4-51
Operation
STC500S3

3. Retract the horizontal and vertical outriggers

as per the following steps:

WARNING

If the outriggers are retracted with the

boom telescoped out, the crane may
overturn. Fully telescope in the boom and
stow in the traveling configuration before
retracting the outriggers.

NOTICE
Boom must be kept at the front of crane
when retracting outriggers;

When retracting outriggers, the vertical

outriggers must be extended prior to the
horizontal ones.

a. Make sure all the control levers are at the

middle position before operation. Then, set the
control levers 1, 2, 3, 4 to the lower position,
shown in Fig.4-2.46.
Middle position
Note: 1, 2, 3, 4 here refers to the control levers (1, 2, 3, 4)
for the left front, right front, left rear and right Lower position
(for vertical outriggers)
rear vertical outriggers.
Fig.4-2.46 Set the control levers 1, 2, 3, 4 to
the lower position

4-52
 Operation
STC500S3

b. Set the master control lever 6 to the upper

position shown in Fig.4-2.47. The four vertical
outriggers are thus retracted as shown in
Upper position
Fig.4-2.48. (retracting outriggers)

Middle position
6 (Master control lever)

Fig.4-2.47 Set the master control lever 6 to the

upper position

Fig.4-2.48 The four vertical outriggers are

retracted

4-53
Operation
STC500S3

c. Set the control levers (2, 4) for the right two

horizontal outriggers to the upper position
Upper position
shown in Fig.4-2.49. (for horizontal outriggers)

Note: 2, 4 here refers to the control levers for

the right two horizontal outriggers.
Middle position

(2, 4)

Fig.4-2.49 Set the control lever for the right

two outriggers to the upper position

d. Set the master control lever 6 to the upper

position shown in Fig.4-2.50. The right two
Upper position
horizontal outriggers are thus retracted as (retracting outriggers)
shown in Fig.4-2.51.

Middle position
6 (Master control lever)

Fig.4-2.50 Set the master control lever 6 to the

upper position

Fig.4-2.51 The right two horizontal outriggers

are retracted

4-54
 Operation
STC500S3

e. Set the control levers (1, 3) for the left two

horizontal outriggers to the upper position Upper position
(for horizontal outriggers)
shown in Fig.4-2.52.

Middle position

(1, 3)

Fig.4-2.52 Set the control lever for the left two

outriggers to the upper position

f. Set the master control lever 6 to the upper

Upper position
position shown in Fig.4-2.53. The left two (retracting outriggers)
horizontal outriggers are thus retracted as
shown in Fig.4-2.54.
Middle position
6 (Master control lever)

Fig.4-2.53 Set the master control lever 6 to the

upper position

Fig.4-2.54 The left two horizontal outriggers

are retracted

4-55
Operation
STC500S3

g. After the four horizontal outriggers have

been retracted, set all the control levers to the Upper position
(for horizontal outriggers)
middle position shown in Fig.4-2.55 and Fig.4-
2.56.

Note: 1, 2, 3, 4 here refers to the control levers

Middle position
for the left front, right front, left rear and right
(1, 2, 3, 4)
rear horizontal outriggers.

Fig.4-2.55 Set the control levers 1, 2, 3, 4 to

the middle position

Upper position
(retracting outriggers)

Middle position
6 (Master control lever)

Fig.4-2.56 Set the master control lever 6 to the

middle position

h. Well stow the outrigger tray after retracting

all the outriggers.

WARNING
Traveling with the crane without first
securing the retracted outriggers with the
locking pins is dangerous. The outriggers
could accidentally extend during travel.
Be sure to securely pin the outriggers
whenever they are stowed.

4-56
 Operation
STC500S3

4.2.4 Locking up and releasing the

locking device on turntable

NOTICE

It is a must to release the mechanical

locking device on the turntable before
getting into the crane operator’s cab.

1:5 1:5
Released locking device Locked up locking device
1 1

Fig.4-2.57 Locked up and released mechanical locking device on the crane

1-Mechanical locking device

4-57
Operation
STC500S3

4.2.5 Getting into crane operator’s cab

4.2.5.1 Opening and closing the door

(1) Opening and closing the door outside cab

a. Opening the door

Insert key into the hole shown in Fig.4-2.58,

rotate it clockwise to unlock the door, pull
handle outwards to open the door.

b. Closing the door

Close the door, insert key into the hole shown

in Fig.4-2.58, rotate it counterclockwise to lock
the door, pull out the key.

WARNING

The door, if not completely shut, could

open when the machine is traveling.
Before traveling, be sure to close and lock
the door.

CAUTION

Do not attempt to shut the door, holding it

at the end. Your fingers may be pinched.
When shutting the door, hold the door
handle.

4-58
 Operation
STC500S3

2 1

Fig.4-2.58 Superstructure cab door

1-Door handle 2-Key hole

4-59
Operation
STC500S3

(2) Opening and closing the door inside cab

Pull inner handle sideways to slide the door

open or shut. See Fig.4-2.59

Fig.4-2.59 Inner handle

4-60
 Operation
STC500S3

4.2.5.2 Adjusting the seat position

WARNING

Adjust the seat position before starting

operation. Making adjustments during
operation could be dangerous.

See Fig.4-2.60

Height adjustment
Pull up the height adjuster lever 3 and adjust
the seat height. Release the lever after
adjustment to lock the seat in position.

Forward/rearward adjustment
Pull up the slide adjuster lever 5, and adjust
the seatforward or rearward. The seat is
locked in position when the lever is released.
Seatback angle adjustment
Fig.4-2.60 Seat
1-Seatback angle adjuster lever
2-Composite angle adjuster lever
3-Height adjuster lever

Pull up the reclining adjuster lever 1 and 4-Rigidness adjuster hand wheel

adjust the angle of the seatback. The seatback 5-Slide adjuster lever

is locked in position when lever is released.

Rigidness adjustment
Rotate the rigidness adjuster hand wheel 4
and adjust preset power to the desired value.
Meanwhile, the preset power adjustment
should be adjusted according to road condition
and driver’s weight.

Composite angle adjustment

Pull up the composite angle adjuster lever
2, and adjust the angle of seat and seatback
compositely. The seat is locked in position
when the lever is released.

4-61
Operation
STC500S3

4.2.5.3 Starting the power

As shown in Fig.4-2.61, insert key into the key

switch on electric cabinet, turn the key to Gear
I to start the power. The crane operator’s cab
is thus energized.

NOTICE

Before starting the power, do activate the

power switch and power takeoff device.

Fig.4-2.61 Location of key switch

4-62
 Operation
STC500S3

4.2.5.4 Throttle operation

The engine speed changes from idling speed

to maximum speed according through the
throttle pedal inside the cab. See Fig.4-2.62
for the location of throttle pedal.

Fig.4-2.62 Throttle pedal

4-63
Operation
STC500S3

4.2.6 Use of performance label

4.2.6.1 Location of lifting height curve/rated

lifting capacity table

Lifting height curve and performance table of

truck crane are located on the right window
inside operator’s cab. See Fig.4-2.63.

2 1

Fig.4-2.63 Location of lifting height curve/performance table

1-Rated lifting performance table 2-Lifting height curve

4-64
 Operation
STC500S3

4.2.6.2 Use of load radius/lifting height

chart

STC500 Working radius-lifting height curve

Lifiting height (m)

Radius (m)

Fig.4-2.64 Lifting height curve

4-65
Operation
STC500S3

The load radius/lifting height chart (shown in

Fig.4-2.64) provides the load radius and lifting
heights in relation to different boom lengths (jib
lengths) and boom angles (jib offset angles).
Use the chart in conjunction with the rated
lifting capacity table when making an operation
plan. See Fig.4-2.65.

The load radius/lifting height chart does not

include the effect of boom deflection. The
greater the weight of the load is, the more
the boom deflects, causing the load radius
to increase somewhat. Take this effect into
consideration when reading the load radius/
lifting height chart.

NOTICE
The values shown in the rated lifting
capacities table are based on ideal
conditions where the crane is set level
on a firm surface, there is no wind or
side load, and the load is not swinging.
When operating the crane under these
conditions is not possible, reduce the
load as necessary according to the actual
operating conditions.

Load radius without load on hook

Load radius with load on hook

Fig.4-2.65 Deflections of boom

4-66
 Operation
STC500S3

4.2.6.3 Rated lifting capacity table

1. Lifting performance table of boom

Table 4-2.1 Lifting performance table of boom

Operation Operation at rear and side area with outrigger fully extended
range(m) 11.5m 15.4m 19.25m 27.0m 34.75m 38.62m 42.5m
3.0 55000 40000 32000 21500
3.5 50000 40000 32000 21500
4.0 44600 40000 32000 21500
4.5 40000 36000 31000 21500 21000 15000
5.0 36200 33200 29000 20000 21000 15000
5.5 32000 30000 27500 19000 21000 14500
6.0 28000 27500 25700 18100 21000 13700 14000 9000
6.5 25800 25500 23900 17500 19500 12800 14000 9000
7.0 23500 23200 21500 17000 18000 12100 14000 9000 11500 9000
7.5 21400 21200 18600 16200 16800 11500 13500 8500 11500 9000
8.0 19500 19300 17000 15600 15800 11000 12700 8500 11000 9000 9000
9.0 15300 15000 13700 13800 14000 10000 11700 7800 10500 8500 8500
10.0 11700 10900 12000 12000 9000 10700 7100 10000 8000 8100
11.0 9600 9000 10600 9900 8200 9400 6400 9000 7500 7800
12.0 8000 8000 8700 9000 7500 8500 5800 8000 7000 7000
14.0 5300 6400 6300 6100 6600 5000 6300 5900 6000
16.0 3500 4600 4700 5000 5000 4400 5000 5000 5200
18.0 3500 4100 4000 3800 4000 4000 4200
20.0 2500 3000 3100 3200 3200 3500 3300
22.0 1900 2300 2200 2700 2400 2800 2600
24.0 1300 1800 1700 2400 1800 2100 2000
26.0 1200 1900 1300 1650 1500
28.0 800 1500 900 1300 1150
30.0 500 1000 600 900 900
32.0 800 600 600
34.0 400

4-67
Operation
STC500S3

Table 4-2.1 Lifting performance table of boom

Operation Operation at rear and side area with outrigger fully extended
range(m) 11.5m 15.4m 19.25m 27.0m 34.75m 38.62m 42.5m
Telescoping condition (%)
Telescoping
Ⅰ,Ⅱ Ⅰ Ⅰ Ⅱ Ⅰ Ⅱ Ⅰ Ⅱ Ⅰ Ⅱ Ⅰ,Ⅱ
mode
2nd boom
0 50 100 0 100 0 100 0 100 50 100
section
3rd boom
0 0 0 33 33 66 66 100 83.3 100 100
section
4th boom
0 0 0 33 33 66 66 100 83.3 100 100
section
5th boom
0 0 0 33 33 66 66 100 83.3 100 100
section
Magnification 12 10 8 6 4 4 3

4-68
 Operation
STC500S3

2. Lifting performance table of jib

Table 4-2.2 Lifting performance table of jib

Operation at rear and side area with outrigger fully extended

Operation angle 42.5+9.2m jib 42.5+16m jib
0° 15° 30° 0° 15° 30°
78° 3500 2400 2000 2400 1450 1000
77° 3200 2300 1900 2400 1400 1000
75° 3000 2200 1800 2300 1300 950
73° 2700 2000 1700 2000 1200 850
71° 2500 1800 1600 1800 1100 850
68° 2200 1700 1400 1500 1000 800
66° 2000 1500 1300 1300 950 760
63° 1800 1400 1100 1100 850 720
61° 1500 1200 950 950 750 650
58° 1100 950 750 650 600 550
56° 700 650 550 500
Min. elevation 55°

4-69
Operation
STC500S3

Note:

1) The given values in the table indicate the

nominal hoisting capacity of crane provided
the crane is even and located on solid plane
ground. Values above the bold line depend
on the crane strength, and the values below
depend on the stability of the crane.

2) Operation range in the table refers to the

actual range in loaded status.

3) The nominal hoisting capacity depending on

the stability shall be determined in accordance
with ISO4305.

4) The nominal hoisting capacity given in the

table includes mass of hoisting hook (main
hoisting hook of 610kg and auxiliary hoisting
hook of 90kg) and spreader.

5) The values given in the table are applicable

to omnibearing (360°) operations provided the
5th outrigger is extended.

6) The nominal hoisting capacity cannot

exceed 4,000kg when using the boom end
pulley. In case of jib extended, the nominal
hoisting capacity of boom shall be less than
2,300kg.

7) If the actual boom length and range are

between the two of the given values, the
nominal hoisting capacity determined by
longer boom length and larger ranger shall
apply.

4-70
 Operation
STC500S3

3. Hoisting performance table of single pulley

at boom end of crane

Table 4-2.3 Hoisting performance table of

single pulley at boom end of crane

Boom
length 11.5 15.4 19.25 27 34.75 38.62 42.5
(m)

For telescoping For telescoping

mode I: 3,500kg mode I: 3,500kg
for range of 3,500kg for for range of 3,500kg for
4.5~17m; For range of 6.5~18m; For range of
telescoping 6~18m; telescoping 6~19m;
Hoisting
mode II: 3,500kg for other mode II: 3,500kg for other
capacity 3500 3500 3500
for range of conditions, for range of conditions,
(kg)
4.5~18mfor refer to Table 6.5~20mfor refer to Table
other conditions, of boom other conditions, of boom
refer to Table performance. refer to Table performance.
of boom of boom
performance. performance.

4-71
Operation
STC500S3

4.2.6.4 Use of rated lifting capacity table

and lifting height curve

(1) Pick out appropriate boom length based on

the lifting height and operation range of the to-
be-lifted load.

As shown in Fig.4-2.66, suppose the lifting

height and operation range for the to-be-lifted
load is 30m and 14m respectively, 34.75m
boom length can be picked out.

STC500 Working radius-lifting height curve

Lifiting height (m)

Radius (m)

Fig.4-2.66 Pick out boom length based on the lifting height and operation range

4-72
 Operation
STC500S3

(2) Pick out rated lifting capacity based on

boom length and operation range.

As shown in Fig.4-2.67. Suppose the

operation range and boom length for the to-
be-lifted load is 15m and 36.7m respectively,
6.6T rated lifting capacity and 64° boom angle
can be picked out.

Operation Operation at rear and side area with outrigger fully extended
range(m) 11.5m 15.4m 19.25m 27.0m 34.75m 38.62m 42.5m
3.05 50004 0000 32000 21500
3.55 0000 40000 32000 21500
4.0 446004 0000 320002 1500
4.5 40000 36000 31000 215002 1000 15000
5.03 6200 33200 29000 200002 1000 15000
5.53 2000 30000 27500 190002 1000 14500
6.02 8000 27500 25700 181002 1000 137001 4000 9000
6.52
7.0
5800
23500
25500
23200
23900
21500
175001
170001
9500
8000
128001
121001
R
4000
4000
9000
9000 11500 9000
7.5 21400 21200 18600 162001 6800 11500 13500 8500 11500 9000
8.01 9500 19300 17000 156001 5800 11000 12700 8500 11000 9000 9000
9.01 5300 15000 13700 13800 14000 100001 1700 7800 10500 8500 8500
10.0 11700 10900 12000 12000 9000 10700 7100 10000 8000 8100
11.0 9600 9000 10600 9900 8200 9400 6400 9000 7500 7800
12.0 8000 8000 8700 9000 7500 8500 5800 8000 7000 7000

Operation range is R 14.0 L

5300 6400 6300 6100 6600 5000 6300 5900 6000
16.03 5004 6004 700 5000 5000 4400 5000 5000 5200
18.03 500 4100 4000 3800 4000 4000 4200

Boom length is L 20.0 2500 3000 3100 3200 3200 3500 3300
22.0 1900 2300 22002 7002 400 2800 2600
24.0 1300 1800 1700 2400 1800 2100 2000
Rated lifting capacity is ? 26.0 1200 1900 1300 1650 1500
28.0 800 1500 900 1300 1150
30.0 500 1000 600 900 900
32.0 800 600 600
34.0 400
Telescoping condition £ %̈£ ©
Telescoping
Ⅰ, ⅡⅠ ⅠⅡ ⅠⅡⅠ ⅡⅠ ⅡⅠ ,Ⅱ
mode
2nd boom
05 0 100 0 100 0 100 0 100 50 100
section
3rd boom
00 03 33 36 66 6 100 83.3 100 100
section
4th boom
00 03 33 36 66 6 100 83.3 100 100
section
5th boom
00 03 33 36 66 6 100 83.3 100 100
section
12 10 86 44 3

Fig.4-2.67 Pick out rated lifting capacity based on operation range and boom length

4-73
Operation
STC500S3

4.3 Lifting Operation

4.3.1 Removing the main hook block

4.3.1.1 Precaution for the use of main hook

block

WARNING

When the overwind cutout function is

deactivated, a hoisting operation is
not automatically stopped even if the
hook block is overhoisted. Overwinding
damages the wire rope and crane and can
result in serious personal injury or death
due to a falling hook block.

Always be careful not to overwind

when the overwind cutout function is
deactivated.

NOTICE

The wire rope may be reeved disorderly if

lifting operation is conducted when wire
rope is still loose.

4-74
 Operation
STC500S3

4.3.1.2 Removing the main hook block

Remove the main hook block as followed:

1) Extend the outriggers and set the crane in a

level position (See chapter 4.2.3 starting from
page 4-40 for detailed operation);

Fig.4-3.1 Extend outrigger, set the crane in a level position

4-75
Operation
STC500S3

2) As shown in Fig.4-3.2, fix the main hook

block onto the chassis platform. Remove the
clamping pin;

1 2 3

Fig.4-3.2 Fix the main hook block onto the chassis platform
1-Clamping pin 2-Locking pin 3-Wire rope for fixing

4-76
 Operation
STC500S3

3) Remove the locking pin;

4) Remove the wire rope for fixing from the

hook block head;

5) Raise the boom slowly and retract the wire

rope for main hook block. Do make sure the
hook block does not collide with boom bracket.
See Fig.4-3.3

NOTICE

a. Raise the boom, taking care not to apply

too much tension to the wire rope, making
sure that the wire rope winds properly
around the drum.

b. Slowly operate the crane, making sure

the hook block does not swing.

Fig.4-3.3 Retract the wire rope when boom is being raised

4-77
Operation
STC500S3

4.3.2 Operation of hoisting mechanism

4.3.2.1 Precautions for the use of hoisting

mechanism

NOTICE

1. Never pull up the control lever of

hoisting mechanism suddenly.

2. Check the brake before starting hoisting.

The operation can only be started if brake
is normal. Do not lift the load or telescope
out the boom before the load leaves the
ground. Only hook up is allowed.

3. Select proper number of parts of line

according to boom length (Refer to
chapter 4.2.6.3 on page 4-67).

4. In case that rope is disorderly reeved

due to the rotation of hook, hoisting can
only be started after the rope is fully
unwound.

5. Make sure at least 3 loops of rope

remained on the winding drum in hook
down operation.

6. Only the vertical hoisting is permitted.

It is prohibited to drag the load on the
ground, and uneven loading shall be
avoided as much as possible.

4-78
 Operation
STC500S3

4.3.2.2 Operation of main hoist

WARNING

Overload is dangerous and can cause

injury and death. Before lifting, ensure
your machine is safely operated within a
safe working range on a flat, solid ground.
When a load is lifted, the boom deflects
and the working radius increases, possibly
exceeding the allowable limit. This result
causes an overload condition. Stop lifting
when the load just clears the ground, and
check the condition of the load, as well
as for any sign of overloading, before
continuing.

WARNING
You shall only start the operation from the
operator's seat.
Sound the horn and start the operation
after you have confirmed that the
surrounding area is clear of personnel or
barriers.

1 3

A
警告：严禁高
CAUTION：
Forbid underway
档起步！
in top grade
！

警告：只
允许用四
CAUTION
：ALLOW 档取力操
TO BOOST
BY FOURTH
作！
GEAR ONLY！

A 4

Fig.4-3.4 Location of control devices for main hoist inside the cab
1- Hand brake 2-Transmission control lever 3-Power takeoff control switch 4-Key switch

4-79
Operation
STC500S3

The operation of main hoist goes as followed:

1. As shown in Fig.4-3.5, Fig.4-3.6 and Fig.4- Forwards Unlock

3.7(1), (2). Do set hand brake “1“ in Fig.4-3.4
to LOCK position; set transmission lever “2“ in
Fig.4-3.4 to Gear 4; activate the power takeoff
control switch “3“ in Fig.4-3.4 and key switch
“4“ in Fig.4-3.4;

Lock

Fig.4-3.5 Set hand brake to LOCK position

Fig.4-3.6 Set transmission control lever to

Gear 4

4-80
 Operation
STC500S3

ON

OFF

Power takeoff switch on FAST transmission

Fig.4-3.7 (1) Activate power takeoff control

switch

Fig.4-3.7 (2) Set key switch to ON position

4-81
Operation
STC500S3

2. Set up outriggers.

See chapter 4.2.3 starting from page 4-40 for

detailed operation;

3. Start the engine

Insert key into the key switch in Fig.4-3.8 on

the electric cabinet inside the cab, turn it to
Gear I to energize the whole system. Turn it to
Gear III to start the engine. Do start the engine
after preheat in cold weather. See Fig.4-3.8.

Fig.4-3.8 Release the key after turning it from

Gear I to Gear III

ON

4. Press the “ON” end to turn on the master OFF

switch, as shown in Fig.4-3.9;

Fig.4-3.9 Turn on the master switch

4-82
 Operation
STC500S3

5. Push the main hoist control lever forwards

“B” in Fig.4-3.10 (1) to lower the main hook B
block “B” in Fig.4-3.10 (2) and raise it “A” in
Fig.4-3.10 (2) by pulling the lever backwards A
“A” in Fig.4-3.10 (1). The operation speed is
regulated through control lever and throttle.

WARNING

Moving the control levers abruptly is

dangerous because it causes the load to
bounce and swing. This practice could
result in damaging the crane, and injury or
death. Be sure to operate the levers slowly
and carefully.
Never attempt to pull a load sideways or
inward by operating the winch. Doing so
may not only cause the boom failure but
also overturn the crane.
Fig.4-3.10 (1) Main hoist control lever
A-Pull control lever backwards
WARNING B-Push control lever forwards

Do keep away from moving mechanism,

otherwise, serious damage or death may
occur.

Fig.4-3.10 (2) Operation of main hoist

A-Raise the main hook block
B-Lower the main hook block

4-83
Operation
STC500S3

4.3.2.3 Auxiliary hoist

WARNING

Overload is dangerous and can cause

injury and death. Before lifting, ensure
your machine is safely operated within a
safe working range on a flat, solid ground.
When a load is lifted, the boom deflects
and the working radius increases, possibly
exceeding the allowable limit. This result
causes an overload condition. Stop lifting
when the load just clears the ground, and
check the condition of the load, as well
as for any sign of overloading, before
continuing.

WARNING

You shall only start the operation from the

operator's seat.
Sound the horn and start the operation
after you have confirmed that the
surrounding area is clear of personnel or
barriers.

The operation of auxiliary hoist as followed:

1. Do set hand brake to LOCK position; set

transmission lever to Gear 4; activate the
power takeoff control switch and key switch;

2. Set up outriggers;

3. Start the engine;

4. Turn on the master switch;

(See chapter 4.3.2.2 starting from page 4-79

to page 4-82 for detailed operation of the
above 4 steps);

4-84
 Operation
STC500S3

5. Push the auxiliary hoist control lever B

forwards “B“ in Fig.4-3.11 (1) to lower the
auxiliary hook block “B“ in Fig.4-3.11 (2) and
raise it “A“ in Fig. 4-3.11 (2) by pulling the lever A
backwards “A“ in Fig. 4-3.11 (1). The operation
speed is regulated through control lever and
throttle.

WARNING

Moving the control levers abruptly is

dangerous because it causes the load to
bounce and swing. This practice could
result in damaging the crane, and injury or
death. Be sure to operate the levers slowly
and carefully.
Never attempt to pull a load sideways or
inward by operating the winch. Doing so
may not only cause the boom failure but
also overturn the crane. Fig.4-3.11 (1) Auxiliary hoist control lever
A-Pull control lever backwards
B-Push control lever forwards
WARNING
Do keep away from moving mechanism,
otherwise, serious damage or death may
occur.

Fig.4-3.11 (2) Operation of auxiliary hoist

A-Raise the auxiliary hook block
B-Lower the auxiliary hook block

4-85
Operation
STC500S3

4.3.2.4 Winch drum monitor mirror

Winch drum monitor mirror is equipped on the

rear end of turntable. Operator can use this
mirror to check the wire rope condition on the
winch drum. See Fig.4-3.12.

When operating in the superstructure cab, to

look at the mirror, operator should turn to the
rear of the cab.

NOTICE

Lifting a load with a wire rope disorderly

wound on a winch will damage the wire
rope and shorten the life of the wire
rope. Do not lift a load with a wire rope
disorderly wound!

Fig.4-3.12 Winch drum monitor mirror

4-86
 Operation
STC500S3

4.3.3 Operation of boom

4.3.3.1 Telescoping operation of boom

(1) Precautions for the telescoping operation

of boom

NOTICE

1. Hook moves up or down along with

the telescoping of boom. Therefore,
hoisting is required when telescoping the
boom to adjust hook height. Hydraulic
oil temperature can slightly affect the
telescoping of boom when it is extended
out. For example, provided the extended
length of boom is 5m, the boom would be
retracted about 40mm if the temperature of
hydraulic oil drops 10℃ .

2. The above-mentioned natural

telescoping length could be affected by
factors such as telescoping status of
boom, boom elevation and lubricating
condition, except hydraulic oil
temperature. Attention shall be paid to the
following items to avoid natural retracting
of boom:
1) Make sure the hydraulic oil is not too
hot.
2) In case of natural telescoping in, the
telescoping operation can be implemented
properly to adjust the length of boom.

3. Completely lower the hook before

extending the boom.

4. When boom has been fully telescoped

in, check to ensure the boom length is in
the specified range with display value on
moment limiter. Then, telescope out the
boom.

4-87
Operation
STC500S3

(2) Telescoping operation of boom

WARNING

Do not expose any part of your body out of

the window, which may otherwise put you
in danger of being hurt by the boom if you
happen to touch the boom control lever
or the boom control lever is moved due to
some other reasons.

NOTICE
Do not press service switch during the
telescoping operation of boom.
Telescoping with load is prohibited.

The telescoping operation of boom goes as

followed:

1. Do set hand brake to LOCK position; set

transmission lever to Gear 4; activate the
power takeoff control switch and key switch;

2. Set up outriggers;

3. Start the engine;

4. Turn on the master switch;

(See chapter 4.3.2.2 starting from page 4-79

to page 4-82 for detailed operation of the
above 4 steps);

4-88
 Operation
STC500S3

5. Push the telescoping operation control lever

forwards “A“ in Fig.4-3.13 (1) to telescope out
the boom “A“ in Fig.4-3.13 (2) and telescope A
in the boom “B“ in Fig.4-3.13 (2) by pulling
the lever backwards “B“ in Fig.4-3.13 (1). The
operation speed is regulated through control B

lever and throttle.

WARNING
Moving the control levers abruptly is
dangerous because it causes the load to
bounce and swing. Operate levers slowly
and carefully.
When the boom is telescoped out, the
working radius increases. Be alert to any
sign of overloading when telescoping out
the boom.
A boom telescoped incorrectly can
collapse if a lift is made in this condition.
Watch out for any error in the boom Fig.4-3.13 (1) Telescoping operation control
section telescoping sequence while lever
A-Push control lever forwards
operating the crane.
B-Pull cotrol lever backwards

WARNING
Do keep away from moving mechanism,
otherwise, serious damage or death may
occur.

A
B

Fig.4-3.13 (2) Telescoping operation of boom

A-Telescope out the boom
B-Telescope in the boom

4-89
Operation
STC500S3

4.3.3.2 Luffing operation of boom

(1) Precautions for luffing operation of boom

NOTICE
1. Only vertical hoisting is permitted. It is
prohibited to drag the load on the ground.
Uneven loading shall be avoided as much
as possible.

2. The elevation limit (operation range) of

boom cannot be exceeded.

3. Operate slowly when starting or

stopping the luffing operation. No acute
operation.

(2) Luffing operation of boom

WARNING

Do not expose any part of your body out of

the window, which may otherwise put you
in danger of being hurt by the boom if you
happen to touch the boom control lever
or the boom control lever is moved due to
some other reasons.

The luffing operation of boom goes as

followed:

1. Do set hand brake to LOCK position; set

transmission lever to Gear 4; activate the
power takeoff control switch and key switch;

2. Set up outriggers;

3. Start the engine;

4. Turn on the master switch;

(See chapter 4.3.2.2 starting from page 4-79

to page 4-82 for detailed operation of the
above 4 steps);

4-90
 Operation
STC500S3

5. Push the luffing operation control lever

forwards “B“ in Fig.4-3.14 (1) to lower the
boom “B“ in Fig.4-3.14 (2) and raise it “A“ in B

Fig. 4-3.14 (2) by pulling the lever backwards

“A“ in Fig.4-3.14 (1). The operation speed is
A
regulated through control lever and throttle.

WARNING

Moving the control levers abruptly is

dangerous because it causes the load to
bounce and swing. Be sure to operate the
levers slowly and carefully.
An overloaded machine could overturn
or be damaged. Use only the hoist-up
operation to raise the load clear of the
ground.
When the boom is lowered, the working
radius increases. Be alert to any sign of
overloading when lowering the boom.
Never try to pull the load inward by raising
the boom. This practice can damage the Fig.4-3.14 (1) Luffing operation control lever
A-Pull control lever backwards
crane, leading to an accident.
B-Push control lever forwards

WARNING
Do keep away from moving mechanism,
otherwise, serious damage or death may
occur.

Fig.4-3.14 (2) Luffing operation of boom

A-Raise the boom
B-Lower the boom

4-91
Operation
STC500S3

4.3.3.3 Swing operation of boom

(1) Precautions for swing operation of boom

NOTICE

1. Before swing operation, check to ensure

the transversal span of outrigger complies
with the specified value.

2. Make sure there is adequate room for

operation.

3. Start or stop swing operation slowly. No

acute operation.

4. Do not pull up luffing control lever

suddenly.

5. Only vertical hoisting is permitted. It is

prohibited to drag the load on the ground.
Uneven loading shall be avoided as much
as possible.

4-92
 Operation
STC500S3

(2) Swing operation of boom

WARNING

During swing operation, one might be

hurt by the machine if he stands nearby.
Serious injury or death could result.
Sound the horn and start the operation
after you have confirmed that the
surrounding area is clear of personnel or
barriers.

NOTICE

The mechanical locking device of turntable

must be disengaged before swing
operation of crane.

1. Release the mechanical locking device 1

(see Fig.4-3.15) to separate the turntable
from chassis, see Fig.4-2.57 “Locked up and
released mechanical locking device on the 2 3
crane” in chapter 4.2.4 on page 4-57 for the
location of mechanical locking device;

2. Do set hand brake to LOCK position; set

4
transmission lever to Gear 4; activate the 5
power takeoff control switch and key switch;

3. Set up outriggers;
Fig.4-3.15 Release mechanical locking device
4. Start the engine; 1-Locking pin 2-Guide tube on locking pin 3-Turntable
4-Chassis 5-Locking pin base
5. Turn on the master switch;

(See chapter 4.3.2.2 starting from page 4-79

to page 4-82 for detailed operation of the steps
2, 3, 4, 5);

4-93
Operation
STC500S3

6. Push swing operation control lever forwards

“A“ in Fig. 4-3.16 (1) to turn turntable right “A“
in Fig. 4-3.16 (2) and turn it left “B“ in Fig.4-
3.16 (2) by pulling the lever backwards “B“ in A
Fig. 4-3.16 (1). Operation speed is regulated
through control lever and throttle.
B
WARNING
Do move the swing control lever slowly
and carefully. Moving the lever abruptly
is dangerous because it causes the load
to bounce and swing. This practice could
result in injury or death and may also
damage the crane.
When swinging a load from the over-front
area to an over-side area, be extremely
careful not to have the crane become
overloaded.
Never try to pull the load inward or
sideways by swinging the boom. This
practice can damage the crane, leading to
an accident.
Fig.4-3.16 (1) Swing operation control lever
A-Push control lever forwards
WARNING B-Pull control lever backwards

Do keep away from moving mechanism,

otherwise, serious damage or death may
occur.

B A

Fig.4-3.16 (2) Swing operation of boom

A-Turn the crane right
B-Turn the crane left

4-94
 Operation
STC500S3

4.3.4 Removing and stowing the single

top

4.3.4.1 Precaution for the use of single top

NOTICE

The single top is mounted on the boom

head and used for lifting relatively light
loads. Although the load that the single top
can handle is limited in weight, the single
top utilizes a single rope arrangement
which significantly shortens hoisting time.

Only auxiliary hoisting mechanism, the

rope hereof and auxiliary hook can be
adopted for single top lift.

4-95
Operation
STC500S3

4.3.4.2 Removing the single top

NOTICE

The rated lifting capacity for a single top

lift is determined by subtracting the mass
of auxiliary lifting equipment suspended
from the boom head from the rated lifting
capacity for a boom lift. The maximum
load permitted for the single top, however,
is limited to 3500Kg. If the load obtained
from the above calculation is over 4000Kg,
4000Kg must be taken as the rated lifting
capacity.

(1) Fully extend the outriggers and set the

crane in a level position (See chapter 4.2.3
starting from page 4-40 for detailed operation);

(2) Lower the boom all the way down;

WARNING

When working at an elevated position, use

a platform or scissor lift to prevent falling
and ensure safety.

Fig.4-3.17 Fully extend the outriggers and set the crane in a level position, lower the boom all the
way down

4-96
 Operation
STC500S3

(3) Pull out the clamping pin shown “2”, see

Fig.4-3.18;

(4) Pull out the locking pin 2, see Fig.4-3.18;

2
3

Fig.4-3.18 Mount single top

1-Locking pin1 2-Clamping pin 3-Locking pin2

(5) Rotate single top around locking pin 1, see

Fig.4-3.19;

Fig.4-3.19 Mount single top

1-Locking pin1

4-97
Operation
STC500S3

(6) Align the locking pin hole on single top with

the one on boom head. Insert locking pin 2,
see Fig.4-3.20;

(7) Insert elastic pin to fix single top onto the

boom head as shown in Fig.4-3.20;

NOTICE

Mount the single top securely. Use the

attached clamp pin to ensure that the
locking pins do not slip out of position. 1

Fig.4-3.20 Mount single top

1-Locking pin2 2-Clamping pin 3-Locking pin1

(8) Hang the rope of auxiliary hoisting

mechanism onto the sheave of top boom
section and single top, see Fig.4-3.21.

Fig.4-3.21 Mount single top

4-98
 Operation
STC500S3

4.3.4.3 Stowing the single top

WARNING

When working at an elevated position, use

a platform or scissor lift to prevent falling
and ensure safety.
Stow the single top securely. Use the
attached clamps to ensure that the locking
pins do not slip out of position.
2

The stowing of single top goes opposite with

mounting step. See the following steps: 3

(1) Lower the boom all the way down, remove

rope clamp, take out wire rope. Then, well
stow the auxiliary hook. See Fig.4-3.22;
1

Fig.4-3.22 Wedge socket on wire rope

1-Loosen nuts on rope clamp
2-Remove rope clamp
3-Remove wire rope

(2) Remove clamp pin;

(3) Remove locking pin 2;
(4) Rotate single top around locking pin 1 to its
original position. Insert locking pin 2;
(5) Do insert clamp pin at last.

NOTICE 3

Stow the single top securely. Use the

attached clamp pin to ensure that the
locking pins do not slip out of position.
1

Fig.4-3.23 Mount single top

1-Locking pin2 2-Clamp pin 3-Locking pin1

4-99
Operation
STC500S3

4.3.5 Operation of jib

4.3.5.1 Precaution for spreading the jib

WARNING

For loaded jib, never swing it to the

front area with no front jack extending.
Otherwise, truck crane may topple over.
Rated lifting capacity is low when front
jack is not extended out.
For the operation of jib, only auxiliary
hoisting mechanism, the rope hereof and
auxiliary hook can be applied in load lift.

NOTICE
Jib should be used under the condition
that boom and outriggers are fully
extended.
Do not fail to make sure the auxiliary
winch wire rope is not wound disorderly
on the drum.

4-100
 Operation
STC500S3

4.3.5.2 Spreading the jib

WARNING

Do not lower the boom to an angle below

0°. This action could cause the jib to
disengage and drop off.
Always make sure that all the pin shafts
are in position before starting any
operation. Without these pins in position,
the jib will drop off when an operation is
started.
Take the necessary precautions to ensure
that nobody enters the area over which the
jib will swing. Anyone standing in this area
could be injured. Also check the adjacent
work area for any structure or other
obstruction that mey present a problem
when operating the jib.
Mount the jib carefully with no load on
the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

(1) Fully extend the outriggers and set the

crane in a level position (See chapter 4.2.3
starting from page 4-40 for detailed operation);

2. Fully retract boom and lay it down at the

rear area;

Fig.4-3.24 Fully retract boom and lay it down at the rear area;

4-101
Operation
STC500S3

3. Remove pin shaft B (see Fig.4-3.25) on the

jib. Rotate it around pin shaft A (see Fig.4-
3.25) to align the pin hole on the jib with the
one on the boom. Insert pin shaft C see Fig.4-
3.26.

WARNING

Do not stand under the working jib.

Fig.4-3.25 Spread jib

1-Pin shaft A 2-Pin shaft B

Fig.4-3.26 Spread jib

1-Pin shaft C 2-Pin shaft A

4-102
 Operation
STC500S3

4. Remove pin shaft A. Rotate the whole jib

around pin shaft C to align the pin hole on the
other side of jib with the one on the boom (see
Fig.4-3.27). Insert pin shaft D (see Fig.4-3.27
for final appearance).

WARNING

Mount the jib carefully with no load on

the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

Fig.4-3.27 Mount jib

1-Pin shaft C 2-Pin shaft D

4-103
Operation
STC500S3

4.3.5.3 Spreading the folding jib

WARNING

All the pin shafts should be kept in

position before starting any operation.
Without these pins in position, the jib will
drop off when an operation is started.

Spread the folding jib based on working

condition.

1. Rotate the folding jib around pin shaft A in

the direction shown in Fig.4-3.28;

WARNING

Do not stand under the working jib.

Fig.4-3.28 Folded folding jib

1-Folding jib 2-Jib assembly
3-Pin shaft A 4-Pin shaft B

4-104
 Operation
STC500S3

2. Remove pin shaft B from the folding jib.

Insert pin shaft B when the folding jib reaches
the position shown in Fig.4-3.29;

WARNING

Mount the folding jib carefully with no load

on the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

4
2
3

Fig.4-3.29 Spreaded folding

1-Folding jib 2-Jib assembly
3-Pin shaft A 4-Pin shaft B

4-105
Operation
STC500S3

4. Remove the wire rope from the center

pulley on the head of boom;

5. Reeve the wire rope through the jib roller

and the head of boom;

6. Properly connect the plug on the boom & jib

along with the socket on the folding jib. Mount
height limiter assembly.

6 5

2 3 4

Fig.4-3.30 Mount height limiter

1-Height limiter assembly 2-Round weight 3-Connection plug on folding jib
4-Connection socket on jib 5-Jib 6-Folding jib

7. Mount auxiliary hook block: reeve the

wire rope on the channel of wedge 4, pack
them together into wedge socket 5, mount 2

rope clamp 3, then tighten the nuts. Align the

mounting hole on the wedge socket with the
one on the top of auxiliary hook block. Mount
3
pin shaft and fix it with split pin.

4
6

Fig.4-3.31 Mount auxiliary hook block

1-Jib 2-Auxiliary wire rope 3-Rope clamp
4-Wedge 5-Wedge socket 6-Auxiliary hook block

4-106
 Operation
STC500S3

4.3.5.4 Adjusting the jib offset angle

1. Properly mount the jib at the state of 0°, see

Fig.4-3.32;

WARNING

When working on a part at an elevated

position, use a platform or scissor lift to
prevent falling and ensure safety.
Secure the pin shafts in place by using the
attached clamping pin.

Fig.4-3.32 0° jib offset angle

4-107
Operation
STC500S3

15°

Fig.4-3.33 15° jib offset angle

30°

Fig.4-3.34 30° jib offset angle

4-108
 Operation
STC500S3

4.3.5.5 Stowing the folding jib

1. Remove auxiliary hook block as shown in 1

Fig.4-3.35. Loosen the nuts on rope clamp
3, pull out the wire rope together with wedge
4 from wedge socket 5. Remove the wedge
socket 5 from auxiliary hook block 6. The 2
auxiliary hook block is thus removed. Return
the removed auxiliary hook block into the drum
on the right side of jib.
3

2. Disconnect the plug on the head of jib along

with the connection socket on the head of
5
boom. Retract the auxiliary wire rope;

4
6

3. As shown in Fig.4-3.36. Remove pin shaft

B, insert it into the hole of folding jib bracket, Fig.4-3.35 Remove auxiliary hook block
then rotate it around pin shaft A. Rotate folding 1-Jib 2-Auxiliary wire rope 3-Rope clamp
jib. 4-Wedge 5-Wedge socket 6-Auxiliary hook block

WARNING

Do not stand under the working jib.

4
2
3

Fig.4-3.36 Spreaded folding jib

1-Folding jib 2-Jib assembly 3-Pin shaft A 4-Pin shaft B

4-109
Operation
STC500S3

4. Insert pin shaft B when folding jib bracket

reaches the position shown in Fig.4-3.37;

WARNING

Stow the folding jib carefully with no load

on the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

Fig.4-3.37 Folded folding jib

1-Folding jib 2-Jib assembly 3-Pin shaft A 4-Pin shaft B

4-110
 Operation
STC500S3

4.3.5.6 Stowing the jib

WARNING

Do not lower the boom to an angle below

0°. The jib could become disengaged and
drop off.
Always make sure that all the pin shafts
are in position before starting any crane
operation. Without these pins in position,
the jib will drop off when an operation is
started.
Take the necessary precautions to ensure
that nobody enters the work area over
which the jib will swing. Anyone standing
in this vicinity could be injured. Also check
the adjacent area for any structure or other
obstruction that may present a problem
when operating the jib.
Stow the jib carefully with no load on
the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

4-111
Operation
STC500S3

1. Remove pin shaft D (see Fig.4-3.38). Rotate

the whole jib around pin shaft C (as shown in
Fig.4-3.39) to align the pin hole on the other
side of jib with the one on the boom, insert pin
shaft A (see Fig.4-3.39). Remove pin shaft C
(see Fig.4-3.39);

WARNING

Do not stand under the working jib.

Fig.4-3.38 Stow jib

1-Pin shaft C 2-Pin shaft D

Fig.4-3.39 Rotate jib

1-Pin shaft C 2-Pin shaft A

4-112
 Operation
STC500S3

2. Keep rotating jib to move it towards the

boom, then insert pin shaft B (see Fig.4-3.40).
Jib is thus properly retracted;

WARNING

Stow the jib carefully with no load on

the crane. When working at an elevated
position, use a platform or scissor lift to
prevent falling and ensure safety.
Use the attached elastic pins to secure the
pin shafts in position.

Fig.4-3.40 Fully retract jib

1-Pin shaft A 2-Pin shaft B

4-113
Operation
STC500S3

4.3.5.7 The mounting and stowing order of

jib

Jib may be damaged if it is used or stowed

with incorrect order. Do use or stow the jib with
the following order:

(1) Operation steps of jib

a. Spread jib b. Change jib offset angle c.
Extend folding jib

(2) Stowing steps of jib

a. Retract folding jib b. Set jib offset angle to
0° c. Retract the whole jib

4-114
 Operation
STC500S3

4.3.6 Removing and stowing auxiliary

hook block

4.3.6.1 Precautions for the use of auxiliary

hook block

NOTICE

The wire rope may be reeved disorderly if

lifting operation is conducted when wire
rope is still loose.

4.3.6.2 Removing auxiliary hook block

Remove auxiliary hook block as followed:

1) Remove auxiliary hook block from its drum

in the direction shown in Fig.4-3.41;

Front of operator's cab

Fig.4-3.41 Remove auxiliary hook block

1-Jib bracket 2-Auxiliary hook block 3-Auxiliary hook block drum

4-115
Operation
STC500S3

2) Extend wire rope out and reeve it through

boom nose pulley through control lever;

3) As shown in Fig.4-3.42. Reeve auxiliary

wire rope onto the wedge channel. Pack them
together into wedge socket, mount rope clamp
and tighten the nut. Align the mounting hole on
the wedge socket with the one on the top of
auxiliary hook block. Mount pin shaft and tight
and fix it with split pin.

NOTICE
2
For the mounting of rope clamp, ensure
the pressure plate of it is mounted on the
longer end of wire rope. 1

3
5

Fig.4-3.42 Mount auxiliary hook block

1-Auxiliary wire rope 2-Rope clamp
3-Wedge 4-Wedge socket 5-Auxiliary hook block

4-116
 Operation
STC500S3

4.3.6.3 Stowing auxiliary hook block

1) Remove auxiliary hook block. As shown in

Fig.4-3.42, loosen the nuts on rope clamp. Pull
out the wire rope together with wedge from
wedge socket. Remove wedge socket from
auxiliary hook block. Auxiliary hook block is
thus removed;

2) As shown in Fig.4-3.43, retract wire rope

through control lever and fix it on the edge of
turntable tail box;

Fig.4-3.43 Fix auxiliary wire rope on the edge of turntable tail box

4-117
Operation
STC500S3

3) Return auxiliary hook into its drum in the

direction shown in Fig.4-3.44.

Front of operator's cab

Fig.4-3.44 Remove auxiliary hook block

1-Jib bracket 2-Auxiliary hook block 3-Auxiliary hook block drum

4-118
 Operation
STC500S3

4.3.7 Reeving wire rope

NOTICE

If the wire rope is reeved in a number of

parts of line greater than the standard
and the boom is raised to a large angle,
the extra wraps of rope that should be left
on the drum will be unwound before the
hook block reaches the ground, causing
damage to the wire rope amd its anchor
at the winch drum. Even with the standard
number of parts of line, this problem will
arise if the load is lowered below the
ground level. When the number of parts
of line is greater than the standard or the
elevation differences, ensure that more
than three wraps of rope will remain on the
winch drum while the load is lowered.
When the number of parts of line is less
than the standard, be sure not to exceed
the allowable load for one part of line.

4.3.7.1 Standard number of parts of line

Select the number of parts of line that

ensures the most efficient operation, taking
into consideration boom length, load weight,
hoisting speed and other conditions such as
winch drum wire rope capacity.

Refer to Table 4-2.1 on page 4-67 and Table

4-2.2 on page 4-69 for the standard number of
parts of line.

4-119
Operation
STC500S3

4.3.7.2 Reeving steps

1) Extend the outriggers (see chapter 4.2.3

starting from page 4-40) and set the boom to
the side or rear area;

2) Lower the boom all the way down and set

the hook block on the ground, see Fig.4-3.45;

Fig.4-3.45 Lower hook block

3) Remove clamp pin (as shown in Fig.4-3.46),

take out pin shaft to disengage wedge socket 1
2 3
with top boom section;

5
4
6

Fig.4-3.46 Reeve wire rope

1-Pin shaft 2-Rope clamp 3-Wedge socket
4-Rope clamp 5-Wedge 6-Wire rope

4-120
 Operation
STC500S3

4) Loosen the nut on the rope clamp, push the

wire rope together with wedge out from wedge
sleeve; 3

Fig.4-3.47 Wedge socket on wire rope

1-Loosen the nut on rope clmap
2-Remove rope clamp
3-Remove wire rope

5) Loosen and remove the rope guard shaft on

4th boom section head. Pull wire rope out from
sheave channel;

6) Remove the weight of the overwind cutout

device from the wire rope;

7) Reeve the wire rope with desired number of

parts of line;
See Fig.4-3.48

Fig.4-3.48 Reeve wire rope

8) Cover the rope end with rope socket and

lock it with rope clamp. Note: cover the rope
with the weight of overwind cutout device
firstly before rope socket;
See Fig.4-3.49

Fig.4-3.49 Cover the rope end with rope

socket

4-121
Operation
STC500S3

9) Fix the rope socket onto the hook block or

the boom with corresponding number of parts
of line.

Fig.4-3.50 Fix rope socket onto the boom

(Even number of parts of line)

Fig.4-3.51 Fix rope socket onto the boom

(Odd number of parts of line)

4-122
 Operation
STC500S3

4.3.7.3 Precaution for reeving wire rope

NOTICE

It is forbidden to lower the hook on

the ground with hoisting mechanism;
otherwise, the wire rope on winch reducer
may be reeved disorderly.

(1) Where the rope socket at rope end should

be installed depends on the number of parts of
line

When the number of parts of line is even,

install the rope socket onto the boom. When
the number is odd, install the rope socket onto
the hook block. See Fig.4-3.50 and Fig.4-3.51.

(2) Where the weight of overwind cutout

device should be installed depends on the
number of parts of line

When the number of parts of line is even:

install the weight onto the rope branch with
wedge sleeve.
When the number is odd: install the weight
onto the branch of neighboring rope. See
Fig.4-3.52.

4-123
Operation
STC500S3

Even number of parts Odd number of parts

Rope socket Weight

(connected to boom)

Weight

Rope socket
(connected to hook block)

Fig.4-3.52 Reeve the wire rope

(3) Be careful to avoid messing up the rope;

(4) It is forbidden to rewind the wire rope for

future use after the change of joint direction.

4-124
 Operation
STC500S3

4.4 After Operation

4.4.1 Retracting hook block and boom

WARNING

You shall only start the operation from the

operator's seat.

Sound the horn and start the operation

after you have confirmed that the
surrounding area is clear of personnel or
barriers.

Properly stow the jib and auxiliary hook block

as mentioned in chapter 4.3.5.5 on page 4-109
~4.3.5.6 on page 4-111 and 4.3.6.3 on page
4-117 if they are applied.
Hook block and boom here refers to main
hook block and boom.

Detailed steps:

4-125
Operation
STC500S3

1) Fully retract boom;

Fig.4-4.1 Fully retract boom

4-126
 Operation
STC500S3

2) Lower the main hook block and move it to

the position for stowing;

Fig.4-4.2 Lower the main hook block and move it to the position for stowing

4-127
Operation
STC500S3

3) Lower the boom when the retracting wire

rope of main hoist in under operation. Stow
the boom onto the boom bracket;

Fig.4-4.3 Lower boom and stow it onto the boom bracket

4-128
 Operation
STC500S3

4) Stow the wire rope below the boom and

properly retract it till it is a little tensioned;

Fig.4-4.4 Stow the wire rope below the boom

4-129
Operation
STC500S3

5) Fix the main hook block onto the chassis

platform with hook block fixing device, see
Fig.4-4.5.

Fig.4-4.5 Fix the main hook block onto the platform

4-130
 Operation
STC500S3

4.4.2 Locking turntable

As shown in Fig.4-4.6, lock the mechanical

locking device to lock the turntable together
with chassis. See Fig.4-2.57 “Locked up and 3
released mechanical locking device on the
1
crane” in chapter 4.2.4 on page 4-57 for the
location of mechanical locking device on the
crane.
4

Fig.4-4.6 Locked mechanical locking device

1-Locking pin
2-Guide tube on locking pin
3-Turntable 4-Chassis
5-Locking pin base

4-131
Operation
STC500S3

4.4.3 Shutting down the equipments in

operator’s cab

1. Restore the rocker swithes on the control

panel to their original position. Set all the
control levers to middle position, see Fig.4-4.7;

Fig.4-4.7 Equipments inside the cab

1-Control panel

4-132
 Operation
STC500S3

2. Insert the start key into key switch, rotate it

counterclockwise to Gear O to deenergize the
whole system;

Fig.4-4.8 Insert the start key into key switch

3. Close and properly lock the operator’s cab

door.
Refer to chapter 4.2.5.1 on page 4-58 for
detailed operation.

4-133
Operation
STC500S3

4.4.4 Retracting outriggers

Refer to chapter 4.2.3 starting from page 4-40

for the steps to retract outriggers.

4.4.5 Shutting down the power takeoff

device and engine

Refer to chapter 4.2.2.3 on page 4-37 for the

steps to shut down the power takeoff device
and engine.

4-134
 Operation
STC500S3

4.5 Operation of Accessories

4.5.1 Operation of the air conditioner

inside the cab

Start the air conditioner or heater based on the

ambient temperature. Start the air conditioning
system when ambient temperature is high and
start the heater when it is low.

4.5.1.1 Operation of air conditioner

(1) Steps to start the air conditioner

Air-conditioner system control panel is

equipped on the evaporator at the back of
operator's seat. See Fig.4-5.1 and Fig.4-5.2

AIR CONDITIONER
自动(Auto) 高速( High)

新风( Fresh) 中速( Middle)

冷风( Cool) 低速( Low)

南京协众汽车空调集团有限公司

Operator's seat

Fig.4-5.1 Location of air-conditioner system control panel

4-135
Operation
STC500S3

Fig.4-5.2 Air-conditioner system control panel

1-Display 2-Cooling operation indicator lamp 3-Fresh air indicator lamp 4-Power indicator lamp
5-Evaporator blower rotational speed indicator lamp (high speed)
6-Evaporator blower rotational speed indicator lamp (moderate speed)
7-Evaporator blower rotational speed indicator lamp (low speed) 8-Automatic control key for air delivery
9-Air delivery set key 10-Fresh air intake port control key 11-Cooling operation control key
12-Control key for temperature increase 13-Control key for temperature decrease 14-Power control key

4-136
 Operation
STC500S3

a. Start the engine

Insert the key into the key switch on the

electric cabinet, rotate it to Gear I to energize
the whole system. Rotate the key to Gear
III from Gear I to start the engine. Start the
engine after preheat in cold weather, see
Fig.4-5.3;

Fig.4-5.3 Turning the key from Gear I to Gear

III

b. Activate power

Pressing the power control key "14" in Fig.4-

5.2, can light up the power indicator lamp for ON
control panel, energize control panel, display
the temperature inside the cab on the screen
and activate the whole system at the same OFF
time.

Fig.4-5.4 Power control key

c. Set air delivery

Pressing air delivery set key "9" in Fig.4-5.2

once: low air flow with corresponding indicator
lamp on;
Pressing it once again: moderate air flow with
corresponding indicator lamp on;
Pressing it the third time: high air flow with
corresponding indicator lamp on;
Pressing it continuously: air flow goes in turn
"low-moderate-high-low"
Fig.4-5.5 Air delivery set key

4-137
Operation
STC500S3

d. Temperature control

1. The temperature can be set with a

decrement of 1°C through the control key
shown in the right illustration "13" in Fig.4-5.2,
and the set temperature can be seen from the
display. Then, after 3 seconds, the set value
would automatically change into the actual
temperature inside the cab.

Also, temperature can be set with an Fig.4-5.6 (1) Control key for temperature
increment of 1°C through the control key decrease
"12" in Fig.4-5.2. The temperature can be set
between 16°C~27°C.

Fig.4-5.6 (2) Control key for temperature

increase

2. With the activation of air delivery regulating

gear and when the set temperature stays
below the one inside the cab, pressing the
cooling operation control key "1" in Fig.4-5.2
can light up the cooling operation indicator
lamp. It means the cooling operation has been
activated.

Fig.4-5.7 Cooling operation control key

4-138
 Operation
STC500S3

(2) Steps to shut off the air conditioner

Pressing the power control key shown in Fig.4- ON

5.8 once again can shut off the air conditioner
system.

OFF
With the completion of crane operation, you
also should shut down the engine and the
power for operator's cab with the following
steps: Fig.4-5.8 Power control key

a. Shut down the engine

Pressing the engine shutdown control switch

shown in Fig.4-5.9 and holding it down for
1~2 seconds can shut down the engine. This
switch can restore to its original position after
released.

Fig.4-5.9 Engine shutdown control switch

b. Cut off the power for operator's cab

Turning the key switch shown in Fig.4-5.10

from Gear III to Gear 0 can cut off the power
for operator' s cab.

Fig.4-5.10 Cut off the power for operator’s cab

4-139
Operation
STC500S3

Refer to the attached Construction Machine

Air Conditioner Installation Instruction for the
operation of air conditioner.

Fig.4-5.11 Instruction on installation and operation of air conditioner

4-140
 Operation
STC500S3

4.5.1.2 Operation of warm air heating

system

(1) Start the warm air heating system

Steps to start the warm air heating system:

a. Start the engine

Insert the key into the key switch on the

electric cabinet, rotate it to Gear I to energize
the whole system. Rotate the key to Gear
III from Gear I to start the engine. Start the
engine after preheat in cold weather, see
Fig.4-5.12;

Fig.4-5.12 Turning the key from Gear I to Gear

III

b. Activate the warm air heating system by

pressing the “ON” end shown in Fig.4-5.13. OFF

Such switch is located on the right armrest box

inside the cab; ON

(2) Shut down the warm air heating system

Shut off the warm air heating system by

pressing the “OFF” end.

Fig.4-5.13 Warm air heating system control

switch

4-141
Operation
STC500S3

4.6 Operation in Cold Weather

4.6.1 Operation instruction

The engine possibly fails to start and the

coolant may freeze under low temperature. In
this case, the following instructions must be
followed.

4.6.2 Fuel and lubricant

Fuel and lubricant with low viscosity shall be

used for all components.
Refer to chapter 5.3 “Recommended oil and
grease“ on page 5-128 for more information
on specification of viscosity.

4.6.3 Coolant of cooling system

WARNING

Anti-freeze liquid is poisonous. Be careful

not to let it contaminate your eyes or skin.
If it contaminates your eyes or skin, flush
with large amount of clean water and refer
to medical care immediately.
When replacing the coolant or disposing
the coolant containing anti-freeze liquid,
which is drained when repairing the
radiator, please contact Sany dealer or a
professional company to dispose it. Since
the anti-freeze liquid is poisonous, do not
drain it to sewage system or leave it on the
ground.
Anti-freeze liquid is flammable, so no
naked fire is allowed to approach it. Do not
smoke while disposing anti-freeze liquid.

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STC500S3

4.6.4 Battery

Battery capacity decreases as the ambient

temperature drops. It is important to keep
battery capacity at 100% level. Do not let the
battery stay long under low temperature so as
to avoid the difficulty in starting your machine.

Since the battery’s capacity will decrease

under low temperature, it is important to cover
the battery or remove it from your machine.
Store your battery in a warm place and
reinstall it before operating your machine.

4.6.5 After each workday

The following items must be observed in order

to prevent that the machine cannot move the
next day due to frozen mud and ice on the
undercarriage.
1. Remove all mud and water from your
machine. Clean especially the piston rods of
hydraulic cylinders in order to prevent mud,
dirt or water from penetrating the cylinders and
spoiling the seals.
2. Park your machine on a hard, level ground.
3.Open the drain valve to discharge
accumulated water of the fuel system so as to
prevent it from freezing.
4. Refill the fuel tank to tis maximum level. In
this way, when ambient temperature drops, the
condensate in the tank could be minimized.

4.6.6 After cold season

When the season changes and the weather

gets warm, perform as described below.
The fuel or lubricant of any components shall
be replaced with the one of specified viscosity.
Refer to chapter 5.3 “Recommended oil and
grease“ on page 5-128 for more information.

4-143
Operation
STC500S3

4.7 Long-term Storage

4.7.1 Before storage

When storing your machine for more than a

month, perform as described below:

1. Clean all parts of your machine and then

store your machine indoors. If you have to
store your machine outdoors, choose a level
ground and cover your machine with canvas.

2. Refill your fuel tank to its maximum level in

order to avoid accumulation of water.

3. Lubricate your machine and change its oil

before storing it.

4. Apply grease to the exposed part of the

piston rod of hydraulic cylinder.

5. Disconnect the battery’s negative terminal

and reinstall its cover, or remove the battery
from your machine and store it in a separate
place.

6. For machines equipped with additional

equipment, the control pedal of additional
equipment shall be placed to locked position.

7. To prevent rusting, please use Sany

specified antifreeze as coolant of the engine.
The engine possibly fails to start and the
coolant may freeze under low temperature. In
this case, the following instructions must be
followed.

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STC500S3

4.7.2 During storage

WARNING
When your machine is stored indoors, it
is important to prevent rusting by opening
the doors and windows to improve
ventilation. This can also prevent gas
poisoning.

During storage, it is important to operate your

machine and drive it for a short distance once
a month. This can help apply a new oil film on
parts and components. Meanwhile, charge the
battery of your machine.

Before operating the work equipment, wipe off

all the grease from the piston rod of hydraulic
cylinder.

If your machine is equipped with air conditioner,

switch on the air conditioner for 3-5 minutes
once a month, which can lubricate all parts of
its compressor. The engine shall run at low
idle speed when air conditioner is working. In
addition, check its refrigerant twice a year.

4.7.3 After storage

Before using your machine again after a

longterm storage, perform as described below:

1. Wipe off the grease from the piston rod of

hydraulic cylinder.

2. Apply lubricant or grease to all necessary

locations.

3. The moisture of air can mix with oils when

your machine has been stored for a long time.
Check the oils before and after starting the
engine. If the oil contains water, remove the
water timely.

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STC500S3

4.8 Transporting the Machine

4.8.1 Lifting the machine

WARNING

Only eligible, experienced operator with

official license (as per local laws) is
allowed to operate a crane.
Do not lift the machine when someone is
riding on it.
Nobody shall be allowed to enter the area
below or around the lifted machine.
Make sure that the wire cables used for
lifting the machine are strong enough to
bear the weight of machine. Never use
damaged or aged wire cable or sling.
Do not lift the machine when its upper
structure has swung aside. Before
lifting, it is important to move the work
equipment to the final drive end and keep
the longitudinal centerlines of the upper
structure and the lower structure parallel.
Keep the machine parallel to the ground
during lifting.
Do not lift the machine at fast speed,
which may otherwise overload the wire
cables or slings and result in rupture.
Besides the attitudes recommended in the
following procedure, do not use any other
attitudes to lift the machine. Do not use
the type of lifting equipment other than the
ones specified in the following procedure.
Otherwise it may have the danger to loose
balance.

4-146
 Operation
STC500S3

(1) The crane can be loaded on a flatbed car

for railway transportation. The tire pressure
shall be 0.5Mpa and the wheels must be
chocked.

(2) The crane shall be fixed on the flatbed car

securely with teathers.

(3) The gravity center of loaded crane shall

be at the rear side of the front axle center (the
rear of machine) (see Fig.4.8.1).

(4) Once loaded, the cab power shall be cut

off, the brake device shall be activated, the
gear shift shall be put into the low speed
position. The control levers and switches of
crane must be put into neutral or off position.

(5) Lock the door and window of crane once it

is loaded to prevent opening.

4-147
Operation
STC500S3

Lifting Location Diagram

S －Centre Of Gravity

Fig.4-8.1 Lift the crane

Boundary of
railway tunnel
Boundary of railway
transportation

Primary over bound

margin line of railway
transportation
Secondary over bound
margin line of railway
transportation

2750
Min. load height of
railway transportation

Fig.4-8.2 Transport the crane by railway

4-148
 Operation
STC500S3

4.8.2 Packing list

1. STC500S3 Truck Crane

2. Documents with the machine

1) STC500S3 truck crane operation manual
2) STC500S3 truck crane certificate
3) Truck crane chassis certificate
4) Wire rope certificate
5) Main hook block certificate
6) Moment limiter operation manual
7) Documents with the engine:
a) Engine use and maintenance manual
b) Engine certificate and warranty card
c) Engine spare parts and dismantling tools
with machine
8) Main accessories table
9) Packing list
10) Tool list with the machine
11) Spare parts and wearing parts table

3. Components (packed) with the machine

1) Spare parts with the machine (see spare
parts list)
2) Tools with the machine

4-149
Operation
STC500S3

4.8.3 Spare parts list

Table 4-8.1 Spare parts list

No. Code Description & Specification Unit

1 10056705 Accessories of O ring 1
2 B230103000319 Rubber pipe 2SN10-DKOL-1650Q/SY1102 2
3 B210770000084 Pressure testing joint SMK20-M14×1.5-PC Stauff 1
4 60029802 Pressure tesing hose K10L-M1/4-4000-B 1
5 B250100000110 Pressure gauge 1453.086.002(40Mpa) Tecsis 1
6 10668724 Spare parts for engine 1
7 10659014 Cleaning agent 4

4-150
 Operation
STC500S3

4.8.4 Attached tools list

SANY provides attached tools list and

accessories.

Table 4-8.2 Attached tools list

No. Code Name Qty.

1 60013280 Attached tool box 2
2 60013468 Attached tool box 1
3 10652505 Engine tool 1
4 A260401030002 Double open-end spanner 8×10GB4388 1
5 A260401030091 Double open-end spanner 13×15GB/T4388 1
6 A260401030028 Double open-end spanner 16×18GB4388 1
7 A260401030005 Double open-end spanner 17×19GB4388 1
8 A260401030029 Double open-end spanner 18×21GB4388 1
9 A260401030007 Double open-end spanner 22×24GB4388 1
10 A260401030008 Double open-end spanner 27×30GB4388 1
11 A260401030031 Double open-end spanner 34×36GB4388 1
12 A260401030040 Double open-end spanner 41×46GB4388 1
13 A260401030044 Double offset ring spanner 13×16GB4388 1
14 A260401030045 Double offset ring spanner 18×21GB4388 1
15 A260401040001 Monkey wrench 150GB4440 1
16 A260401040004 Monkey wrench 300GB4440 1
17 A260402010005 Minus screw driver (rubber handle) 100×0.6×4-2CQB3863 1
18 A260402010016 Minus screw driver (rubber handle) 200×1.2×8-2CQB3863 1
19 A260402020007 Cross screw driver 75×3-2CQB3864 (rubber handle) 1
20 A260402020006 Cross screw driver 200×8-2CQB3864 (rubber handle) 1
21 A260404000010 Sharp nose pliers 160QB2440.1 1
22 A260404000002 Wire pliers 180QB2442.1 1
23 A260401020001 Inner hexagon spanner 10 pieces per set GB5356 1
24 A260401030089 Socket spanner 27 pieces per set GB3390.1, 4-04 1
25 A260401030105 Single open-end spanner 70GB4388 1
26 A260403010003 Fitter’s hammer0.8QB1290.3 1
27 A229900002672 Triangle warning plate JSP-A01 1
28 A260409000001 Grease Gun A400JB7942.1 1
29 A241100000010 Working lamp 24V/15W 1
30 A260409000409 Tyre valve spanner 39D-01075 1

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Operation
STC500S3

Table 4-8.2 Attached tools list

No. Code Name Qty.

31 A250100000121 Tyre pressure gauge 0-1MPa02912D-010 1
32 A230103000849 Air charging hose assembly 39N-01310-B 1
33 A260401010096 Tyre sleeve 32×33 1
34 A260409000457 Tyre lever with sleeve spanner handle18×500 1
35 A550300000228 Work clothes(for customer) 2
36 10679577 Attached foam case(case1#) 1
37 10679578 Attached foam case(case2#) 1
38 10844841 Oiling funnel 1

NOTICE

The attached accessories vary with the

development of products. Refer to packing
list for detailed accessories.

4-152
 Maintenance
STC500S3

Maintenance

5 Maintenance
5.1 Maintenance of Chassis............................................................................................ 5-3
5.2 Maintenance for Superstructure............................................................................ 5-101
5.3 Recommended Oil and Grease............................................................................. 5-128

5-1
Maintenance
STC500S3

E
G
PA
K
AN
BL

5-2
 Maintenance
STC500S3

5 MAINTENANCE
5.1 Maintenance of Chassis

5.1.1 Basic maintenance

5.1.1.1 Chassis inspection

Identification code of truck (VIN code): upon

delivery, manufacturing code of truck has been
engraved on the right side of chassis frame,
where is adjacent to front wheels. When you
want to maintain chassis or purchase fittings,
do remember VIN code of the truck, and Right side of frame Chassis data plate
contact local service station for service as
soon as possible. Fig.5-1.1

Engine No.: when you want to repair engine

or purchase spare parts, engine serial number
and other serial numbers are necessary.
Engine model and serial number are engraved
on engine cylinder body. Contact service
station and use the above serial numbers that
service can be gained successfully and in
time. HINO engine is as the figure:

Fig.5-1.2

To maintain optimum per formance and

prolong service life, it’s necessary to inspect
and maintain truck. The owner shall implement
“daily” and “regular” inspections, to ensure
safety, reduce emission of “exhaust gas” and
lower noise.

Fig.5-1.3

5-3
Maintenance
STC500S3

Inspection of new truck: during initial running

of 2000km-3000km, you need to change
lubricant for engine, transmission gear and
Do inspect carefully
differential gear; and during initial 5000 km,
you need to change lubricant for power
steering.

Regular inspection: performance of truck,

service performance of each component and
its equipment are upon to service time limit
and maintenance of truck. Please inspect and Fig.5-1.4
maintain as above carefully.

Daily inspection: the driver shall inspect the

whole truck before each startup to avoid
possible safety risk. Daily inspection is simple
and easy to implement. The inspection items
include surroundings of engine, brake system,
steering system, lighting system and other
systems which may affect running and exist
possible safety risk.

Line inspection: inspect whether electrical

wire is fixed. Pay attention to bend, damage
and corrosion of line. In case of fault, please
inspect truck and go to SANY service station
for inspection and repair.
CAUTION: do not add other lines. If you want
to increase configuration like lighting, look for
SANY service station.

5-4
 Maintenance
STC500S3

5.1.1.2 Breaking-in of new truck

Breaking-in of new truck is an important phase

to ensure long-term running of truck. Moving
parts at various positions are fit up after
breaking-in, so as to prolong service life of
chassis. Therefore, breaking-in work must be
done carefully.

During initial 1000km, do limit rotation speed

of engine. Thereafter, improve rotation
speed from low to high gradually to complete
breaking-in. Applicable range of maximum
rotation speed of new truck’s engine: 1500r/
min- 1600r/min. Breaking-in of new truck

Precautions on breaking-in:

Breaking-in mileage of new truck is 2000km-

3000km; The engine shall avoid running in
n
high speed zone (above 1600r/min) or low r/mi
00
speed zone (below 900r/min) for a long time. 16
Optimum rotation speed of engine during m in ～
00r/
running shall be limited among 900 r/min-
V=9
1600r/min.
Fig.5-1.5
Load of truck in breaking-in shall not exceed
60% of specified value. Overload is prohibited;

Maximum speed of truck during runningin shall

not exceed 50km/h; During breaking-in, drive
on flat and good road other than bad one.

5-5
Maintenance
STC500S3

5.1.1.3 Chassis maintenance

The truck, electrical joint, electrical element,

electronic equipment, plug and horn shall be
averted from cleaning. During flushing with
water pipe, do prevent water entering air
intake.

After running on road eroded by salt (sea

water) or chemicals, do clean the truck
thoroughly.

After cleaning, trample slightly to inspect

brake pedal. If the brake functions abnormally,
drive the truck slowly, repeat trampling slightly
till it is dried thoroughly. Pay attention to the
front and rear direction of the truck during this
operation.

5-6
 Maintenance
STC500S3

NOTICE
Avoid flushing wiring joint of chassis
directly at high pressure. Although
the joint provides waterproof function,
flushing at high pressure will deform
waterproof rubber and let water enter
the plug. After immersion, the water can
not evaporate for waterproof design.
Consequently, the wiring will be broken for
rust and electrical corrosion.
Do not sprinkle water on electrical element
of engine, otherwise startup of engine will
fail or electrical element will be damaged.
Do not clean truck with spiculate tools
which will damage surface painting etc.
Do not clean inside of cab by sprinkling,
because electrical element will fail for
water sprinkled on sound box or other
electrical elements.
Do not clean safety belt with organic
solvent, whiten or colorize it; otherwise
safety belt will become inferior. Do clean
safety belt with cleaning agent without
organic solvent, then reuse safety belt
thoroughly dried. Do not clean the cab
inside with organic solvent; the solute will
result in color change or contamination.
Some common cleaning agents may
contain solvable agent, so do use it after
inspection.

5-7
Maintenance
STC500S3

5.1.2 Daily inspection and maintenance

Before startup, do inspect carefully around

the truck for leakage of engine oil, clutch
fluid, cooling fluid and fuel (mainly for engine,
transmission, differential and power steering
etc.). If any leakage track is found on the
ground, immediately inspect level of engine
oil, clutch fluid, cooling fluid and fuel. Refer to
contents in the following regular maintenance
part for method to inspect engine oil, steering
oil, clutch fluid and cooling fluid.
Fig.5-1.6

NOTICE
Environment will be polluted by oil, grease
and cleaning agent poured on ground, in
water or river.

Inspect whether vents of transmission and

differential are blocked. See Fig.5-1.7.

Inspect for air leakage.

Inspect all pipeline systems for leakage. In

case of the above failures, contact SANY
service station for inspection and repair.

Fig.5-1.7

5-8
 Maintenance
STC500S3

5.1.2.1 Hydraulic oil

Before sent to customer, hydraulic oil tank has

been filled with Caltex VG46 hydraulic oil as
specified.

WARNING

Hydraulic oil is toxic. Keep away from

children and pets. If not reused, dispose
of in accordance with local environmental
regulations.

(1) Replacement period of hydraulic oil

Date for delivery 2000 hours’ operation Filtering or replacing oil every 6 months Filtering or replacing oil

NOTICE

This crane is of full hydraulic drive. Quality,

viscosity and cleaness of hydraulic oil
are necessities in crane operation. Crane
may be seriously damaged and service
time may be shortened due to improper
replacement of hydraulic oil. SANY will
bear no responsibility for any result
caused by improper replacement and
filtering of hydraulic oil.

5-9
Maintenance
STC500S3

(2) Drain of hydraulic oil tank

CAUTION

When the engine has just been stopped,

the parts and oil are still hot and can cause
serious burn. Wait for the temperature to
cool down before doing this job.

Step 1: There are two stop valves as shown in

Fig.5-1.9, close the two stop valves. Close stop valve
See Fig.5-1.8.

Step 2: Use a wrench to loosen two drain

screws under the tank, as shown in Fig.5-1.9.
For there is a clapboard in the tank, oil tank
may not be completely drained if only one
screw is loosened. Place a container below
the oil drain screws.

Step 3: Drain the hydraulic oil tank completely,

and tighten the two drain screws. Fig.5-1.8 Close the two stop valves

A direction
1
2

A direction

6 7 5 4 8 3

Fig.5-1.9 Location of liquidometer

1-Air filter 2-Liquidometer 3-Drain port 4-Return adaptor body
5-Stop valve 6-Stop valve 7-Drain screw 8-Drain screw

5-10
 Maintenance
STC500S3

(3) Replacement steps of hydraulic oil

Step 1: Drain hydraulic oil off, disassemble

the master return pipe from the return adaptor
body (see Fig.5-1.9 No.4 on page 5-10).

Step 2: Carefully clean oil tank and filter with

chemical cleaning agent of a solid particle
contamination grade below 18/15. After airing,
wash them again with new hydraulic oil of the
same grade. Then, drain cleaning oil off to fill
in with new one.

Step 3: Open the two stop valves. Open stop valve

See Fig.5-1.10.

NOTICE

Open two stop valves before start the

engine. Start the engine when stop valves
are closed will cause oil pump damage.

Step 4: Start engine and run it at low speed.

Fig.5-1.10 Open the two stop valves
Oil pump starts to operate: it controls each
mechanism, functions to drain the original oil
off by newly filled one. Never let the drained oil
into oil tank till new oil flows out of return pipe.

Step 5: Finally, stop the oil pump. Add fresh

hydraulic oil into oil tank continuously during
oil replacement of each circuit. This can
effectively avoid air entering into oil pump.

Step 6: Connect the master return pipe with oil

tank. Initialize each part, add oil till it reaches
what is specified.

5-11
Maintenance
STC500S3

(4) High-pressure filter replacement

CAUTION
Never replace the filter immediately after
the engine is shut off, as all parts are still
hot. Wait for the parts to cool down before
replacing the filter.

a. Deactivate the hydraulic system and wait

for the parts to cool down. Remove the high-
pressure filter from the machine.
See Fig.5-1.11 and Fig.5-1.12.

b. Use a pneumatic tool to remove the outer

cover of the high-pressure filter.
1
c. Remove the old filter cartridge.

d. Install a new filter cartridge, use a Fig.5-1.11 Location of high-pressure filter

pneumatic tool to install the outer cover of the
high-pressure filter, and restore the filter to the
original position on the machine.

Fig.5-1.12 High-pressure filter

5-12
 Maintenance
STC500S3

(5) Hydraulic oil temperature

Observe the temperature of hydraulic oil

through scales on liquidometer. The maximum
operating temperature of hydraulic oil is 80 ℃
(the maximum scale).
See Fig.5-1.13.

A direction
1
2

A direction

6 5 4 3

Fig.5-1.13 Location of liquidometer

1-Air filter 2-Liquidometer 3-Drain port 4-Return adaptor body
5-Stop valve 6-Stop valve

(1) Hydraulic oil content

The maximum oil content of tank is 980L,

there is still 315L in tank at minimum content.
Add oil enough as specified when scale line
on liquidometer stays below the minimum
content.

(5) Performance and brand of hydraulic oil

Refer to chapter 5.3 on page 5-128.

5-13
Maintenance
STC500S3

5.1.2.2 Engine oil

In most cases, engine damage results from

improper use of engine oil. Proper use of
engine oil is key for proper use of chassis.
Main purpose of engine oil is to lubricate and
cool. Engine oil can transmit heat of engine to
cylinder body and finally radiate outside.

WARNING
The skin touching used engine oil for a
long time will be sensitive or get cancer.
Therefore, wash hands thoroughly with
soap and warm water immediately to
protect skin after treating the used engine
oil.

NOTICE

Engine oil may deteriorate in advance if

engine is always running at high speed or
under heavy load. Replace the oil if it is
badly black.
Engine oil should be replaced after the
first 2000km operation.
Engine oil may get watery in summer while
thick in winter. It is recommended to adopt
the engine oil of a viscosity suitable for
ambient temperature shown in Table 5-1.1;
otherwise, difficult start of engine may
occur in winter.
Never mix different engine oil.

5-14
 Maintenance
STC500S3

1. Damage caused by improper engine oil:

a) Excessively less engine oil will result in

high temperature, and shorten service time of
engine oil.

b) Lubricating function of inferior engine oil will

disappear that frictional parts will damage and
consequently damage the engine.

c) If the cylinder wall or piston ring is damaged

by inferior engine oil, seal of engine will be
affected that oil burning will happen.

Recommended engine oil: Shell CG-415W40

(temperature above -20°C ), Mobil HD15W-40
(temperature below -20°C )

See Table 5-1.1 for viscosity degree and

corresponding applicable temperature.
Most engine oil consumption will be faster
above 5°C , so inspect more frequently.

Fig.5-1.1 Viscosity of engine oil

Viscosity of engine oil Ambient temperature

5W For winter above -30°C

10W For winter above -25°C
15W For winter above -15°C
20W For winter above -10°C
20 For summer below 20°C
30 For summer below 30°C
40 For summer below 40°C
50 For high temperature

5-15
Maintenance
STC500S3

2. Related requirements on engine oil:

a) Engine oil must be heat and oxidation

resistant, and the viscosity must be applicable
to different ambient temperatures. Engine oil
applicable to environment shall be changed
based on service climate conditions of the
machine.

b) The engine oil filled must be of proper

quality, class and viscosity. When general
engine oil for the whole year or multigrade oil
in winter is used, do not refill common engine
oil which would affect startup performance
under lower temperature.

c) Common engine oil can be refilled in spring

or during use of general engine oil. Compared
with general engine oil of the same trademark,
pressure of multigrade oil will be lower.
The multigrade oil provides good viscosity-
temperature performance, its viscosity is high
at high temperature, low at low temperature,
and slightly low among normal temperature
range, so low pressure is normal.

d) The gas entering crankcase from

combustion chamber is corrosive, so keep
ventilation of crankcase is an idea method to
avoid engine oil from deteriorating.

e) Maintain engine oil filter frequently, for

regular inspection and maintenance of engine
oil filter can effectively solve failure of engine
caused by inferior engine oil.

f) Replace engine oil regularly. Engine oil will

fail to lubricate and cool normally after use for
a certain time, so replacing engine oil regularly
can maintain its function effectively.

5-16
 Maintenance
STC500S3

3. Inspect engine oil level:

CAUTION

To reduce the possibility of personal

injury, do avoid direct contact of hot oil
with your skin.

a) Make sure the machine is on flat ground;

b) Start engine to normal working temperature;

c) Stop engine and wait for a few minutes

(about 5min) till oil returns to oil pan;

d) Take out engine oil level gauge, and refit it

after wiping up with clean cloth;

e) Take out engine oil level gauge again, and

observe height of oil level. The normal level
is among groove zone. If insufficient, clean Fig.5-1.14
oil of the same trademark and type shall be
replenished; if excessive, drain redundant
engine oil from oil drain bolt.

5-17
Maintenance
STC500S3

4. Precautions during engine oil replacing:

a) During oil replacing, thoroughly drain waste

oil which may contaminate the newly filled
engine oil.

b) In general, drain waste engine oil at high

temperature, and then fill oil for cleaning, start
to operate at idle speed for 10min and drain,
and finally fill with clean engine oil.

c) During oil filling, do not spill. If engine oil

sprinkles on exhaust tube, it will be ignited
easily to result in fire, so pay attention to oil
filling.

d) During inspection after shutdown, be careful

not be burnt by high temperature from running
engine or the engine just stopped.

5-18
 Maintenance
STC500S3

5. Steps to replace engine oil:

a) Dismantle cover of engine oil filling inlet,

drain bolt of oil pan and engine oil filter, and
then drain engine oil (engine oil is more easily
to be drained under engine warmingup);

b) Tighten drain bolt after draining engine oil.

New washer for drain bolt must be used after
each removing.

c) Fill engine oil from oil filling inlet through

engine oil filter;

d) Check whether engine oil level is normal

with oil gauge after filling for 10min;

e) Start engine for idle run;

f) Shut down engine, and check whether

engine oil level is normal with oil gauge after
Fig.5-1.15
30min; replenish if engine oil level is low. At
the same time, check oil drain bolt for leakage.

CAUTION

When inspect or fill engine oil, do not

touch radiator hose, which is hot to cause
burns.
Do not spatter during replenishing engine
oil. If engine oil sticks on exhaust pipe, fire
may be caused by hot exhaust pipe, so be
careful during replenishing.

NOTICE

Replenishment of engine oil shall not

be excessive, otherwise engine will be
damaged.
Upon oil replacing, also replace filter
cartridge of engine oil filter.

5-19
Maintenance
STC500S3

5.1.2.3 Gearbox oil

Inspect and replenish gearbox oil:

a) Park truck on flat ground (check oil level

after shutdown for one minute);

b) Dismantle the gearbox oil port bolt;

see Fig.5-1.16

c) Clean the gearbox oil port bolt;

Fig.5-1.16
d) Check whether oil level is on the top of
inspection hole (relative position between
inspection hole and level);
see Fig.5-1.17

e) If oil level is too low, replenish through bolt

hole of oil port.

NOTICE

Do not fill excessive oil; otherwise it will

flow out from seal of input and output
shafts of transmission.
Do not use engine oil of different Fig.5-1.17
trademarks or types; otherwise it may
bring negative effect.

5-20
 Maintenance
STC500S3

5.1.2.4 Differential oil

1. Inspection and supply of differential oil:

a) Park truck on flat ground;

b) Dismantle the screw of oil inlet;

see Fig.5-1.18

c) Clean the screw of oil inlet;

d) Check whether oil level is below the bolt

hole of filling inlet (relative position between
bolt hole of filling inlet and level); Fig.5-1.18

e) Replenish oil if level is excessively low.

2. Replace oil:

a) Dismantle drain bolt and filling bolt at the

bottom of rear axle housing;

It is easier to drain oil at high temperature;

drain bolt is magnetic, so remove the scarp
iron adhered on it.
Fig.5-1.19
b) After draining oil, clean drain bolt and
replace with a new gasket and assemble it.
(Tightening moment of drain bolt: 130 N.m
-150 N.m)

c) Fill oil up to proper position of filling inlet.

(Before assembling bolt, clean drain bolt and Oil inlet

replace with a new gasket and assemble it.

Tightening moment of filling inlet bolt is among
130 N.m -150 N.m.)

Oil oulet

Fig.5-1.20

5-21
Maintenance
STC500S3

5.1.2.5 Cooling fluid

Engine cooling fluid is to cool body of engine in

service and prevents freezing and rusting. The
machine has been filled with -40°C cooling
fluid in factory before sent to the custormer.

WARNING

The cooling fluid is poisonous, so do not

drink;
If cooling fluid is drunk by mistakenly, do
refer to medical care immediately;
If cooling fluid entering eyes accidentally,
flush the eyes with lots of clean water
immediately for at least 15 min, and go to
hospital whenever possible;
If cooling fluid sticks on skin, please wash
with alkaline water thoroughly, and then
apply medicine for skin curing;
Tighten fluid storage tank, and store at a
safe place inaccessible to children;
Antifreeze is inflammable, so avoid open
fire during filling;
If the engine overheats, the cooling fluid
shall be refilled after engine cooling
down. If cover of expansion water tank is
removed while temperature of cooling fluid
is high, the hot cooling fluid and steam
will burst forth from filling inlet to cause
burns.

5-22
 Maintenance
STC500S3

(1) Proportioning of cooling fluid

Solid point of cooling fluid changes as

concentration of antifreezing fluid. Select
proper concentration as per the following
table to prevent frozen cooling fluid damaging
engine body. Proportion of antifreezing fluid
shall be among 30%-60%. If exceeding 60%,
antifreezing function will disappear; if less than
30%, anticorrosion function may abate. It is
generally recommended to use mixture of 50%
antifreezing fluid and 50% soft water.

Table 5-1.2

Solid point of cooling Proportion of

fluid°C(°F) antifreezing fluid (%)

-12(10.4) 30
-15(5) 35
-20(-4) 40
-25(-13) 45
-30(-22) 50
-35(-31) 55
-40(-40) 60

(2) Cooling fluid used in SANY chassis

Cooling fluid used in SANY chassis is solution

containing 50% water and 50% glycol.
Besides of heat exchange, the cooling fluid
also functions to prevent freezing, boiling
and corrosion. It can prevent fouling in cooler
chamber, reduce cavitation and rust of water
jacket, improve boiling point in hot summer
and prevent freezing in winter. Under standard
atmospheric pressure, the boiling point is
108°C, and freezing point is -45°C. In good
airproof cooling system, frequent filling of
cooling fluid is unnecessary, and maintenance
work can be reduced.

5-23
Maintenance
STC500S3

(3) Cooling fluid filling

a) Remove cover of engine expansion water

tank, and fill cooling fluid from filling inlet;

b) Tightly tighten cover of expansion water

tank;

c) When engine overheats, firstly check

whether engine is shut down and cooling
fluid is at proper temperature, and then shut
down engine, open cover of expansion water
tank to fill cooling fluid from filling inlet. At this
time, check whether cooling fluid level will
lower again (check after 5 seconds), and then
tighten cover of expansion water tank;

d) Replacing mileage or time interval;

e) Replace once every 600,000km or every

3 years, and take the one firstly reached as
reference. Drain inner cooling fluid, flush with
new cooling fluid, and then refill new cooling
fluid.

f) To properly exhaust air from cooling system,

start engine for idle run at slightly high rotation
speed till cooling fluid reaches normal service
temperature range and keep the engine run
for 10min.

NOTICE

The cooling fluid shall be filled slowly to

prevent air entering, otherwise engine will
overheat and cooling fluid pump will leak;
The cooling fluid shall be filled up to
specified level. Excessively low level will
result in engine overheating and corrosion
of cooling system etc.;
If cooling fluid sticks on paint of the
machine, flush it with water immediately.

5-24
 Maintenance
STC500S3

5.1.2.6 Fuel

Check whether fuel in tank is sufficient as per

pointer of fuel gauge. 1/1 indicates full, 1/2
indicates only 1/2 of fuel is left, and 0 indicates
fuel is insufficient and need to be replenished
in time.

1. Fuel selection
Fig.5-1.21 Fuel gauge

The fuel tank must be kept clean, and proper

fuel must be chosen according to different
temperature in different seasons. The table
below may be used as reference to use fuel:

Table 5-1.3 Recommended fuel

Ambient temperature Name and grade of fuel

More than 4 ℃ No. 0 diesel oil (GB/T19147-2003)
More than -5℃ No. -10 diesel oil (GB/T19147-2003)
More than -14℃ No. -20 diesel oil (GB/T19147-2003)
More than -29℃ No. -35 diesel oil (GB/T19147-2003)
More than -44℃ No. -50 diesel oil (GB/T19147-2003)

5-25
Maintenance
STC500S3

2. Precautions for fuel filling

WARNING

Explosive gas mixture may be produced

during the process of fueling; the
overflowed diesel oil or hydraulic oil may
be ignited when contacting a searing
surface.

Auto fuel is an inflammable substance,

so when filling oil, do follow the following
instructions; otherwise, it is easy to give rise to
fire or explosion:

a) Read and observe all warning notes at the Fig.5-1.22

establishment of a service station;

b) Before contacting the fuel tank, eliminate

potential risks of static discharge through
contacting other metal parts of the truck, and
keep a certain distance from the neck of the
fuel filler, petrol nozzle, or other gas sources;

c) Once starting the filling operation, do not

return to the truck, do not touch, rub, or glide
over any article or fabric (polyester, damask,
nylon, etc.), so as to avoid generating static
electricity and hence causing explosion;

d) Place by all means the container on the

ground before filling oil when using a standard
portable fuel container. The static discharge of
the container may light up the fuel steam, thus
giving rise to fire;

5-26
 Maintenance
STC500S3

e) Do not use any cell phone when fueling

since current and electronic interference of the
cell phone may light up the fuel steam, thus
giving rise to fire;

f) Stop the engine by all means when fueling

since the spark generated by the engine at
relevant electronic parts may light up the fuel
steam, thus giving rise to fire; When finishing
the fueling task, check and confirm that fuel
tank cover and fuel filler door are closed tightly
before starting the engine;

g) In a service station, it is prohibited to use

match or cigar lighter and smoke or leave any
cigarette ignited inside the truck. The auto fuel
is highly combustible, and it may cause fire
when being lighted up;

h) If a fire breaks out during the fueling

process, leave the truck far away and contact
the service station and local fire brigade, and
then follow safety directions.

In addition, the fuel may harm physical health

and environment, so it should be avoided to
get fuel into eyes or on skin. If any fuel gets
into eyes, rinse your eyes with large amount
of water immediately and then get medical
help; if any clothes are stained with fuel, rinse
the clothes immediately; if fuel is eaten by
mistake, get medical help immediately; and
keep children away from fuel.

5-27
Maintenance
STC500S3

5.1.2.7 Clutch brake fluid

Brake fluid must be DOT4 or 901.

Before filling brake fluid, check whether clutch

oil can is clean; if not, clean it.
Clutch oil can

If foreign matters are found after opening The highest level

clutch oil can, please contact SANY service The normal level
station for inspection and repair.
The lowest level
Inspection and filling:

a) Check whether level in clutch oil can is

normal. Clutch oil can is on the crane bracket
after the driver's cab.

See Fig.5-1.23

b) When brake fluid is among the maximum

and minimum levels, it indicates normal.

c) If brake fluid is too low, firstly check pipeline

Fig.5-1.23
for leakage; if no leakage found, fill brake fluid
up to the maximum level.

d) Fill brake fluid with cover of clutch oil can

filling inlet dismantled. Drain original brake
fluid during replacing brake fluid, and brake
fluid must be changed by SANY service
station.

WARNING

Excessively long utilization of brake fluid

is dangerous, which may result in lowering
of boiling point to cause air resistance.

NOTICE
If brake fluid exceeds the maximum level,
leakage will appear. Therefore, avoid
excessive filling during filling.
For brake fluid provides strong
absorbability, prevent water entering
clutch oil can during inspection and filling
of brake fluid.
Painting surface will be damaged if brake
fluid spatters on it during inspection and
filling of brake fluid, do flush it with clean
water immediately.

5-28
 Maintenance
STC500S3

5.1.2.8 Drain of water accumulated in air

reservoir

Rotate vent valve at bottom of air reservoir

(see Fig.5-1.24) and observe whether water
flows out. Generally, no water will flow out.
Only when temperature exceeds 6°C, some
water draining from vent is normal.

If water or oil fluid drains from water outlet

during inspection, it indicates drier does not
work. In such case, contact SANY service
station for inspection and repair.

Fig.5-1.24

5.1.2.9 Inspection of lighting system

a) Turn on all switches to check whether

lighting and flash functions of all luminaries
are normal;

b) Trample brake pedal to check whether

brake lamp is on;

c) Put transmission at “reserve gear” position

to check whether reversing light is on and
back-up buzzer sounds;

d) Check inside of all luminaries for dust and

water, or damage and discoloration, and
whether retroreflectors of all luminaries are
intact;

e) In case of dust, clean it in time; in case of

water, disconnect connector firstly and drain
water off, find out causes and troubleshoot;

f) Check whether all alarm and indicating

lamps function normally. If all alarms are off
after engine start, there is no problem. If the
lamps are off during startup, it indicates lamp
or fuse is damaged, check and replace with
new parts.

5-29
Maintenance
STC500S3

5.1.2.10 Air pressure and inflation

Check air pressure of foot brake with air

pressure gauge, restart engine and inflate, SYT

and check time for air pressure alarm lamp

going out. If the time measured complies with
specified value, the inflation time is normal.

Time for inflation shall not exceed 4min;

otherwise check air reservoir and its pipeline
or air compressor. When air reservoir is full,
Fig.5-1.25 Air pressure gauge
excessive air will exhaust from the drier, and
air compressor starts unloading and does not
inflate any more.

5.1.2.11 Steering mechanism

(1) Check free travel of steering system:

Free travel of steering system is 10°- 15° upon

returning of the truck, park and ignite to steer.
When tires controlled by straight steering
coupling bar does not move, make sure
maximum angle of steering wheel turning from
left to right.

CAUTION

Check free travel of steering wheel during

running of engine.
Excessively big free gap of steering wheel
will greatly affect control of truck, which
may result in injuries or property loss.

5-30
 Maintenance
STC500S3

(2) Inspect steering wheel for looseness:

Swing steering wheel to the front and back,

left and right, up and down to inspect related
parts of steering column for looseness.

(3) Inspect runout and deviation of steering

system:

During driving, inspect and ensure that

steering wheel does not deviate. During
straight running without control of steering
wheel, the normal condition is that the truck
deviates within 2m in 100m.

The whole truck does not deflect to left or right, 1

and the normal codition is deflecting to the
right for road draignage slope. In such case,
please inspect ball of steering transverse and
straight coupling bar for looseness. Repalce or
adjust if necessary.

Steering shall be without abnormal reluctance

or jamming.

(4) Inspect horn:

Fig.5-1.26 Steering wheel

Ensure horn sounds normal, and no
1- Horn
abnormities are discovered between horn
button and steering wheel.

5-31
Maintenance
STC500S3

5.1.2.12 Working condition of exhaust

brake

Inspection steps:

a) When engine is running at idle speed

or accelerating, and clutch pedal is at fully
released position (not trampled), check
whether exhaust brake functions normally. At
this time, open exhaust brake switch that the
lamp shall be on, otherwise exhaust brake is Left control lever on combined switch
in trouble and needs to be inspected.
Fig.5-1.27 Press the left control lever end
b) Trample throttle pedal or clutch pedal, if
engine sounds as original with indicating lamp
off, it indicates exhaust brake system works
normally.

c) Ensure that exhaust brake functions

normally and indicating lamp is on when
rotation speed of engine slows down.

CAUTION
Fig.5-1.28 Exhaust brake indicator
if calibration of idle rotation speed is
too low, engine may go out while using
exhaust brake. Pay attention to calibration
of idle rotation speed.

5-32
 Maintenance
STC500S3

5.1.2.13 Foot brake inspection

For safety, foot brake plays a key role,

inspection and maintenance carelessness
and wrong adjustment will result in serious
accident.

Check functions of air pressure alarm switch:

a) Start engine and increase air pressure

to 0.8MPa, And then shut down engine and
trample brake pedal to lower air pressure. Air pressure alarm light
When air pressure is lower than 0.55MP, air
Fig.5-1.29
pressure alarm light will be on;

See Fig.5-1.29

b) When air pressure alarm light is on, release

parking brake handle, if the buzzer sends out The air pressure alar m indicator light is on.

sound at this time, it indicates alarm switch

works normally. Loosen parking brake valve

See Fig.5-1.30

c) After releasing parking brake handle, start

engine and apply throttle to improve rotation
The buzzer alarms.
speed of engine till air pressure reaching
0.55MPa, at this time, the buzzer stops
sounding and air pressure alarm light is off.
Fig.5-1.30
See Fig.5-1.31

Travel inspection of brake pedal:

a) Trample brake pedal lightly to check free

travel, of which the normal value is 12mm-
18mm;
The buzzer does
not alarm
b ) Tr a m p l i n g o f b r a k e p e d a l s h a l l b e
thoroughly smooth;

c) There shall be exhaust sound while

releasing brake pedal.
The air pressure alarm
indicator light is off

Fig.5-1.31

5-33
Maintenance
STC500S3

5.1.2.14 Inspection of clutch

(1) Check free travel of clutch pedal

When press clutch pedal manually, there will

be resistance at two places:

a) The travel to the first resistance is free

travel of clutch pedal, which is to guarantee
smooth oil returning of clutch main pump;

Adjustment range: 10mm-20mm.

b) The travel to the second resistance is

working travel controlled by the clutch, which
is to guarantee necessary travel controlled by
the clutch;

Effective range: 20mm-30mm. Fig.5-1.32

Both the obove travels are called as free travel

of clutch. If the travel exceeds limit value,
please contact SANY after-sales service
department for necessary inspection and
adjustment.

(2) Check travel of clutch pedal

a) Check whether clutch pedal is too hard

or soft, or there is abnormal noise while
trampling;

b) Check whether gear shift is stable;

c) Use normal utilization and operation method

to loosen clutch pedal gradually after gear Fig.5-1.33
shifting. The combination of clutch shall be
stable without sliding and impacting.

5-34
 Maintenance
STC500S3

5.1.2.15 Battery

WARNING

Harm of battery acid liquor: it may lead to

blindness in contact with eyes; result in
chemical skin burn; and damage clothes.

A. Prevention and treatment of possible

danger

(1) Accidental short circuit of chassis battery

Prevention: when install battery by metal tools

or diagnose trouble by metal lead, avoid direct
short circuit of positive and negative terminals
of battery.

Protection: wear protective glasses and

gloves.

Treatment of emergency: during burning, cut

off metallic conductor causing outer short
circuit of battery by tools other than by hands,
and extinguish fire by fire extinguisher.

(2) Vent gas of battery

Prevention: keep ventilation of charging place.

Smoking is prohibited to avoid sparkle and
open fire. Connection sequence of battery
harness: firstly connect positive line and then
the negative line; disconnection sequence of
battery harness: firstly disconnect negative
line of battery, and then the positive line.

Protection: wear protective glasses and

acidproof clothes.

Treatment of emergency: when the battery

bursts, large amount of sulfuric acid will
spatter out. The operator shall flush the
positions spattered with water immediately; if
necessary, send personnel ablated by sulfuric
aid to hospital immediately.

5-35
Maintenance
STC500S3

(3) Chemical accident

Any liquid coming from lead-acid battery is

electrolyte containing dilute sulfuric acid,
which is corrosive to harm skins and eyes. If
skins touch sulfuric acid, immediately flush
skins with much clean water and take off the
contaminated clothes; if eyes touch sulfuric
acid, immediately flush them with clean water
for at least 10min and go to hospital; if sulfuric
acid enters mouth accidentally, drink much
water or milk and go to hospital whenever
possible.

The following are prohibited adjacent to

battery acid liquor: smoking, fire and open fire,
ignition sources (such as electric device).

(4) Lead-acid battery may come out with

explosive gas containing hydrogen during
charging. Therefore, smoking or sparkle is
prohibited adjacent battery. Before moving
battery, firstly touch one earthing metallic
object to release possible static electric charge
on body. Do not charge battery in closed
space. Ventilation must be sufficient at storage
place of battery.

B. Treatment and recycling

The waste lead-acid battery shall be recycled.

The battery contains lead and dilute sulfuric
acid, so treat them as per requirements of
local government. Do not put them on ground,
in lake or river and at other unapproved
places.

5-36
 Maintenance
STC500S3

C. Maintenance of battery

(1) Pay attention to the following points during

maintenance of battery daily used:

a) Form a habit of conserving energy of

battery;

b) Ensure electric system closed during break

and shutdown;

c) During “overhaul”, cut off electric

connections of battery;

d) Upon completion of all maintenance, check

whether electric eye of battery is green;

e) If battery is lack of electricity (electric eye

is black), analyze to judge cause of battery
failure, and charge as per supplementary
charging process of battery.

(2) Pay attention to the following points during

maintenance of battery for storage truck:

a) If the truck has been stored for more than

15 days, cut off negative connecting line of
battery;

b) For batteries connected with connecting line

of truck, charge once every month for at least
30min.

c) For batteries disconnected with connecting

line of truck, charge additionally once every
three months with current at 1/10 of battery
capacity for 8h-10h.

d) For batteries stored for more than one

year, if the above supplementary charging
requirements are not observed, replace
batteries and dispose them as scrap.

5-37
Maintenance
STC500S3

(3) Key maintenance of battery:

a) During utilization, frequently check vent plug

for blockage and battery for dehydration. If the
level is at minimum level line (Min), replenish
pure water accordingly to keep level proper
(adjacent to Max). Generally, replenish water
after using for 1-1.5 months and 3-4 months in
summer and winter respectively.

b) Avoid using electric appliances (such as

lamp, air-conditioner and loudspeaker etc.) of
truck for a long time during showdown of truck
engine, so as to prevent deep discharging of
battery, which will result in failure startup of
truck and service life shortened of battery.

c) Natural current leakage caused by loading

of truck is unavoidable, so for truck stopped for
more than 20 days, disassemble negative lead
of battery to avoid current leakage caused by
loading and deep discharging of battery.

d) During utilization, if open circuit voltage

of battery “+” and “-” terminals is lower than
12.4V that startup is difficult and light is dark,
reassemble battery from truck for full charging.

e) Wipe water droplet on battery cover after

water filling to keep surface of battery dry, so
as to avoid current leakage and prevent fire
accident.

f) Check level height of battery regularly and

replenish water in time.

5-38
 Maintenance
STC500S3

D. Battery charging

If battery is lack of electricity for that normal

charging is unavailable, which has the
following causes, such as abnormal utilization
like long-term service of electric appliances
on truck during shutdown of truck, current
leakage and long-term shutdown of truck, or
charging trouble of truck engine, the battery
need to be charged additionally.

(1) Visual inspection before charging:

a) The battery with broken container or leaking

acid cannot be charged additionally, and shall
be replaced after finding causes;

b) The battery with broken end post cannot

be charged additionally, and shall be replaced
after finding causes;

c) The battery expanded for overdischarge or

overcharge cannot be charged additionally,
and shall be replaced;

d) Before supplementary charging, clean

end post and remove oxide scale on surface.
During supplementary charging, apply grease
to terminal to prevent electrical erosion;

e) Open fire is prohibited in environment with

sufficient ventilation;

5-39
Maintenance
STC500S3

(2) Precautions during charging:

a) Wear safety glasses;

b) During charging, keep the environment

ventilated and under normal temperature;

c) During charging, smoking is prohibited and

introduction of tinder shall be avoided;

d ) While connecting line after charging, firstly

connect positive line; while disconnecting line
before charging, firstly disconnect negative
line.

e) Anode of charger connects to anode

o f battery, and cathodes also conn e c t
accordingly, do not charge battery in series;

f) Ensure end post of battery is clean and

connection of charging circuit is in good
condition.

5.1.2.16 Daily inspection of buffer block

As for rubber parts installed on chassis, such

as buffer block for front and rear suspension,
suspension cushion of engine etc., the
customer shall check during daily inspection
and maintenance. In case of abnormal wear,
crack or desquamation, abnormal aging etc.,
the user shall replace such parts in time to
avoid accident.

5-40
 Maintenance
STC500S3

5.1.2.17 Tire pressure

Pressure inspection:

a) Check tire pressure frequently, tire inflation

pressure of single tire is (0.88±0.005) MPa,
and that of double tire is (0.81±0.005) MPa.
Inflate additionally if pressure is insufficient.
Meanwhile, frequently check whether tire nut
is loose.

b) When tire pressure difference reaches

0.02MPa (cold pressure), inflate additionally in
time.

c) Size of new tire will change (expand) after

use for a certain time, so pressure will reduce
accordingly. Therefore, check tire pressure
before driving. After driving for 2000km-
3000km, it’s necessary to check tire pressure
and refill to standard pressure;

d) Standard pressure of both tires shall be the

same;

e) Spare tire of truck shall be available all the

time.

Tire inflation:

Please inflate the tire refer to page 5-71.

5-41
Maintenance
STC500S3

5.1.2 Regular maintenance

5.1.2.1 Maintenance cycle

Inspection and maintenance shall be carried

out once every 5,000km or every month, and
the class of inspection and maintenance shall
be as the specified mileage in the table above.

For regular inspection and maintenance

mileage, refer to Table 5-1.3.

Table 5-1.3 Average mileage table for regular inspection and maintenance Unit: 1000km
Second-class maintenance

Second-class maintenance

Fourth-class maintenance
Third-class maintenance
First-class maintenance

First-class maintenance

First-class maintenance

First-class maintenance
Routine check

Routine check

Routine check

Routine check

Routine check

Routine check

Routine check

Routine check
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160

165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

For assembly oil replacing average mileage,

see Table 5-1.4.

Table 5-1.4 Assembly oil replacing average mileage under normal condition

Type Engine Transmission Front/Rear Axle Remarks

Initial check ● ● ● Traveling for 1,500km
Routine check ●
First-class maintenance ●
Second-class maintenance ● ● ●
Third-class maintenance ● ● ●
Fourth-class maintenance ● ● ●

5-42
 Maintenance
STC500S3

5.1.2.2 Different classes for maintenance items

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Transmission
check check maintenance maintenance maintenance maintenance

Check the Check it

lubricating oil level of once every
transmission. week.

Replace the
lubricating oil of
1,000km of traveling for Initial replacement and once after every 20,000
transmission (at least
once every year).

Replace the filter

cartridge washer and At the time of oil change
O-ring.

Replace the
ventilation device of ● ● ●
transmission.

Initial Routine First-class Second-class Third-class Fourth-class

Dual Front Axles
check check maintenance maintenance maintenance maintenance

Check and adjust the

clearance of rolling At the time of the first Second-class maintenance
cone bearing.

Replace the
lubricating grease of ● ●
wheel hub.

5-43
Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Third and Fifth Axles
check check maintenance maintenance maintenance maintenance

Check the oil levels

of main reductor and ● ● ● ● ● ●
wheel reductor

Check and adjust the

clearance of rolling
cone bearing of hub.

Clean the ventilation

● ● ● ●
device.

Replace the
lubricating oil of main
● ● ● ●
reductor and wheel
reductor.

Check the oil level of

countershaft bearing ● ● ● ● ●
or replace the oil.

5-44
 Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Drive Shaft
check check maintenance maintenance maintenance maintenance

Retighten the bolt of

●
drive shaft.

Visually check
the drive shaft for
● ● ●
connection and
abrasion.

Initial Routine First-class Second-class Third-class Fourth-class

Cab
check check maintenance maintenance maintenance maintenance

Check the operation

● ● ● ● ● ●
of wiper.

Retighten the locking

● ● ● ●
handle of cab.

Retighten the radiation

●
cover of engine.

5-45
Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Chassis
check check maintenance maintenance maintenance maintenance

Check the towing

hook for fixation and ● ● ● ● ●
operation.

Retighten the bolt of

●
cross beam.

Tighten the U-bolts

and supports of front ● ● ● ●
and rear leaf springs.

Check the fixing

● ● ●
device of spare tire.

Check and adjust the

clearance of lateral ● ● ●
baffle of leaf spring.

Check the nut of

● ● ● ● ●
wheel for fixation.

Check the storage

● ● ●
battery for fixation.

Check the fuel tank

● ● ●
for fixation.

5-46
 Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Brake System
check check maintenance maintenance maintenance maintenance

Drain water from air

● ● ● ● ● ●
reservoir.

Check the pressure

system for sealing
● ● ● ● ●
(with air pressure
gauge).

Check the thickness of

brake plate lining and
● ● ●
adjusting clearance of
brake.

Clean the wheel

● ●
brake.

Check the brake

pipeline and
● ● ● ●
vulnerable parts of
hose.

Check the function of

● ● ● ●
brake chamber.

Check the efficiency

of foot brake, hand
● ● ● ● ●
brake and exhaust
brake.

5-47
Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Complete Vehicle
check check maintenance maintenance maintenance maintenance

Carry out short-

● ● ● ● ●
distance trial drive.

Check the working

condition of balance ● ● ● ●
beam suspension.

Check the bolt of

frame for fixation and ● ● ● ● ● ●
tighten it.

Check the nut of tire

● ● ● ● ●
for tightness.

Tighten the U-bolts

and supports of front ● ● ● ●
and rear leaf springs.

Initial Routine First-class Second-class Third-class Fourth-class

Electrical System
check check maintenance maintenance maintenance maintenance

Check the working

condition of electrical
system (indicator,
● ● ● ● ● ●
headlamp, width lamp,
wiper, heater and
ventilation device).

Check the storage

battery for electrolyte
● ● ● ● ●
level, proportion and
unit voltage.

Check the terminal

of storage battery
for fixation and coat ● ● ● ● ●
poles with lubricating
grease.

Check the accuracy of

electronic tachometer ● ● ● ● ● ●
and rotation speed.

5-48
 Maintenance
STC500S3

Table 5-1.5 Maintenance classes for different assembly items

Initial Routine First-class Second-class Third-class Fourth-class

Steering System
check check maintenance maintenance maintenance maintenance

Replace the steering

gear oil (20,000- ●
25,000km).

Check and adjust the

●
front wheel alignment.

Check the oil level in

● ● ● ● ●
steering oil tank.

Check the oil filter of

● ●
steering oil tank.

Check the function of

● ●
steering system.

Check the clearance

● ● ●
of steering linkage.

Check the bolt,

connector and locking
●
piece of steering
linkage.

5-49
Maintenance
STC500S3

5.1.2.3 First class maintenance

First class maintenance focuses on lubricating

and fastening. Apart from routine maintenance
items everyday, main contents also include the
following items:

1) Cleaning: flush truck body and the chassis,

cleanse the engine and different parts of the
chassis, wash fuel pump, clean air filter, and
replace machine oil filter;

2) Fastening inspection: check the fastening

condition of peripheral connecting bolts
and nuts of engine, chassis, seat, and truck
body. If necessary, test and tighten. All those
with required torque should be paid special
attention;

3) Adjustment: Check tightness of engine belt,

free play of brake pedal, free play of clutch
pedal, free swinging capacity of steering
wheel, and travel of brake control lever;

4) Tire operation: Inflate as per requirements,

equip enough inflating valve cap, and check
whether there’s serious scratch on outer
surface of the tire.

5-50
 Maintenance
STC500S3

5.1.2.4 Second class maintenance

Second class maintenance focuses on

inspection and adjustment. Maintenance items
include:

1) All the items in first class maintenance;

2) Clean fuel filter, and replace fuel coarse

filter paper core;

3) Check oil volume of clutch main pump and

sub pump;

4) Overhaul wheel brake, clean, lubricate,

and adjust the clearance between wheel hub
bearing, brake friction plate, and brake drum.
Replace the position of the wheels;

5) Replace lubricating oil for the engine,

gearbox, intermediate and rear axle;

6) Discharge sediment out of fuel tank, and

clean fuel filter;

7) Check and adjust valve clearance;

8) If needed, overhaul oil pump and oil delivery

pump, check and adjust oil spraying pressure
and atomization condition;

5-51
Maintenance
STC500S3

9) Check fastening condition of cylinder cover

bolts, and tighten to required torque under the
thermal condition;

10) Check and adjust free play of clutch pedal

and brake pedal;

11) Check oil level in steering gear oil tank,

and if insufficient, refill as per required oil level;

12) Check the free wheeling capacity of

steering wheel, and adjust if necessary;

13) Check whether the drive shaft cross

bearing and intermediate support are loose,
and check the fastening condition of different
flange nuts;

14) Check and adjust toe-in;

15) Check the fastening condition of front leaf

spring U-bolts, rear leaf spring locking bolts,
and lugs, and tighten the bolts;

16) Clean and lubricate engine and generator

bearing;

17) Check whether there is oil or air leakage

in brake pipeline and clutch pipeline, and
promptly tighten or replace;

18) Check pneumatic brake system, and clean

or replace air filter cartridge.

5-52
 Maintenance
STC500S3

5.1.2.5 Third class maintenance

When conducting third class maintenance to

automobile, e.g. some parts of the engine has
great distortion which causes properties of the
engine to decline greatly and oil consumption
to increase; do the following operation to the
engine:

1. Dismantle cylinder cover, and check

elements such as valve, valve seat, valve pipe,
valve spring, and pitman arm. If necessary,
repair, grind, or replace;

2. Check wearing condition of piston ring,

piston, cylinder bushing, connecting rod
bushing, and connecting rod bearing shell. If
necessary, polish or replace;

3. Measure axial clearance of crank shaft, and

check the wearing condition of thrust plate and
main bearing bush. If there’s serious peeling,
erosion, or scratch, it should be replaced;

NOTICE

Wash engine crank shaft box, gearbox,

differential, and steering gear. Change
lubricating oil for different sections.

4. Check timing gear; observe the wearing

condition of driving gear, and engaging
surface. If necessary, repair or replace;

5. Wash cylinder body, oil sump and machine

oil filter strainer;

6. Breaking-in maintenance: can conduct as

per first class maintenance items;

7. Seasonal maintenance: conduct combining

with second class maintenance.

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Maintenance
STC500S3

5.1.3 Regular maintenance for power

system

5.1.3.1 Maintenance norms of engine

See attached Engine operation & maintenance

instruction for detailed method. Do conduct
maintenance as specified!

Table 5-1.6 Maintenance norms for engine

Diesel Engine First Regular First Class Second Class Third Class Fourth Class
Maintenance Item Inspection Inspection Maintenance Maintenance Maintenance Maintenance
Replace diesel and oil ● ● ● ● ● ●

Replace oil filter or

● Whenever replacing diesel oil and oil
filter cartridge

Inspect and adjust

● ● ● ● ●
valve clearance

Replace fuel filter

● ● ● ●
cartridge

Inspect coolant
capacity and add ● ● ● ● ● ●
sufficient

Fasten cooling pipeline

●
clip

Fasten air intake

pipeline, hose, and
● ● ● ● ●
flange connecting
pieces

Inspect air filter

maintenance indicator ● ● ● ●
light or indicator light

Clean dust collection

cup of the air filter
● ● ● ● ●
(excluding automatic
dust exhaust type)

5-54
 Maintenance
STC500S3

Table 5-1.6 Maintenance norms for engine

Diesel Engine First Regular First Class Second Class Third Class Fourth Class
Maintenance Item Inspection Inspection Maintenance Maintenance Maintenance Maintenance
Clean main filter
When indicator is on
cartridge of air filter

Replace main filter

Refer to relevant norms in manual
cartridge of air filter

Replace safety filter

After main filter cartridge has been cleaned for 5 times
cartridge of air filter

Inspect and fasten

● ● ● ● ● ●
V-belt

Inspect bearing
clearance of ●
supercharger

Inspect and adjust

travel distance of ● ● ● ● ● ●
clutch

Note: ● Maintenance marker is required

5-55
Maintenance
STC500S3

5.1.3.2 Fuel filter and fuel-water separator

A. Interval of replacement

Fuel filter: Every 60000 km or every year.

Fuel-water separator: Every 100000 km or

every year. Inspect every 20000 km or every 3
months.
1
NOTICE
Please use a original brand filter, use
tinpot filter will affect engine working and
control of exhaust. 2

B. Steps of replacement
3
4
1. Refer to Fig.5-1.36 on page 5-57 see steps
to replace fuel filter. Fig.5-1.34 Fuel filter
1-Filter seat 2-Filter cartridge 3-Roller 4-Drain valve

Before replace the filter cartridge, release the

drain valve under roller (see Fig.5-1.34) to
drain water from filter. Tighten the drain valve
by hand after water drained.

a) Dismantle the filter cartridge with roller from

cylinder head, then remove the filter cartridge
from roller.

NOTICE
Do not damage the roller, for it is still
usable.
Do not tighten filter cartridge by tools.

b) Clean the inside of roller and groove of

O-ring.

c) Install a new filter cartridge to roller. Tighten

it by hand.

d) Fill fuel into filter cartridge and roller.

5-56
 Maintenance
STC500S3

e) Coat fuel to the gasket surface above

the filter cartridge. Tighten the gasket to the
cylinder head by hand. When the gasket
surface contact to the cylinder head, tighten
an additional 1/2 to 3/4 of a turn.
1
f) Refer to following steps to exhaust air from 2
fuel system:

1) Tighten vent plug on fuel filter.

2) Press button of manual oil pump manually

3
till no air is exhausted from vent plug.

3) Tighten vent plug with 7N•m moment. Fig.5-1.35

1-Vent plug 2-Manual pump 3-Oil drain hose

4) Start the engine, check if there is leakage.

Dismantle the Remove roller Lubricate roller

Drain
filter from cylinder from filter and new O-ring

1 2 3
Tighten roller
to the filter Fill in fuel Lubricate filter gasket Tighten by hand

4 5 6 7

Fig.5-1.36 Steps to replace filter

5-57
Maintenance
STC500S3

2. Steps to clean or replace fuel-water

separator

Fuel-water separator is an equipment to

separate water from fuel system, which can
avoid failure caused by water contained in fuel
as possible. See Fig.5-1.37 for location.
1 2
Steps:
Fig.5-1.37
1-Fuel-water separator 2-Fuel tank
a) Remove the filter cartridge.

b) Dissolve neutral wash in hot water, then put

filter roller into it.

c) Wash off smudgy water in filter roller.

d) Clean the filter roller till the water in roller

become clean.

e) Wash the filter roller with fresh water, totally

1
drain the water and install it.

f) Start the engine, check if there is leakage.

NOTICE Fig.5-1.38 Fuel-water separator

1-Filter roller
Drain all the oil into the vessel, and treat it
by proper method. Do not spatter it out.
Improper fuel filter will shorten service life
of engine and fuel injection system.

NOTICE
Tighten fuel filter with special tools and
fuel filter wrench, general tools (such as
crawler type tools) may scratch or cave
outer surface of fuel filter cartridge, which
may cause oil leakage.

5-58
 Maintenance
STC500S3

5.1.3.3 Engine oil filter

1
1. Interval of replacement
2
Every 10000 km or 250 hours.
3
2. Steps to replace filter cartridge
4

CAUTION
Improper engine oil will shorten service
5
life of engine, and even cause injury and
property loss. 6

NOTICE 7

Upon oil replacing, also replace filter

cartridge of engine oil filter.
10 8

a) Place container below the oil drain cock of

fuel filter. 9

b) Loosen the cocks for bleed and oil drain.

Drain oil and deposit off from filter. Fig.5-1.39 Engine oil filter
1-Bleed cock 2-Filter cover 3-Washer
c) Remove center long threaded rod. Dismantle 4-Filter cartridge 5-Spring support
filter, filter cartridge, spring support and spring. 6-Spring 7-Filter 8-Washer
9-Center long threaded rod
d) Clean each part except filter cartridge with 10-Oil drain cock
engine oil.

e) Replace a new filter cartridge.

f) Install washer to center long threaded rod

and insert the rod into filter, sequent install
spring, spring support and filter cartridge in
filter, install washer or O-ring and rotate the
center long threaded rod into filter cover.

5-59
Maintenance
STC500S3

5.1.3.4 Air filter

1
Air filter provides dust indicator, which displays
whether air filter is blocked or with excessive
resistance. It also provides dust discharge
valve, which automatically collects and
discharges dust. 2

Interval of inspection and cleaning:

Every 10000 km or 200 hours (every 5000 km

or 100 hours in dusty place),or signal of dust
indicator is red. Fig.5-1.40
1-Air filter 2-Engine
Interval of replacement:

Every 60000 km or every year, or signal of

dust indicator is still red after cleaning the out Push this button to make maintenance indicatior reset
filter cartridge. When the color changes from blue to red,
it indicates the air filter be maintained.

a) Check whether signal of dust indicator is

red;

b) If indicator signal is still green or yellow, it

indicates current air filter works normally. If it
turns red, clean or replace air filter cartridge as Air filter maintenance indicator

per driving mileage.

Fig.5-1.41
Clean air filter:

Clean primary filter cartridge rather than

secondary filter cartridge. Meanwhile, do not
replace filter cartridge until specified regular
Butterfly nut
replacement mileage or time is reached. Cap

Steps to clean filter cartridge: Filter

Filter cartridge
cartridge
a) Disassemble fixed cover and filter cartridge
nut to dismantle filter cartridge. Butterfly nut
See Fig.5-4.42
Fig.5-1.42

5-60
 Maintenance
STC500S3

b) Wipe filter cover and inside of filter housing

with a clean and dry cloth. Do not make water
directly enter filter tank during cleaning filter.

See Fig.5-1.43

c) Clean dust discharge valve, do not damage

or lose it; otherwise air and dust will enter air
filter easily. In such case, replace with a new
valve.

d) Check whether rubber seal and hose are

damaged, and nut is loose. If damaged,
replace with a new nut; if loose, retighten the
nut.

e) Clean air filter cartridge. Purge filter

cartridge with compressed air nozzle (air
pressure less than 690Kpa) to remove dust Fig.5-1.43
and dirt on it. Purge dust from inside to
outside.

See Fig.5-1.44

f) Assemble a new filter cartridge as per

sequence reverse to disassembly. Tighten nut
thoroughly manually; Do not distort rubber
seal during assembly. If nut is not tightened
thoroughly, assembly surface of filter cartridge
may distort that dust may enter engine, which
consequently may result in excessive wear of
piston and cylinder liner.

g) After cleaning filter cartridge, press button at

end of dust indicator to switch signal to green.
Fig.5-1.44

CAUTION

Do not suck in dust during cleaning filter

cartridge, otherwise it is harmful to health.
Neither clean dust or dirt by knocking,
nor do with excessively high pressure
compressed air, otherwise filter cartridge
will be distorted to cause damage to truck.

5-61
Maintenance
STC500S3

5.1.4 Regular maintenance for traveling

system

5.1.4.1 Axle

A. New axle application

1) Before using a new axle, add 90# heavy

loading gear oil (GL-5) through oil port. The oil
should be added till it reaches the same level
Oil port
with oil port.
See Fig.5-1.45. Fig.5-1.45 Oil port on gearbox

2) Before using a new axle, add enough 2#

lithium grease from different lubricating nozzle.

3) After using a new axle, the whole vehicle

must have 1500km breaking-in. Readjust
brake clearance, recheck fasteners (excluding
bolts with glue), and then put it into service.

5-62
 Maintenance
STC500S3

B. Axle maintenance

1) Regularly clear away mud and dust from

ventilation plug of axle housing.

2) Regularly check oil port bolts and drain

plug. The sealing gasket should be timely
tightened or replced if there is oil leakage.

3) Refill 2# lithium grease from different

lubricating nozzle after every 2000km. Wash
ventilation plug; inspect the tighteness for half
axle bolts; check gear oil level in the housing
(open oil level bolts for inspection).

4) Check brake clearance after every 5000km.

5) Check the tighteness of brake base plate

after every 8000~10000km. Check wheel
hub bearing for looseness; check brake
pad for wear. Replace brake pad if if its
wearing surpasses limit concave pit. Check
the quality of gear. Replace the oil if there is
any deterioration and dilution, etc. The first
oil replacement should be conducted after
1500km; while every 24000km in the future.

6) Dismantle the bolts and nuts for cleaning,

if the driven bevel gear and differential left
housing bolts and left & right differential
housing connecting bolts are loose. Then
apply locking glue on outer thread of the
cleaned bolts, tighten them as per required
torque.

5-63
Maintenance
STC500S3

C. Axle adjustment

Adjustment of brake clearance: when the

clearance between brake pad and brake
drum is too large, brake ability may decrease.
Adjust hob hexagonal head on adjusting arm.
Rotate by counter-clockwise direction and
make a zero clearance. Then reverse till the
ball bearing dropping noise is heard twice, the
clearance is 0.5~1.0mm.

Wheel hub bearing pre-tightening force

adjustment:

1) Remove lock sheet, tighten and adjust nuts

with special wrench. Tightening torque should
be more than 500N.m.

2) Rotate brake drum 2~3 circles to correctly

position bearing, tighten it with more than
500N.m torque.

3) Rotate adjusting nuts 1/4~1/6 circle

oppositely, rotate brake drum 2~3 circles.
The starting force on wheel hub is 30~65N
measured by spring scale.

4) Install the lock sheet, press the sheet and

tighten the screws.

5-64
 Maintenance
STC500S3

5.1.4.2 Wheel & tire

(1) First-class maintenance

1. Tighten the wheel nuts. Check if there

is leakage from valve cock, if valve cap is
complete. Repair or complete if necessary.

2. Dig out the dirt in wheel and carpolite or

foreign matters accumulated in the wheel gure.
If there is deep hole caused by those foreign
matters, tamp it with raw glue. Especially for
radial wheel, it may be seriously damaged by
moisture.

3. Check the wearing condition of wheel.If

there exists abnormal wear or deformation,
find out the cause to trouble shoot.

4. If it is necessary to check the inside of outer

wheel, dismount the wheel and repair it if
damage exists.

5. Check if the wheel rim, retainer ring or lock

ring is operating normally.

5-65
Maintenance
STC500S3

6. Check the pressure for wheel (including

spare wheel) is normal, add it enough as
specified.

NOTICE
The pressure for spare wheel should be
higher than the one for the traveling wheel.
Hint: It is recommended to check the
pressure for wheel (including spare wheel)
before each long traveling or each month.

7. Check if there is scratch caused by other

machine, if the spare wheel bracket is
complete and firmly tightened. Trouble shoot
the problem if necessary.

8. Shift the wheel position if necessary (if just

one side of wheel is seriously worn). Do make
sure the wheel gure is evenly worn.

Fill the maintenance record after the above

maintenance.

5-66
 Maintenance
STC500S3

(2) Second-class maintenance

Apart from the items in first-class maintenance,

conduct the following items:

1. Dismount the wheel, measure the weaing

of ,circumference and section width change
according to standard. Those information
can be taken as reference in profile shift and
matching.

2. Dismounting the wheel for check

1) Check if there is interior damage,

delamination or deformation on the tire crown,
tire shoulder, the side and inside of tire;

2) Check if the inner wheel, rim band is folded,

if the valve cock or valve core is complete.

3) Check if the wheel rim, retainer ring and

lock ring is deformed or rustes. Paint it if
necessary.

4) Check if the bolt hole on wheel rim is

overworn or cracked.

5-67
Maintenance
STC500S3

3. After trouble shooting the faults from the

above check, assemble and inflate the wheel.

4. After every 20000km, conduct profile shift

on the wheels with the order of number. As
shown in Fig.5-1.46.

5. Find out the cause and trouble shoot it

if the wheels are found worn or damaged
abnormally.

Fill the maintenance record after the above

maintenance.

Fig.5-1.46 Profile shift diagram of axle 4 tire

5-68
 Maintenance
STC500S3

5.1.4.3 Wheel replacement

NOTICE

In disassembly and assembly of wheel, do

not damage the tread on hub bolts or inner
wheel nuts;
Replace the wheel tray and wheel ring if
there is deformation or crack;
Do keep brake drum and wheel rim away
from paint, lubricating grease or other dirt;
Clean press surface of wheel nuts. Make
sure there is no dirt or lubricating grease.

(1) Disassembly of wheel

a. Prop up outrigger till tire is away from

ground.

b. Loosen wheel nuts with attached spanner

(when conducting on double wheels, loosen
the outer wheel nuts).

c. Loosen all wheel nuts (or outer wheel nuts),

remove wheel. See Fig.5-1.47.

Fig.5-1.47 Wheel disassembly

1-Wheel nut

5-69
Maintenance
STC500S3

(2) Wheel assembly

WARNING

It is extremely prohibited to assemble

wheels of different type on the same
vehicle.

a. Align the hub bolts with the hole on wheel

tray with wheel rod. Assemble the wheel tray.

b. Set hub bolts in the middle of bolt hole. Fix

wheel position. Loosen wheel nuts temporarily.

c. Tighten wheel nuts for 3 times according to

cross order.
1) Tighten wheel nuts by a wrench;
2) Tighten wheel nuts again by a electrical
wrench;
3) Tighten wheel nuts to specified torque (550-
600N·m) by a torque wrench. Make a mark on
the tightened wheel.

d. Finally, let down the wheel.

5-70
 Maintenance
STC500S3

(3) Wheel inflation

a. Wheel inflation should be conducted

according to pressure label and measure with
barometer in cold state. If it is measured in hot,
the temperature should be little higher than
standard pressure, adopt the revised value.
Regularly regulate barometer to guarantee
correctness.

b. Inflate the wheel with a little air after wheel

assembly. Inflate it to specified pressure after
the inner wheel is extended.

c. Check if valve core properly matchs with

valve noozle before inflation. Remove dirt.
Check if there is air leakage after inflation,
tighten valve cap.

d. Air inflated should not have moisture and

oil-mist in.

e. Do take safety measure during inflation.

Hammer lock ring lightly with hand hammer
to embed wheel into wheel rim loop channel.
This can prevent the disengagement of lock
ring.

WARNING

If the pressure of wheel is too low or too

high, it will cause driving uncomfortable
and abnormal worn of tires. Especially
when the wheel inflated insufficiently may
cause overheat and blowout.

5-71
Maintenance
STC500S3

5.1.4.4 Steel plate spring

Table 5-1.7 Maintenance table for steel plate spring

Number of
Name of lubricating Lubricating Lubricating
No. lubricating Lubricant type
location period (km) method
port
Front and rear steel plate
1 6 2000 Injection 2# lithium base grease
spring pin shaft

Front and rear steel plate

2 6 10000 Coating 2# lithium base grease
spring

Refer to table 5-1.7 for steel plate spring

maintenance. Remove oil cups shown in
Fig.5-1.48 and Fig.5-1.49 before inject the pin
shaft,after injection, install the oil cups. 4 3

Fig.5-1.48 Front steel plate spring

1-Pin shaft 2, 3-Front steel plate spring 4-Oil cup

1
2

Fig.5-1.49 Rear steel plate spring

1-Oil cup 2-Pin shaft 3-Rear steel plate spring

5-72
 Maintenance
STC500S3

5.1.4.5 Adjustment of toe-in

1) Toe-in measurement

The measurement of toe-in goes as followed:

1. Mark on the level beside center of left &
right rims, along with the front part of tire
beside center (left & right). As marker A in
Fig.5-1.50.

2. Measure the distance between the two

markers with tape measure and record them
accordingly. As marker L1 in Fig.5-1.50.

3. Move the tire half a circle to fall the markers

onto the rear part of tire (next to the center
level).

4. Measure and record the distance (L2)

between the two markers.

5. The difference value is the toe-in value (L2-

L1). It should be in a range of 3-5mm.

A A
L1

Fig.5-1.50 Adjustmen of toe-in

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Maintenance
STC500S3

2) Adjust toe-in as followed once unqualified

value is gained:

a. Loosen the bolt shown in Fig.5-1.51 (left

equals to right).

b. Properly rotate the steering tie rod shown in

the figure. Rotate it forward, the toe-in value
decrease, rotate it backward the toe-in value
increase.

c. Measure toe-in.

d. Tighten the bolt shown in following figure

once qualified value is gained. Otherwise,
rotate the tie rod till the specified value is
reached.

Adjustment of toe-in of axle 2 is the same.

Fig.5-1.51 Adjustmen of toe-in

1-Bolt 2-Steering tie rod

5-74
 Maintenance
STC500S3

5.1.5 Maintenance for steering system

5.1.5.1 Steering gear

A. Maintenance for steering gear

1) This integral power steering gear is of

constant flow type structure. It operates based
on oil pump driven by engine. The truck
cannot coast with engine off. It can prevent
heavy steering brought by engine shut off and
any accident.

2) If there is any fault for steering system

caused by oil pump or pipeline, the steering
gear could act as mechanical steering gear.
It can propel to steer to drive truck to repair
station. Long time propelled steering is not
allowed. Vehicles are not allowed to be
overloaded to guarantee safe traveling.

3) Keep power steering system inside clean.

It is not allowed to hold oil with unclean
container in oil filling. Parts can’t be piled at
will when dismantled for inspection. During
assembly, any foreign matter is not allowed to
enter. Oil level should not be lower than what
is specified.

5-75
Maintenance
STC500S3

4) User can not dismantle the control valve

part of the steering gear at will.

5) When assembling steering plumbing arm,

guarantee the wheels are rightly set. Scribed
line of plumbing arm should be aligned with
that on output end face of pitman arm. When
truck is traveling straight, if steering wheel free
clearance is found too big or too small, check
steer free joint and tie rod system.

6) During steering, turn steering wheel to limit

position. Long time should be avoided incase
that it may influence the service life of steering
oil pump.

7) Oil inlet and outlet of power steering gear

can not be reversely connected. Connect the
inlet and outlet pipe as per the arrow direction
on the steering gear front cap. Inlet is high
pressure oil of the steering oil pump, while
outlet is low pressure one of the oil return
tank. See Fig.5-1.52.

2
11
1
5

10

3
4
7

Fig.5-1.52 Power steering gear

1-Steering straight draw bar assembly 2-Washer 3-Washer 4-Washer 5-Steering plmbing arm 6-Bolt
7-Nut 8-Bolt 9-Power steering gear 10-Angle steering gear 11-Steering intermediate drive shaft

5-76
 Maintenance
STC500S3

B. Below are provisions for replacing power

steering hydraulic oil:

1) Replace power steering hydraulic oil after

the first 3000km, and every 5000km in the
future. Meanwhile, oil should be replaced
when it is found deteriorated.

2) Remove the steering plumbing arm from

steering pitman arm shaft. Unscrew the inlet
and outlet oil pipe of the steering gear.

3) Drain oil off steering system, start the

engine, promptly drain off oil, and immediately
shut it down. If the oil is deteriorated, add
clean oil into the oil tank. And wash and clean
the system as per this method till clean oil
runs out.

4) Drain oil off the steering gear, turn the

steering wheel to the left and right limit. Drain
oil off the steering gear. When oil is totally
drained, reassemble the inlet and outlet port
joint and steering plumbing arm.

CAUTION

User is not allowed to unscrew the sealing

nut under the steering gear. Otherwise, it
will cause steering gear adjustment invalid
or serious result of losing assistant power,
etc..
Power steering system oil must be clean.
Adopt Shell 46# hydraulic oil, and never
mix with other oil.
Oil tank filter cartridge shall be replaced
once after every 5000km.
Pay attention when draining steering
system oil. Be cautious of the oil drained
from the system which may splash onto
your body.

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C. Oil filling for steering system

NOTICE

Proper oil height: When engine is running,

oil should not exceed the upper part of eye 1
hole or below the lower part.
2

1) Fill up oil to the oil tank via oil port. Start the
engine, and then immediately shut it down.
Check oil level in oil tank and fill. Repeat this
for several times till the oil tank level reach
required height.

2) Start the engine, run idle for 2 minutes.

Shut down the engine, and then check the oil
level in the oil tank.

3) Restart the engine, turn the steering wheel

to left and right limit. Check the oil level in the
tank. If necessary, fill oil till the oil level reach
required height.
See Fig.5-1.53. Fig.5-1.53 Steering oil tank
1-Oil port 2-Eye hole

D. Exhaust for steering system

1) Engine runs idle. Turn steering wheel to the

left and right with full travel for several times.

2) Loosen the bleed screw one circle, set the

steering gear in middle position. Drain off the
air and vaporized oil. When clean oil runs out,
screw up the bleed screw and check oil tank
level and fill it.

3) Tightening torque for bleed screw is 4~6Nm.

When the bleed screw is loose, never steer,
otherwise air may enter.

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E. Check for steering limit valve

Turn steering wheel manually to left and right

limit. If frizzles of oil running noise could be
heard, it represents normal pressure relief.

F. Seal checks for power steering gear

Visually check whether there’s oil leakage on

the outer surface of steering gear. Wipe up
the surface oil with rag if oil is found. Manually
turn steering wheel to limit position and keep it
at high pressure state. Check oil leakage, if oil
is found, immediately contact repair station of
the steering gear manufacturer.

G. Check and adjustment for free play

Keep the vehicle still and start the engine.

Slightly turn steering wheel with hand and
visually inspect the steering condition of the
wheel. Free play is big if wheel remains still
when steering wheel is turned quite a large
angle (approximately 30°). The potential
causes for big free play are as follows:

Free clearance of steering column and

steering gear is big, clearance between
steering wheel and steering column is big,
clearance between connecting part yoke and
spline shaft is big, and ball pin clearance etc..
As for steering gear, method for adjusting
free clearance is: loosen hex nuts on pitman
arm shaft and side cover assembly. Turn
and adjust the bolt stud with right-angled
screwdriver. Eliminate clearance between
pitman arm shaft and rack piston. When the
adjustment is finished, tighten hex nuts.

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5.1.5.2 Steering oil pump

A. Hydraulic oil

WARNING

Hydraulic oil is toxic. Keep away from

children and pets. If not reused, dispose
of in accordance with local environmental
regulations.

1) Correctly select hydraulic oil, it is forbidden

to use two different hydraulic oil in steering oil
pump. Otherwise the efficiency and service life
of oil pump may be severely affected.

2) It should be specially noticed: Steering

gear in dead point cannot last more than 10
seconds. Otherwise it will cause steering oil
pump damage. (Steering gear of SANY crane
is with relief valve, so this defect doesn’t exist)
As the steering gear is turned to a dead point,
cut-off may occur. Meanwhile, much oil may
overflow from oil pump. The oil may form
internal circulation in the pump, all hydraulic
energy may be transformed into thermal
energy. Besides, temperature may go up
very quickly. The oil pump temperature may
reach around 180 degree in quite a short time.
Internal metal parts in oil pump may deform.
Apart from those, fit clearance may change
and makes inner metal parts engaged. Aging
sealing elements may cause air leakage and
oil leakage. Steering oil pump may be invalid
in a short period.

3) Oil in steering system cannot be

overheated. Otherwise sealing pieces in the
oil pump and steering gear may shrink and
harden. Besides, crack may occur, and lose
the sealing effect.

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4) For new crane, after 2500km run-in period,

maintain steering system (namely replacing
oil, cleaning steering system). Oil needs to
be timely replaced after every 5000km in the
future. Meanwhile, wash or replace the oil
strainer in the oil tank. Otherwise pump flow
valve may be plugged or the pump may be
invalid.

5) Before replacing oil pump, wash steering

system. Drain off the residue oil. Add certain
amount of petrol or alcohol into the oil tank to
wash the whole system. If necessary, start the
engine idle till it is clean.

6) Add 25 micrometer oil filter into the oil

suction pipeline or steering oil tank.

7) Steering oil tank must be installed above

the oil inlet port of steering oil pump.

8) Check oil in the steering oil tank monthly.

Check if the volume gets less, if oil gets
deteriorated, or if foreign matter is too much.
Should there be any abnormality, timely add
oil or replace it.

9) During application, regularly check steering

oil pump. Check if there is leakage, if it runs
normally, and if there’s impact or abnormal
noise.

10) Effective length of the joint thread

connecting steering oil pump and inlet and
outlet port shall be less than 12mm (Effective
length of thread at steering pump inlet and
outlet port is 12mm~14mm).

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B. Notice for steering oil pump hydraulic oil

filling and exhaust

1) Connect pipeline. Fill Shell 46# anti-friction

hydraulic oil or similar property one into the oil
tank.

2) Start the engine. Run it idle. Repeatedly

turn steering wheel to left and right limit
position to flow oil completely. Meanwhile, fill
hydraulic oil into oil tank till the oil does not
go down and no bubble in it. Drain air off the
system, add hydraulic oil till it can reach the
marking position.

NOTICE

Different anti-friction hydraulic oil cannot

be used at the same time (steering
hydraulic oil cannot be mixed).
Only after oil filling, could the engine be
started idle. Running with oil is prohibited.
When dismantling or replacing pipeline,
do keep them clean. Pay attention to seal
between pipeline and steering oil pump
inlet & outlet. Do prevent oil or air leakage.
It is prohibited for non-professional
personnel to assemble and disassemble
steering oil pump parts personally.

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5.1.6 Maintenance for transmission

system

5.1.6.1 Clutch

During the use of clutch, it should be well

maintained as followed:

1. Regularly check clamp screw on pedal

Oil can
bracket. If loose, promptly tighten.
Maximum level

2. Coat the pedal bracket with a little lithium Normal level

lubricating grease (oil cup) monthly. Minimum level

3. Usually check the joint of clutch booster

system pipeline in case of leakage.

4. Usually check brake fluid level in the grease

nipple of clutch booster system. Normally it
should be between H and L line. If it’s below L,
add brake fluid as specified in chassis manual.
See Fig.5-1.54.
Fig.5-1.54 Oil can of clucth

NOTICE
It is recommended the to-be-added
automobile brake fluid should be the same
as the original. If different, drain off the
original brake fluid from system and then
add new one.

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5. Observe clutch plate wearing through

conical body air port. Adjust and replace clutch
plate when necessary.

6. When it is needed to replace clutch booster

pump, adjust clutch operating system as
specified. Add automobile brake fluid into
system and drain air off.

a. Open the cover on clutch booster oil cup

behind the driver’s cab. Add brake fluid to the
oil cup till it reaches 3/4 to 4/5 of the cup.

b. Open the rubber cap of bleeder cap on

clutch cylinder. Loosen bleeder cap of the
clutch cylinder. Repeatedly tread the clutch
pedal till brake fluid spray out from bleeder
cap. Meanwhile, tread down clutch pedal
and screw up bleeder cap. During this period
notice oil level in the oil cup, add oil timely as
specified.

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5.1.6.2 Gearbox

During the use of gearbox, it should be well

maintained as followed:

1. Regularly check and maintain enough

lubricating oil level.

After traveling, vehicle should be parked on

flat road. When oil level is still and temperature Oil port
goes down a little, observe it from side conical
eye hole. The level should be aligned with Fig.5-1.55 Gearbox
bottom edge of the eye hole. See Fig.5-1.55.

2. Replace lubricating oil as per stipulated oil

replacing period.

a. After the first 2000~5000km of gearbox,

replace lubricating oil.

b. Check lubricating oil volume and quality

after every 10000km. Add or replace the oil
based on the result.

c. Change lubricating oil after every 50000km-

once a year at least.

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3. Correctly use lubricating oil

a. Add GL-5(85W/90) vehicle gear oil.

b. Dismantle conical oil level inspection hole

screw plugs on the side of gearbox housing.
Add oil till it overflows out of the hole. See
Fig.5-1.55.

c. To-be-added lubricating oil should be the

same model as that of the original.

4. Avoid towing or coasting.

When vehicle is towed with rear wheel on the

ground and transmission system connected,
intermediate shaft gear and main shaft gear of
the main gearbox don’t rotate. However, main
shaft is spinning at high speed driven by rear
wheel. Serious damage to gearbox may occur
due to lubricant deficiency.

NOTICE

Never coast in neutral gear with vehicle

shut down.
Never tread clutch pedal to coast vehicle
in neutral gear.
When vehicle needs to be towed, pull out
half axle or take out drive shaft to tow.

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5.1.6.3 Power takeoff device

During the use of power takeoff device, it

should be well maintained as followed:

1. Promptly fill and replace lubricating oil

(lubricating oil brand should be the same as
gearbox).

2. QH70 power takeoff device inner chamber

communicates with gearbox, no need to add
lubricating oil separately. However, for those
installed on top left or right of gearbox, front or
rear cap housing, the chamber is different from
gearbox. They must be filled with lubricating
oil separately.

3. Power takeoff device must be added with

new oil after the first 20 hours to avoid impurity
from breaking-in. For every 500 hours in the
future, new oil should be added. This can
prevent deterioration of lubricating oil.

4. For gearbox assembly newly equipped

with power takeoff device, oil replacing period
should be shortened. This can avoid early
wearing of power takeoff device.

5. Should there be any fault or abnormal

noise, promptly check and replace damaged
parts. This can guarantee normal operation of
power takeoff device.

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5.1.6.4 Drive shaft

During the use of drive shaft, it should be well

maintained as followed:

1. Before using drive shaft, coat cross shaft

with MoS2 lithium or 2# lithium lubricating
grease. Besides, free joint bearing and sliding
spline should also be coated. See Fig.5-1.56.

2. After every 3000km, free joint and grease

nozzle on sliding spline need to be coated with
MoS2 lithium or 2# lithium lubricating grease.

3. During the use of drive shaft, usually check

if connecting nuts on flange are loose. Tighten
drive shaft connecting bolts as per tightening
torque (280-300N·m) stipulated in manual.

NOTICE

During the use of drive shaft, transmission

torque can never surpass drive the
permitted one.

Fig.5-1.56 Drive shaft

1-Front section of drive shaft 2-Free joint bearing base 3-Erection flange 4-Free joint cross shaft

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4. Check whether drive shaft cross bearing

and intermediate support is loose after every
20000km. When maintenance is needed,
maintenance and disassembly sequence of
drive shaft system must comply with: drive
shaft system disassembly must be from rear
to front; drive shaft system reassembly should
be from front the rear.

5. For reassembling disassembled drive

shafts, guarantee assembly arrows are in a
line. In replacing drive shaft parts, reconduct
dynamic balance test after replace.

6. For mounting drive shaft with belt slip

yoke, guarantee sliding spline interface to
be arranged downward. This can prevent
rainwater, mud or sand entering spline
engaged position.

7. Guarantee following maintenance data after

drive shaft is maintained:

Table 5-1.7 Maintenance data for drive shaft

Maintenance
Item Using Limit
Standard (mm)
Radial run-out of drive shaft 0.75 1.5
Sliding spline tooth clearance 0.025 ～ 0.115 0.4
Clearance between free joint and needle roller bearing 0.02 ～ 0.09 0.25
Cross shaft neck seriously peeled off and wearing extent - 0.01
Axial clearance of intermediate support shaft - 0.5
Intermediate support bearing seat inner bore surface wearing extent - 0.05

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5.1.7 Regular maintenance for brake

system

5.1.7.1 Brake

Regularly check wear of brake shoe and

cleft between brake hub and shoe. The
more frequent the brake is applied, the more
frequent the inspection shall be.

Check brake friction plate for wear.

a) Dismantle rubber plug in inspection hole of

brake.

See Fig.5-1.57

Fig.5-1.57
b) Wear indication platform of friction plate
can be seen from side of friction plate. Check
whether there is a ladder for indication
platform.

See Fig.5-1.58

If friction plate has been worn to indicating

step, replace brake liner.

Thickness of brake friction plate:

Standard thickness Service limit

14.5mm 5.5mm

Fig.5-1.58

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c) After inspection, reassemble rubber plug

dismantled tightly.

WARNING
When brake liner exceeds service limit,
do not use any more. Otherwise rivet will
damage brake hub, and brake performance
will be affected greatly to cause driving
risk.

d) Check brake pipeline:

Check whether there is interference between

brake pipeline and other parts, pipe clamp is
loose or connection leaks. In case of trouble,
treat it in time.

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5.1.7.2 Air drier

Air drier is a device to remove water

1 2 3
accumulated in truck pipeline and moisture
in compressed air from air compressor. Air
drier effectively solves problems caused by
accumulated water and oil stain, such as
rust of elements in brake system, cracking of
rubber seal, grease decomposition, pipeline
blockage and misoperation of elements like
vale, prolong service life of brake elements
and ensure driving safety.

Interval of inspection:

Every three months or every 15000 km driving.

Interval of replacement:

Every year or every 60000 km driving.

Check carefully if there is oil drained from drain Fig.5-1.59

1- Air drier 2- Drain hole 3- Air reservoir
hole of air drier. If oil is drained from drain
hole, it may be the failure of air compressor
or oil soaked into desiccant. Please contact
service station for inspection or replacement.

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5.1.8 Maintenance for air conditioner

Proper maintenance is a necessity for the

service time of air conditioner. Refer to attched
Construction Vehicle Installation Instruction for
detailed maintenance.

(1) Daily maintenance

1) Check and clean the condenser of air

conditioner. Do keep the cooling blade inside
clean, make sure there is no block. Clean
the condenser with nothing but cold water or
compressed air. Hot water or heated air is
extremely prohibited.

2) Check the quantity of coolant through

the level detecting window on the receiver.
Normally, there is no bubbles in the receiver
except when engine speed changes.

3) Check the tension condition of the drive belt

on the compressor.

4) Check if the appearance is normal, or each

joint is firmly connected.

5) Check if the power of cooling system is

firmlt connected, if there exists trip-out or short
circuit.

NOTICE

However the air conditioner is running, do

conduct check and maintenance on the
piepeline and other devices.
If the air conditioner is to be idle for a
long period, do operate it once a month
(10 mins each time). In winter, warm air
conditioner up before operating it.
To avoid core body of air conditioner
cracks in winter, do add antifreeze fluid to
the heater.

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STC500S3

(2) Regular maintenance for air conditioner

Table 5-1.8 Regular maintenance items and period of air conditioner

Maintenance period
System components Maintenance
Each month Half a year Each year
Check if pipeline is worn or if it is
Freezing pipe ●
complete

Check if there is leakage (oil track

Joint ●
exists with leakage)

Check the operation condition of

Condenser ●
cooling blade
Cooling Check the operation condition or
system Receiver ●
replace it if necessary

Freezing Check coolant through viewing

●
mixture window

Main body of Check the installation condition of

●
air conditioner main body (looseness is prohibited)

Check the vehicle body and sealing

Sealing ●
condition
Heater water
Check sealing condition ●
valve
Solenoid Check the operating condition of
●
clutch clutch
Check if the belt is complete and the
Belt ●
tension
Compresser
Check the installation condition
Fixing bracket ●
(looseness is prohibited)

Operation of Check if the operation sound is

●
compressor normal

Check if the line is worn or if it is

Power line ●
complete

Circuit Check if it can be released and if it is

Connector ●
system complete

Check if it can be released and if it is

Control switch ●
complete

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5.1.9 Lubricating of chassis

5.1.9.1 Precaution for lubricating of chassis

Correct lubricating to automobile could reduce

parts wearing. The following should be noticed
in lubricating:

NOTICE

Normally, lubrication should be conducted

as per maintenance period. Properly
shorten maintenance period under
extreme environment.
Select and use specified lubricating oil.
The substitute oil should be of the similar
performance as specified one. Do regularly
check the substitute oil.
Engine oil replacement should be done
under thermal condition. This can
guarantee the oil be drained off completely.
Check whether there is any abnormal color
or foreign objects during oil draining.
Clear foreign objects away from drain bolt
after oil has been extremely drained off.
See following table for lubricating location
and method.
Before lubrication, clean the oil port. After
lubrication, clear dust or dirt away from
parts surface.
Replace filter cartridge with a new one,
add new oil to the upper limit. To avoid
engine start with no lubricating oil, the
start button shall be pressed when there
is no oil in high-pressure oil pump. Restart
engine and run it at low speed after a
short period’ s idling. Check if there is any
leakage. Check the oil level and add it to
the upper limit of oil gauge after engine
has been shut down for 5 minutes.
Replace oil filter cartridge: when replacing
oil, filter cartridge should be replaced
along. Apply sealing spacer with a layer of
thin oil, then tighten the filter.

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5.1.9.2 Lubricating location and method of

chassis

See Fig.5-1.60, Fig.5-1.61 and Table 5-1.9 for

lubricating position and method of chassis.

Fig.5-1.60 Location of chassis lubricating label

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Fig.5-1.61 Lubricating map of chassis

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STC500S3

Table 5-1.9 Lubricating method of chassis

Name of Lubricating Lubricating Lubricating

No. Lubricant Variety
Lubricating Point point number Period Method

Grease gun Multipurpose lithium base

1 Fan shaft 1 1500
filling grease for automobile

Grease gun Multipurpose lithium base

2 Steering knuckle 2 5000
filling grease for automobile

Grease gun Multipurpose lithium base

3 Tie rod ball pin 2 5000
filling grease for automobile

Clutch release Grease gun Multipurpose lithium base

4 1 1500
bearing filling grease for automobile

Clutch release fork Grease gun Multipurpose lithium base

5 2 1500
shaft filling grease for automobile

Clutch output shaft Grease gun Multipurpose lithium base

6 1 1500
bearing filling grease for automobile

GL-4 85W/90 lubricating

7 Gearbox
8 Power takeoff
1500 oil (above -12℃ )
Oil replacing GL-4 80W/90 lubricating
1
oil (above -26℃ )
10000 GL-4 75W/90 lubricating
oil (above -40℃ )
GL-4 85W/90 lubricating
1500 oil (above -12℃ )
GL-4 80W/90 lubricating
1 Oil replacing
oil (above -26℃ )
5000 GL-4 75W/90 lubricating
oil (above -40℃ )

Free joint bearing Grease gun Multipurpose lithium base

9 4 1500
of drive shaft filling grease for automobile

Intermediate
Grease gun Multipurpose lithium base
10 bearing of drive 1 1500
filling grease for automobile
shaft

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Table 5-1.9 Lubricating method of chassis

Name of Lubricating Lubricating Lubricating

No. Lubricant Variety
Lubricating Point point number Period Method

Sliding fork of drive Grease gun Multipurpose lithium base

11 2 5000
shaft filling grease for automobile

GL-4 85W/90 lubricating

1500 Oil filling oil (above -12℃ )
Center reducer of
GL-4 80W/90 lubricating
12 internediate, rear 2
oil (above -26℃ )
axle
10000 Oil replacing GL-4 75W/90 lubricating
oil (above -40℃ )

Spring pin shaft

Grease gun Multipurpose lithium base
13 of front, rear steel 4 2000
filling grease for automobile
plate

Front, rear steel Multipurpose lithium base

14 4 10000 Oil brushing
plate spring grease for automobile

GL-4 85W/90 lubricating

1500 Oil filling oil (above -12℃ )
Wheel reducer of
GL-4 80W/90 lubricating
15 intermediate, rear 4
oil (above -26℃ )
axle
GL-4 75W/90 lubricating
10000 Oil replacing
oil (above -40℃ )

Balance beam of Grease gun Multipurpose lithium base

16 6 5000
rear suspension filling grease for automobile

Bearing of front,
Multipurpose lithium base
17 intermediate, rear 6 5000 Oil coating
grease for automobile
brake hub

Front, intermediate,
Grease gun Multipurpose lithium base
18 rear brake 6 2500
filling grease for automobile
camshaft

Battery electrode Each

19 4 Oil brushing Industrial vaseline LF40
mast season

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Table 5-1.9 Lubricating method of chassis

Name of Lubricating Lubricating Lubricating

No. Lubricant Variety
Lubricating Point point number Period Method

Refer to Operation
20 Engine oil sump 1 5000 Oil replacing
Instruction of Engine

N46 hydraulic oil for

summer; N32 hydraulic
Oil can of steering oil for winter; use 10#
21 1 10000 Oil replacing
power cylinder aircraft hydraulic oil if
there’s frost in plateau
cold area

Steering pitman
arm straight pull rod Grease gun Multipurpose lithium base
22 5 5000
and power cylinder filling grease for automobile
front, rear pin

Gear shifting lever

23 1 5000 Dripping HJ-20 mechanical oil
support

Accelerator pedal
24 1 5000 Dripping HJ-20 mechanical oil
oil

Free joint for

25 1 5000 Dripping HJ-20 mechanical oil
steering gear

26 Oil can of clutch 1 5000 Dripping DOT3

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5.2 Maintenance for

Superstructure

5.2.1 Regular maintenance

5.2.1.1 Daily maintenance

Daily maintenance should be conducted

before, during or after each operation.

Table 5-2.1 Daily maintenance list

NO. Part Item Technical specification

No block, no leakage, correct operation, reliable
1 Hydaulic parts Check
function
Operating
2 Check, adjust No skewness, no block, reliable function
mechanism
3 Lock up device Check No defect, no skewness, reliable function
Each mechanism and No abnormalities like deformation,unsoldering,
4 Check, tighten
structural member looseness
5 Boom, jib Check No deformation, damage, normal telescoping
Steel rope, sheave
6 Check No wear, twist, no block on sheave
and hook block
7 Shaft pin and bush Check, lubricate No looseness,add lubricating grease per 8 hours
Check the quality and quantity of each drive gear
8 Lubricating location Check, add oil, add lubricating grease to each lubricating point,
eliminate leakage

9 Link on each part Check, tighten No looseness, damage

Safety protector,
10 Check Operating normally
warning device

Vehicle body is clean with no obstacle for vision, no

11 Complete vehicle Clean
foreign objects in cab

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STC500S3

5.2.1.2 Weekly maintenance

Weekly maintenance should be conducted

mainly by operator instructed by professional
personnel.

Table 5-2.2 Weekly maintenance list

NO. Part Item Technical specification

1 Hydraulic oil tank Check, add No contamination, no leakage

Check, add oil, add lubricating grease to each oil
2 Each lubricating point Check, add
adding point
No damage, deformation, easy operation, return
3 Working mechanism Check, adjust
automatically
Check , tighten
4 Swing mechanism swing support Tightening torque 1050N.m
bolts

5 Hoisting mechanism Check wire rope Replace when it is needed to be rejected

Boom, jib, pulley and

6 Check No deformation, damage, no block on pulley
hook block

7 Shaft pin and bush Check, lubricate No serious wear, add lubricating grease per 8 hours

Check the quality and quantity of each drive gear

8 Lubricating location Check, add oil, add lubricating grease to each lubricating point,
eliminate leakage

Normal operation of transmission device, correct

indicating of instrument, reliable brake function,
9 Complete vehicle Check, test
clean vehicle, complete attached devices, excellent
outrigger function

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5.2.1.3 Monthly maintenance

Monthly maintenance should be conducted

mainly by professional personnel with operator
involved.

Table 5-2.3 Monthly maintenance list

NO. Part Item Technical specification

Check, analyse on oil

Hydraulic oil
1 quality, clean or replace No contamination, no abnormal color or odour from oil
tank
filter cartridge

Swing
2 Adjust brake clearance Swing brake clearance 0.25mm
mechanism

Check, tighten
Hoisting Tighten with specified tightening torque
3 connecting bolts
mechanism Clearance between brake and brake drum 0.8-1.0mm
Adjust brake

Check, pipeline- No damage on pipeline, no leakage on joint, normal

sealed hydraulic operating of pump and motor, no abnormal noise
Hydraulic
4 pump, hydraulic motor, or overheat, no serious wear on hydraulic cylinder,
parts
hydraulic cylinder, valve, no leakage, no leakage on valves, no block, normal
accumulator pressure for accumulator

Shaft pin
5 Check, lubricate No serious wear, add lubricating grease per 8 hours
and bush

Check the quality and quantity of each drive gear

Lubricating
6 Check, add oil, add lubricating grease to each lubricating point,
location
eliminate leakage

Safety
protector, Flexible transmission, complete warning label, error for
7 Check, test
warning moment limiter no more than ±5%
device

Normal operation of transmission device, correct

Complete indicating of instrument, reliable brake function, clean
8 Check, test
vehicle vehicle, complete attached devices, excellent outrigger
function

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5.2.1.4 Yearly maintenance

Yearly maintenance should be conducted

by technician, professional personnel with
operator involved.

Table 5-2.4 Yearly maintenance list

NO. Part Item Technical specification

Check, analyse
on oil quality,
1 Hydraulic oil tank No abnormal color or odour from oil
clean or replace
filter cartridge

Pipeline,
hydraulic cylinder,
hydraulic pump, No leakage on pipeline, no damage on hose, no scratch
2 Hydraulic parts
hydraulic motor, on operating surface of piston rod, no leakage
operating valve,
accumulator

Operating No block, looseness, easy operation, can return

3 Check, adjust
mechanism automatically

Main frame and No damage, deformation, each attached part complete,

4 Check, tighten
fastening parts firmly connected

5-104
 Maintenance
STC500S3

Table 5-2.4 Yearly maintenance list

NO. Part Item Technical specification

Check wear on
gear and gear Wear on gear and gear ring no more than 0.25mm,
Swing
5 ring, tighten bolts, tighten fastening bolts, tightening torque 1050N.m, add
mechanism
add lubricatig lubricatig grease full
grease

6 Boom, jib Check and test Normal telescoping

Steel rope, Cable end firmly connected, normal wear,

7 sheave and hook Check and test sheave rotates flexibly, no looseness on bearing, wear
block on hook block no more than 1mm of original

Shaft pin and

8 Check No bend, damage, wear no more than 1mm
bush
Check, replace
Lubricating
9 gear oil for each Replace with the brand and quantity as specified
location
reducer
Coating surface
Derust, paint
10 of complete Clean surface, no air bubble, no rust
repair
vehicle

Tighten without disassembly, permitted moment error

11 Bolt, pipe joint Check, tighten
±10%

Normal operating of each operating menchanism, no

overheat, noise and leakage on hydraulic system, correct
12 Complete vehicle Check, test
indicating of instrument, effective operating of safety
protector, reliable brake function

5-105
Maintenance
STC500S3

5.2.2 Routine check for key parts

Conduct routine check on superstructure key

parts as specified in Table 5-2.5.

Table 5-2.5 Routine check on superstructure

key parts

Structural member Routine check

1. If there is crack, bend or damage.
2. If the lock bolt on bottom hinge shaft of boom is loose.
3. If there is scratch on sliding surface.
Boom
4. If there is wear or damage on hinge shaft sleeve.
5. Lubrication on sliding surface.
6. If there is deformation or crack on boom.
1. If there is crack, bend or damage.
Jib
2. Lubrication on connecting pin and pin sleeve.
1. If there is crack.
Winding drum
2. If the wire rope is wound in disorder.
1. Swing of hook block.
2. If there is deformation.
3. If the cross beam can swing normally.
4. Connecting between cross beam and hook block.
Hook block and
5. If there is deformation on holder.
sheave
6. Swing of sheave (if there is noise).
7. If there is crack or damage on sheave.
8. If there is bend or damage on sheave bracket and protection cover.
9. Lubrication.

5-106
 Maintenance
STC500S3

Table 5-2.5 Routine check on superstructure key parts

Structural member Routine check

1. Diameter.
2. Rope wire rupture
3. Twist.
4. Deformation.
Wire rope 5. Rust prevention.
6. If rope socket, wedge are correctly positioned.
7. Connecting between wire rope and rope socket.
8. If there is damage or crack on pin shaft and bush on rope socket.
9. If wire rope is normally reeved through sheave.
Operating handle 1. Function.
and pedal 2. If there is oil clearance.
1. If there is scratch or deformation on surface.
Level gauge 2. If it is well mounted.
3. The state of air bubble.

5-107
Maintenance
STC500S3

5.2.3 Adjustment, cleaning and

replacement of parts

5.2.3.1 Replacement of wire rope

(1) Replacement standard for wire rope

Wire rope may get fatigue as time passing by.

It is seriously dangerous for future use if no
measure is taken.

Wire rope should be checked and replaced

based on GB5972-2006 "Specification on
check and rejection of wire rope for truck
crane". The replacement conditions are listed
as followed:

● Rope rupture for each section reaches 10%

(rope heart excluded);
● Diameter decreases by above 7% of the
nominal one;
● Wire rope is twisted;
● Obvious deformation(section sinks,wire
extends out) or rust;
● Disorderly rope end.

(2) Requirements for newly adopted wire rope

The newly adopted wire rope should be of

similar type and specification of the original
one. When different wire rope is adopted, the
performance of it should be equivalent with
the original one. Besides, its channel can
be matched to the one on winding drum and
sheave.

If the required wire rope is cut from a longer

one, the two ends should be well treated. This
can effectively prevent looseness of wire rope.

5-108
 Maintenance
STC500S3

(3) Replacement of wire rope

Before replacement, do set the truck crane on

solid and flat ground with boom completely
retracted. Then, replace the wire rope as
followed (taking main wire rope for example):

1) Lower the main hook onto the ground.

See Fig.5-2.1

Fig.5-2.1 Lower hook

2) Dismantle rope socket out from top boom

section or main hook.
See Fig.5-2.2

Fig.5-2.2(1) Rope socket fixed onto the boom

(Even number of parts of line)

Fig.5-2.2(2) Rope socket fixed onto the main

hook (Odd number of parts of line)

5-109
Maintenance
STC500S3

3) Disassemble wire rope out from rope 2

socket.
See Fig.5-2.3

Fig.5-2.3 Disassemble wire rope out from rope

socket
1-Loosen clamp nut 2-Dismantle rope clamp
3-Disassemble wire rope
4) Pull wire rope out from winding drum.
See Fig.5-2.4

NOTICE
When there are only 3-loop wire rope
left, hook lowering may be limited by
overlowering protection device. This
operation can be released through
“emergency release” till wire rope is
completely reeled off.

Fig.5-2.4 Pull wire rope out along sheave

Hand hammer
5) Dismantle wire rope from winding drum.
Steel bar
See Fig.5-2.5
Drum

NOTICE
Wedge
Wire rope
Do properly store wedge.
Fig.5-2.5 Dismantle one end of wire rope from
winding drum

5-110
 Maintenance
STC500S3

6) Reeve new wire rope through the sheave

above the top boom section

See Fig.5-2.6

Fig.5-2.6 Reeve new wire rope through the

upper sheave of top boom section

NOTICE

Tightly wind the wire rope end with wire or

polyethylene plastic belt.

See Fig.5-2.7

Fig.5-2.7 End disposal of wire rope

7) Fix wire rope end onto the main winding

drum. Drum
See Fig.5-2.8

Wedge
Wire rope

Fig.5-2.8 Fix one end of wire rope onto

winding drum

5-111
Maintenance
STC500S3

NOTICE
Correctly mount wedge.
Never expose the rope head from the outer
round surface of winding drum.

See Fig.5-2.9

Fig.5-2.9 Rope head should never be exposed

outside winding drum

8) Wind wire rope up.

See Fig.5-2.10

NOTICE

Keep wire rope orderly on winding drum!

Fig.5-2.10 Wind wire rope up

9) Reeve wire rope through the sheaves

on top boom section and hook block with
corresponding number of parts of line.
See Fig.5-2.11

Fig.5-2.11 Reeve wire rope

5-112
 Maintenance
STC500S3

10) Mount rope socket and rope clamp onto

the wire rope.
See Fig.5-2.12

Fig.5-2.12 Fix wire rope end onto rope socket

11) Ring top boom section or main hook with

rope socket with corresponding number of
parts of line.
See Fig.5-2.13

Fig.5-2.13(1) Rope socket fixed onto the boom

(Even number of parts of line)

Fig.5-2.13(2) Rope socket fixed onto the main

hook (Odd number of parts of line)

5-113
Maintenance
STC500S3

12) Lift boom to the highest elevation and

extend it out. Lower the hook till 3-loop wire
rope is left.
See Fig.5-2.14

Fig.5-2.14 Lift hook block

13) Lift a load weights 30% of Maximum

Permitted Load for single section. Reeve wire
rope onto the winding drum.
See Fig.5-2.15

CAUTION
Rated total lifting capacity should never be
exceeded! Load weight：W=0.3NP

Permitted Maximum Load Capacity for Number of parts of line：N

wire rope single piece is 48.8kN. Permitted maximum load capacity

for lifting wire rope single piece:P
Never rewind the rope onto hoisting
mechanism after the change of joint
direction. Fig.5-2.15 Trial lifting

14) Unload from main hook.

(4) Maintenance of wire rope

1) Daily check the wire rope before and after

operation everyday. Replace wire rope as
needed refer to chapter 5.2.3.1 on page 5-108.

2) Coat wire rope with extreme pressure

lithium base grease 2# once a week.

5-114
 Maintenance
STC500S3

5.2.3.2 Hook block replacement

The hook block cannot be used any more

if any one problem stated followed occurs
(defect cannot be repaired through welding).

1. There exist cracks and crevasse on the

hook;

2. The open degree of hook has exceeded

10% of the original size;

3. The wear and tear of dangerous cross

section reaches 10% of the original size;

4. The section wear of roping is above 10% of

the original height;

5. The deformation of hook has exceeded 10°;

6. There are plastic deformation on the

dangerous cross section (hook end and screw
thread) and hooked bar.

5-115
Maintenance
STC500S3

5.2.3.3 Adjustment for telescoping rope of

boom

If telescoping boom cannot fully retract after

full retraction of boom. It means the boom
telescoping rope has not been properly
adjusted. Adjust the rope as followed:

(1) Adjustment for retracting wire rope of top

boom section

1) Open the head cover of top boom section. Adjusting nut Locking nut
Expose the nut on rope head of retracting wire
rope.

2) Loosen locking nut. Tighten adjusting nut till

the wire rope is tightened.

3) Tighten locking nut, mount encloser.

See Fig.5-2.16
Fig.5-2.16 Boom head at top boom section

NOTICE

Adjusting nut cannot be over-fastened;

otherwise, wire rope may be always
tightened. Do refasten the lock nut after
adjustment of adjusting nut.

5-116
 Maintenance
STC500S3

(2) Adjustment for retracting wire rope of basic

boom

1) Pick out the rope heads on retracting rope

at the sides of boom. It should be noticed that
they exist on the two symmetrical sides.

2) Loosen locking nut. Tighten adjusting nut till

the extending wire rope is tightened. Basic boom

3) Tighten the locking nut.

Adjusting nut
See Fig.5-2.17
Locking nut

NOTICE Fig.5-2.17 Adjust the retracting wire rope on

basic boom
Adjusting nut cannot be over-fastened;
otherwise, wire rope may be always
tightened. Do refasten the lock nut after
adjustment of adjusting nut.

5-117
Maintenance
STC500S3

5.2.3.4 Adjustment for 3-ring protector

1) To prevent winch rope being released

thoroughly, 3-ring protectors on main, auxiliary
winch give out warning signal and the
operation of lowering hook will be limited when
there are about three loops of rope left. This
limit can be released through the operation of
hook rising. See Fig.5-2.18. 1

Fig.5-2.18 Location of 3-ring protector

1-3-ring protector

2) Adjustment of 3-ring protector

Step 1: Release the rope till there are three

loops left;

Step 2: Loosen the mounting bolts on the

outer casing of 3-ring protector, then open the
shell. See Fig.5-2.19.

1 2
Fig.5-2.19 Outer casing on 3-ring protector
1-Outer casing on 3-ring protector 2-Tail case

5-118
 Maintenance
STC500S3

Step 3: Loosen the retaining screw on drive

shaft. Rotate cam clockwise till it can press 1 2 3 4
down the roller on stroke switch. Thus, the two
cable conductors on stroke switch are properly
connected. See Fig.5-2.20.

Step 4: Tighten the retaining bolts on drive Fig.5-2.20 Inner structure of the 3-ring
shaft and properly restore the outer casing. protector
1-Cam 2-Screw 3-Drive shaft 4-Roller
See Fig.5-2.20.

5-119
Maintenance
STC500S3

5.2.4 Regular maintenance for winch

reducer and swing mechanism

Do adopt the gear oil recommended in this

manual. Crane has been properly filled with
L-CKD220 Great Wall Industrial Close Type
Gear Oil before sent to customer. The content
for winch reducer is 1.5L, Swing reducer 4.5L.

(1) Oil replacement period

1) Main, auxiliary winch reducer

Replace the lubricating oil after the first 100

hours’operation, again after another 500
hours. Thereafter, the lubricanting oil should
be replaced every 1,000 hours’ operation or at
least once a year.

2) Swing mechanism

Lubricating oil should be replaced after the

first 150 hours’operation. Thereafter, it should
be replaced every 1500 hours, at least once a
year.

CAUTION
The reducer is still hot just after the
operation. Wait for the parts to cool down
before maintenance.

NOTICE

Even ahead of the replacement period,

replace the gear oil timely if it is seriously
contaminated.
Regularly check oil level. Add it enough if
it is below specified value.
Never mix different gear oil.

5-120
 Maintenance
STC500S3

(2) Oil replacing location

1) Winch reducer

A direction
1 2 3

Fig.5-3.4 Winch reducer

1-Oil fill/drain thread screw 2-Dust cover 3-Rope wedge 4-Oil fill port 5-Oil drain port

2) Swing reducer

1 4 A direction
2 3

6
5

Fig.5-3.5 Swing reducer

1-Oil drain port 2-Oil fill port 3-Ventilation plug 4-Oil port location
5-Oil drain port location 6-Ventilation plug location

5-121
Maintenance
STC500S3

5.2.5 Regular maintenance for swing

support

1. Interval of maintenance

Regular inspect swing support screws every

500 hours or 6 months; lubricate the swing
support 2-5 times a week.

2. Location of maintenance

See Fig.5-2.23

3. Maintenance method
1
If any screw is found loosened, please contact 2
3
our service station to tighten. The tighten
torque is 1050N·m.

Coat the swing support gear surface with

lithium base grease(GB/T5671-1995); inject Fig.5-2.23 Swing support
1- Screw 2- Lubricating port 3- Swing support
2# lithium base grease to lubricating ports with
a grease gun.

WARNING

Loosened or broken screws will cause

crane superstructure disengaged
from chassis, therefore cause serious
accidents. Regular check the screws,
if any screw is found loosened, please
contact our service station to tighten
it. Contact service station to tighten all
screws at least once a year.

5-122
 Maintenance
STC500S3

5.2.6 Regular maintenance for boom

Table 5-2.6 Regular maintenance table for boom

Lubricating Lubricating
No. Name of lubricating location Lubricant type
period method

1 Boom hoisting sheave set Every week Injection
2 Slider for 2nd, 3rd, 4th boom sections Every week Coating,injection
Traveling surface of sliders for 2nd,
3 Every week Coating
3rd, 4th boom sections
4 Jib sheave Before use Injection
5 Boom rear hinged shaft Every week Coating,injection
lithium base grease
lithium base grease
lithium base grease
lithium base grease
lithium base grease

Refer to table 5-2.6 for boom regular

maintenance; see Fig.5-2.24 for lubricating
location.

6
3
4
5

Fig.5-3.24 Lubricating location on the boom

1,2- Jib sheave 3- Upper Bbom sheave 4- Lower boom sheave
5- Boom head sheave 6- Slider 7-Boom rear hinged shaft

5-123
Maintenance
STC500S3

5.2.7 Regular maintenance for key

kinematic pair

The key kinematic pair of this crane is three

hinge shaft, see No.4, 5 and 6 in Fig.5-2.25.

Table 5-2.7 Three hinge shaft maintenance table

Lubricating
No. Name of lubricating location Lubricating method Lubricant type
period
1 Upper hinged shaft of luffing cylinder Every week Injection lithium base grease
2 Lower hinged shaft of luffing cylinder Every week Injection lithium base grease
3 Boom rear hinged shaft Every week Injection lithium base grease

Refer to table 5-2.7 for three hinge shaft

regular maintenance; inject lithium base
grease to oil cup, see Fig.5-2.25 for lubricating
location.

4 3

5
6

Fig.5-2.25 Lubricating location on the three hinge shaft

1,2,3- Oil cup 4-Boom rear hinged shaft 5-Lower hinged shaft of luffing cylinder
6-Upper hinged shaft of luffing cylinder

5-124
 Maintenance
STC500S3

5.2.8 Lubrication of superstructure

5.2.8.1 Lubricating location

The superstructure lubricating label is located

on the side glass inside the cab. See Fig.5-
2.26. Refer to Fig.5-2.27 and Table 5-2.8 for
lubricating location.

NOTICE

Do not mix hydraulic oil, gear oil and

lubricating grease of different brands.

Fig.5-2.26 Location of superstructure lubricating label

5-125
5-126
STC500S3
Maintenance

Lubricating Map of Superstructure

1 2 2

1 2 1 2 2
The Second Lithium-base
1 1 1 1
Lubricant 1

The Standard GB/T5671-1995

Lithium-base Lubricant
2

LS2 Industrial Gear

Lubricating Oil

Fig.5-2.27 Lubricating map of superstructure

Note:The number which located
1
in the symbol means the number
of places which need to apply lubricant

Once per week (or 20 to 100 Hours) 2 1

Once per month (or 200 to 400 Hours)

Once per year 1

 Maintenance
STC500S3

5.2.8.2 Lubricating method of

superstructure

Table 5-2.8 Lubricating method of superstructure

No. Name of lubricating location Lubricating period Lubricating method

1 Main hook sheave set Every week Oil chamber injection

2 Boom hoisting sheave set Every week Oil chamber injection
3 Slider for 2nd, 3rd, 4th boom sections Every week Coating, oil chamber injection

Traveling surface of sliders for 2nd, 3rd, 4th

4 Every week Coating
boom sections

5 Upper, lower hinged shaft of luffing cylinder Every week Oil chamber injection
6 Jib sheave Before used Oil chamber injection
7 Boom rear hinged shaft Every week Coating, oil chamber injection
8 Swing support 2-5 times per week Oil chamber injection
9 Pinion of Swing mechanism Every week Coating
10 Auxiliary hook Before used Coating
11 Wire rope Every week Coating
12 Wire rope (for boom telescoping) Every week Coating
13 Float Every week Oil chamber injection
14 Winch bearing seat Every week Oil chamber injection

NOTICE
Before oil filling, clean oil cup and the to-
be-applied surface.
The sliding surface not listed should also
be added with lubricating oil regularly.
Different lubricating grease cannot be
mixed.
For bush, shaft and bearing, add
lubricating grease to them till the original
one is squeezed out.
Store the boom onto boom bracket. If
piston rod of luffing cylinder is exposed,
lubricate it with lubricating grease once
per month.
Do adopt proper gear oil under
different ambient temperature (refer
to Recommended oil and lubricating
grease in chapter 5.3 on page 5-128).
Reducing mechanism may be damaged by
unqualified gear oil or the one of improper
viscosity.

5-127
Maintenance
STC500S3

5.3 Recommended Oil and Grease

(1) Recommended oil and grease at different
ambient temperature

Table 5-3.1

NO. Applicable location Temperature Description

Antiwear hydraulic oil 6146
Above -10℃
Shell antiwear hydraulic oil VG46
Great Wall L-HS low freezing-point hydraulic oil 32
Anti-wear hydraulic oil MOBIL DTE13M(208L)
Hydraulic/steering -10~-35℃
1 Shell anti-wear hydraulic oil VG32 (Tellus T) (anti-wear
system
hydraulic oil HV32#)
Great Wall 8132 synthetic ashless antiwear hydraulic oil
Below -35℃ Mobil SHC525
Hydraulic Shell Tellus Arctic32
Industrial gear oil L-CKD220
Above -20℃
Shell gear oil VG150
2 Reducer L-CKT220 synthetic industrial gear oil
Below -20℃ Mobil synthetic gear oil 220
Shell Omala HD220
Molybdenum disulfide extreme pressure lithium base
grease 2#(for Swing support)
Above -20℃ General lithium base grease II (for bearing and hub)
Swing support/ Extreme pressure lithium base grease EP2 (for Swing
3
bearing/hub support)
Great Wall L-XEGHB2
Below -20℃ Mobil synthetic grease 220
Shell lubricating grease EM220
Engine oil for diesel machine 15W/40CF4
Above -20℃
Shell engine oil for diesel machine CG-415W40
4 Engine oil
0W/40CF-4
Below -20℃
Mobil HD15W-40 208L/Barrel
Above -20℃ Shell gear oil 80W/90GL-5
Synthetic gear oil for heavy-loaded vehicle 75W/90GL-5
5 Gearbox and axle
Below -20℃ Mobil synthetic gear oil 75W-90
Shell ASX75W-90

5-128
 Maintenance
STC500S3

(2) Recommended brake fluid at different

ambient temperature

Table 5-3.2

Temperature Description
Great Wall synthetic automobile brake fluid DOT4
Above -45℃ Mobil DOT4
Automobile brake fluid 901

(3) Recommended antifreeze fluid at different

ambient temperature

Table 5-3.3

Temperature Description
Great Wall organic antifreeze fluid -50#
Above -45℃ Mobil antifreeze fluid (icepoint -45℃ )
Shell antifreeze fluid (icepoint -45℃ )

5-129
Maintenance
STC500S3

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5-130
 Troubleshooting
STC500S3

Troubleshooting

6 Troubleshooting
6.1 Common Faults and Troubleshooting of Superstructure........................................... 6-3
6.2 Common Faults and Troubleshooting of Chassis.................................................... 6-11
6.3 Schematic Diagrams of Complete Vehicle.............................................................. 6-60

6-1
Troubleshooting
STC500S3

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6-2
 Troubleshooting
STC500S3

6 TROUBLESHOOTING

6.1 Common Faults

and Troubleshooting of
Superstructure

6.1.1 Mechanical system

Refer to Table 6-1.1 for common faults and

troubleshooting on mechanical system of
superstructure.

Table 6-1.1 Common faults and troubleshooting on mechanical system of superstructure

No. Condition Cause Remedy

Clearance between sliders of boom

Adjust
improperly adjusted
Boom shaking in
1 Lacking of lubricating grease on the
telescoping Apply lubricating grease
slider
Telescoping rope loosened Adjust
Connecting shaft wears out or
Repair and add lubricating grease
Boom shaking in lacking of lubricating grease
2
luffing
Pivot bearing of cylinder damaged Replace with new one

Boom deforms Inspect, repair

Fault of telescoping mechanism,
3 No retracting of boom
such as telescoping rope damaged, Inspect, repair
skipping, pulley damaged

Adjust the clearance between

Severe asynchrony of
4 Fixed outrigger box deforms movable outrigger and fixed
outrigger extending
outrigger

Abnormal sound or Adjust the clearance between

5 shaking in outrigger Fixed outrigger box deforms movable outrigger and fixed
telescoping outrigger

6-3
Troubleshooting
STC500S3

6.1.2 Hydraulic system

Refer to Table 6-1.2 for common faults and

troubleshooting on main parts of hydraulic
system.

Table 6-1.2 Common faults and troubleshooting on main parts of hydraulic system

No. Location Condition Cause Troubleshooting

Oil shortage Add oil
Repair and exhaust the
Air in oil-intake pipeline
air
Hydraulic
1 Noise Loose construction bolt Tighten the bolt
pump
Hydraulic oil polluted Change or filter the oil
Drive shaft vibrates Repair
Free joint wears out Replace
Low pressure of chassis
Adjust to 20MPa
overflow valve

Valve core of chassis overflow

No operation Disassemble and clean
valve blocked by dirt

Fault of chassis multi-way valve Repair

Disassemble and
Valve core stroke of chassis clean the valve core,
2 Outrigger multi-way valve unfulfilled adjust the draw-bar
Slow operation
mechanism

Pressure of overflow valve is

Adjust
set too low

Vertical cylinder Ineffective bidirectional Disassemble and clean

automatically extends hydraulic lock or replace
out or withdraws in
hoisting or traveling Replace the relevant
Internal leakage or external
status sealing parts or replace
leakage of cylinder
the whole part

6-4

Table 6-1.2 Common faults and troubleshooting on main parts of hydraulic system
No. Location Condition Cause
Hydraulic motor damaged
Fault of reducer or brake of
swing mechanism
No swing Low pressure of chassis
overflow valve
Fault of swing control solenoid
valve
Low pressure of chassis
overflow valve
Severe leakage of hydraulic
Slow swing
motor
Severe internal leakage of valve
or reversing unfulfilled
Swing
3 Fault of swing balance valve
mechanism
Great shock of swing,
unstable Fault of one-way throttle valve
Fault of swing brake
Swing mechanism worn out
severely
Free slide solenoid valve
Unable to practice blocked, unable to reverse or
free slide – lock in fault of solenoid valve circuit
changeover of swing
mechanism Low pressure of oil intake pipe
of brake
Troubleshooting
STC500S3
Troubleshooting
Repair or replace
Repair
Disassemble and clean
or adjust
Disassemble and clean
or replace
Disassemble and clean
or adjust
Repair or replace
Check and replace the
sealing part
Adjust the balance valve
and check the damping
inside the valve
Check the damping
inside the valve and
pressure of accumulator
Inspect and repair
Inspect and repair
Inspect, repair
Adjust the pressure of
low-pressure oil source
of main valve
6-5
Troubleshooting
STC500S3

Table 6-1.2 Common faults and troubleshooting on main parts of hydraulic system

No. Location Condition Cause Troubleshooting

Pressure of multi-way overflow

valve on superstructure is set Adjust
too low
No luffing up
Severe internal leakage of
operation Inspect and repair
cylinder
Severe internal leakage of main
Inspect and repair
pump
Same as causes 1, 2, 3 of no
Inspect and repair
luffing up operation
Luffing No luffing down Valve core of balance valve
4 Clean or replace
mechanism operation blocked
Control oil circuit of balance
Clean
valve blocked
Fault of balance valve Clean and adjust
Boom shaking when
High pressure of luffing down
luffing down Adjust
secondary overflow

Automatic withdrawal Internal leakage of cylinder Repair or replace

of telescoping
Internal leakage of balance
cylinder Clean or replace
valve

6-6
 Troubleshooting
STC500S3

Table 6-1.2 Common faults and troubleshooting on main parts of hydraulic system

No. Location Condition Cause Troubleshooting

Low pressure of main valve

Disassemble, clean and
extending secondary overflow
adjust
valve

No extending Same as causes 1, 2, 3 of no

Inspect and adjust
operation luffing up operation

Check relevant circuit

Fault of telescoping control
and inspect the control
valve
valve

Low pressure of main valve

Disassemble, clean and
withdrawing secondary overflow
adjust
Telescoping valve
5
mechanism Valve core of balance valve
Repair or replace
No retracting blocked
operation Same as causes 1, 2, 3 of no
Inspect and adjust
luffing up operation

Check relevant circuit

Fault of telescoping control
and inspect the control
valve
valve

Fault in balance valve, unable

Boom retracts Repair
to lock
naturally during
operation Internal leakage of cylinder Repair

Pressure of multi-way overflow

valve on superstructure is set Adjust
too low
Fault of hydraulic motor Inspect and repair
Severe internal leakage of main
Inspect and repair
Hoisting No hook lifting/ pump
6
mechanism lowering operation Control oil circuit of balance
Clean
valve blocked

Fault of moment limiter signal Inspect and repair

Fault of main valve brake oil

Inspect and repair
circuit

6-7
Troubleshooting
STC500S3

Table 6-1.2 Common faults and troubleshooting on main parts of hydraulic system

No. Location Condition Cause Troubleshooting

Fault of overflow valve Clean and adjust
Oil pump damaged Inspect and repair
System pressure Fault of central swing joint Inspect and repair
cannot build up Inspect and repair the
Fault of master control solenoid
circuit and solenoid
valve
7 Others valve

Severe internal leakage of main

Inspect and repair
High temperature of pump
hydraulic oil, slow
Severe leakage of hoisting
operation of actuating Inspect and repair
motor
mechanism
Fault of radiator Inspect and repair

6-8
 Troubleshooting
STC500S3

6.1.3 Electrical system

Refer to Table 6-1.3 for common faults and

troubleshooting on electrical system.

Table 6-1.3 Common faults and troubleshooting on electrical system

No. Condition Cause Troubleshooting

Bulb damaged Replace
Fuse burns out Replace
Work lamp, boom lamp and
1 Poor earthing Repair
indoor lamp cannot light up
Open circuit Repair
Ineffective switch Repair or replace
Fuse burns out Replace
Ineffective switch Replace
2 No operation of wiper Motor damaged Replace
Poor earthing Repair
Open circuit Repair
3 Silent buzzer Fault of moment limiter Contact our service station
Unable to operate the crane in Fuse burns out or loosened Repair or replace
4
the cab Open circuit, ineffective switch Repair or replace
Fuse burns out Replace
5 Poor operation of moment limiter Ineffective relay Replace
Fault of moment limiter Contact us
Fuse burns out Replace
Fault of winding box Repair or replace
Open circuit Repair
6 Fault of height limiter Fault of limit switch Replace
Hammer cable broken Replace
Poor earthing of limit switch Repair
Fault of moment limiter Contact us

6-9
Troubleshooting
STC500S3

Table 6-1.3 Common faults and troubleshooting on electrical system

No. Condition Cause Troubleshooting

Check 4-way plug of cable

Pull wire of length sensor fails
and replace the pull wire
Improper adjustment of
Readjust
potentiometer of length sensor
Skidding of internal transmission
7 Fault of length sensor displayed Adjust the gear backlash
gear of length sensor
Short circuit or open circuit of
Repair or replace
cable and cable gland
Improper setting of length
Contact our company
parameter

Short circuit or grounding of

shielding cable and pull wire Repair or replace
8 False overwind alarmer cable core of length sensor

Earthing fault of overwind switch Repair or replace

Short circuit or open circuit of Repair or replace cable

Fault of pressure sensor (P1) cable and cable gland gland of cable P1
9
signal displayed Replace the pressure
Fault of pressure sensor P1
sensor

6-10
 Troubleshooting
STC500S3

6.2 Common Faults and

Troubleshooting of Chassis

6.2.1 Mechanical system

6.2.1.1 Engine

Refer to attched Operation and Maintenance

Instruction of Engine for common faults and
troubleshooting of engine.

6.2.1.2 Traveling system

Refer to Table 6-2.1 for common faults and

troubleshooting on traveling system.

Table 6-2.1 Common faults and troubleshooting on traveling system

Condition Cause Troubleshooting

Wash and clean oil seal outer ring and housing

oil seal seat hole, apply Loctite 603 retaining
Input shaft driving gear shaft oil seal is
glue at oil seal outer ring, and infuse oil seal
damaged or abrasive, or oil seal spring is
into oil seal seat hole.
loose
Check axle housing ventilation unit (should be
checked regularly).

Wheel hub oil seal leaks: two wheel

hub oil seals are assembled in wrong Reassemble wheel hub oil seal.
Oil
sequence
leakage
After dismantlement, clear the end cap and
Shaft head end cap leaks oil outside:
planet carrier end face. Then apply Loctite 587
the contacting surface of end cap and
sealing glue on connecting surface ceaselessly,
planetary gear carrier is not sealed
and reassemble.

Axle housing ventilation hole leaks

outside, while the wheel redactor is Check the direction of half axle oil seal or
always short of oil. Half axle oil seal is replace half axle oil seal.
installed reversely or damaged.

6-11
Troubleshooting
STC500S3

Table 6-2.1 Common faults and troubleshooting on traveling system

Condition Cause Troubleshooting

Pretightening force for wheel hub bearing

is too strong: during maintenance, fail to
tighten shaft head knurled cap according
Wheel Reassemble wheel hub as per requirements.
to requirements, and too much tightening
hub
torque for knurled cap increases the
heating
bearing pretightening force.

Wheel hub bearing is distorted or

Repair or replace
damaged.
Fault in brake chamber and brake control
Check and replace air circuit
air circuit

Brake camshaft is crank and distorted,

shaft lining is severely short of oil, or
Check, repair, and lubricate
brake camshaft bracket is distorted or is
mispositioned.
Brake
drum Brake shoe return spring is ruptured or
Replace
heating loose.
Clearance between brake lining and
Adjust clearance
brake drum is too small.

Recommend using engine exhaust brake to

Braking is too frequent reduce the speed. Try to avoid using service
brake frequently .

Constant noise for gear wearing, and the

Check and repair bearing or driving gear.
noise gets louder with speed increase.

No obvious noise during normal straight-
Central line traveling, but abnormal noise will
driving appear when turning a corner.
abnormal
noise Constant noise appears after drive and
driven gear replacement, and the noise
gets louder with speed increase
Check differential gear or the tightness of
differential lock sliding sleeve, and repair or
replace differential gear.
Check backlash clearance between drive and
driven gear, and whether the tooth contact
track is qualified. Specially notice whether the
drivegear matches the driven gear.

Housing deformation Check and replace

Wheel rim is distorted Check, repair or replace
Back
Wheel hub bearing is loose Check, repair or replace
wheel
Tighten or replace steel plate spring. Check
rubs tires Back axle at malposition
whether central bolts are ruptured or not.

6-12
 Troubleshooting
STC500S3

6.2.1.3 Steering system

Refer to Table 6-2.2 for common faults and

troubleshooting on power steering gear.

Table 6-2.2 Common faults and troubleshooting on power steering gear

Condition Cause Troubleshooting

Check oil tank level and fill enough oil as per

Hydraulic system lacks of oil
requirements
Degas and check oil level and tightness of the
Air in hydraulic system
pipe joint
Left & right Filter plugged, poor cleanness Clean the filter and filter cartridge, and replace oil
steering is Oil pump pressure is insufficient Overhaul oil pump
heavy Leakage inside the steering gear is
Overhaul or change seal ring
serious
Front wheel is locked (brake fails to
Overhaul brake binding position
reset)

Oil leakage volume of the both sides

of the internal piston in steering gear Replace seal ring
Left & right
is different
steering
heaviness Limit valve is improperly adjusted,
Readjusted
is different and opened too early

Air in single chamber Degas

Oil supply of the oil pump is Oil tank is deficient of oil, shall add oil and
During insufficient overhaul oil pump
quick Oil leakage on the two sides of
steering, steering gear inter piston, mainly
steering Replace oil seal again
caused by sealing damage or over
wheel feel wearing
heavy
Sucked in air Degas and check the seal of the connecting part

6-13
Troubleshooting
STC500S3

Table 6-2.2 Common faults and troubleshooting on power steering gear

Condition Cause Troubleshooting

For steering oil pump with floating

copper bush, the bush gets stuck and
Overhaul oil pump
cannot closely contact with wheel
end face

Check stuck point, jack up front axle, and steer

When
steering gear box. If the engine is not started,
steering Dirt at steering gear piston seal ring
steering gear could turn freely, otherwise oil pump
sometimes
fails
heavy and
sometimes Thrust bearing on steering gear guide
Replace bearing
light screw damaged
Hydraulic oil too dirty Replace oil
Steering knuckle pin bearing broken Replace bearing
Air in hydraulic system Degas
Check stuck position, and check the input shaft
Steering shaft gets stuck
whether it bears radial shearing force
Bubble in oil and direction not stable Check and troubleshooting
Front wheel is locked (brake fails to
Overhaul brake
reset)

Tightness of two wheel bearing

Deviation different (one is too loose and the Check and adjust
other is too tight)

Pressure of left and right tire doesn’t

meet the requirements (too much Air inflating
difference)

Inside of hydraulic system isn’t

Degas
degassed completely
Oil tank lacks of oil, and air enters oil
Vibration Fill oil and degas
pump
Oil line seal is poor and air enters Check oil line and improve seal

6-14
 Troubleshooting
STC500S3

Table 6-2.2 Common faults and troubleshooting on power steering gear

Condition Cause Troubleshooting

Oil sea damaged and leaks Check and replace oil seal
O-ring seal ring leaks oil Check and replace O-ring
Oil pipe leaks oil or damaged Check or replace oil pipe
Steering
Connecting part of oil pipe joint leaks
gear oil Check leaking point
oil
leakage
Viscosity of oil is not enough Properly use oil
Steering gear hydraulic elements
Check and tighten
contact face loose
Some position of the oil pipe in
Check oil line, and replace oil pipe
Abnormal hydraulic pipeline is cracked
noise Oil pump output volume is not stable Replace oil pump
during Oil tank lacks of oil Fill oil
steering Check steering pipe column, tie rod, and
Vehicle chassis fails
suspension system, etc.

6-15
Troubleshooting
STC500S3

6.2.1.4 Transmission system

a. Refer to Table 6-2.3 for common faults and

troubleshooting on clutch

Table 6-2.3 Common faults and troubleshooting on clutch

Condition Cause Troubleshooting

Clutch pedal free travel is too narrow or without free
travel
Clutch pressure plate is too thin, or pressure plate
and flywheel deform
Pressure spring is softened or fractured
Clutch
Clutch release lever height is improperly adjusted
slides
Check and adjust free travel of
clutch pedal
Check and replace pressure plate
and flywheel
Replace pressure plate spring
Check and adjust release lever
height

Friction plate gets thinner because of wear,

Replace friction lining or clear away
hardening, or corrosion. Rivet exposed or stuck with
oil fouling
oil fouling

Connecting bolts between clutch cover and flywheel

Check and tighten connecting bolts
get loose
Check and adjust free travel of
Free travel of clutch pedal is over wide
clutch pedal

Release lever distorted and bent, inner end surface

Check, repair, and replace release
not in the same level, some release lever or
lever or adjusting screw
adjusting screw fractures

Check, repair, and replace friction

Driven disk wraping, rivet loose, friction lining cracks lining, and add proper adjusting
Clutch or fractures, or new friction lining too thick spacer between clutch cover and
release flywheel
is not
thorough Pressure spring elasticity different or individual Check, adjust or replace pressure
spring fractured spring

Double friction lining central pressure plate limit

Check and adjust limit screw, and
screw is improperly adjusted and release spring
change release spring
fractured

Driven disk hub key groove and clutch shaft key

tooth are rusted, which makes driven disk move Check, remove rust, and lubricating
difficultly

6-16
 Troubleshooting
STC500S3

Table 6-2.3 Common faults and troubleshooting on clutch

Condition Cause Troubleshooting

Check, rectify, or replace

Diaphragm spring wraping
diaphragm spring
Wash, lubricate, or replace release
Release bearing stuck
bearing
Clutch
Check, repair or replace friction
judders Friction lining is worn or surface hardened
lining
Retaining bolts for engine bracket get loose Check and tighten bolts
Driven disk spline seriously worn, and clutch shaft
Check and replace parts
bent
Clutch release bearing worn, too tight, or without Check and replace bearing or refill
lubricating oil lubricating oil
Rivets on driven disk get loose Check and re tighten the rivets
Clutch Release lever is improperly adjusted Check and adjust release lever
makes Return spring for release lever or release bearing is
Check, rectify or replace
noise broken, deformed or loose
Bolts for flywheel get loose Check and tighten bolts
Check and replace bearing or refill
Front bearing for clutch shaft worn or deficient of oil
lubricating oil

6-17
Troubleshooting
STC500S3

b. Refer to Table 6-2.4 for common faults and

troubleshooting on gearbox

Table 6-2.4 Common faults and troubleshooting on gearbox

Condition Cause Troubleshooting

Splitter Pressure regulating valve defects (2)

transmission high Air pipe or joint loose (9)
and low gear Air pipe or joint clamped flat (10)
section is out of Influenced by shaft distortion, gear is away from counter position (2)(4)
gear or gear slides Engaging gear tooth has taper (2)
Shift fork wearing (2)
Lock-up spring weak or missing (2)(7)
Influenced by shaft distortion, gear away from counter position (2)(4)
Main transmission Engaging gear taper (2)
out of gear or gear Slide sleeve fork groove wearing (2)
slides Connecting rod movement fault (10)
Connecting rod improperly adjusted (8)
Engine support damaged (2)
Engine and gearbox not aligned (2)(6)
Pressure regulating valve defects (2)
Air pipe or joint loose (9)
Air pipe clamped flat (10)
High and low Double H air valve piston stuck (12)
gear section gear Gear shifting air cylinder O-ring damaged (12)(2)
shifting lags or Air cylinder piston nuts loose (9)(12)
fails to shift Air cylinder piston ruptured (2)(13)
Synchronizer spring damaged (2)(4)
Synchronizer damaged (2)
No lubricant on air cylinder O-ring (13)

6-18
 Troubleshooting
STC500S3

Table 6-2.4 Common faults and troubleshooting on gearbox

Condition Cause Troubleshooting

Shift fork shaft bent (2)(3)
Burr on shift fork shaft (5)
Lock-up spring too hard (2)
Gear shifting mechanism housing ruptured (2)
Main transmission
Influenced by shaft distortion, gear away from counter position (2)(4)
shifting difficult or
Main shaft distorted (2)
unable to shift
Didn't use clutch (1)(4)
Connecting rod movement fault (10)
Clutch improperly adjusted (6)
Engine support damaged (2)(4)
Cannot be Interlocking steel ball not installed (2)
interlocked Interlocking pin not installed (2)
Shift fork wearing (2)
Influenced by shaft distortion, gear away from counter position (2)(4)
Intermediate shaft brake fails to work (2)(9)(8)
Creak noise when
Connecting rod movement fault (10)
starting to turn
Connecting rod improperly adjusted (6)
control lever
Gear shifting mechanism housing inner bushing wearing (2)
Clutch improperly adjusted (6)
Main shaft distorted (2)
Fail to shift to
Connecting rod movement fault (10)
neutral gear
Connecting rod improperly adjusted (6)
Influenced by shaft distortion, gear away from counter position (2)(4)
Gear cracks or gear tooth burr (5)(2)
Main shaft gear tolerance too big (8)
Splitter intermediate shaft front bearing inner race drops (7)
Loud noise Bearing damaged (2)
Oil level too low (2)(4)
Lubricating oil quality is poor (2)(4)
Oil not changed in time (2)(4)
Different oil mix used (2)
Gear makes noise Main shaft gear tolerance too big (6)
when idling Engine running not steady (6)

6-19
Troubleshooting
STC500S3

Table 6-2.4 Common faults and troubleshooting on gearbox

Condition Cause Troubleshooting

Engine support damaged (2)
Output shaft screw tightening torque insufficient (6)
Much vibration
Drive shaft improperly assembled (6)
Suspension wearing (2)(6)
Main shaft washer Oil level too low (2)(4)(6)
burnt Vehicle towing or sliding method improper (2)(4)(6)
Start with too high gear (1)(2)
Input shaft spline Impacting load (1)(2)
worn or damaged Clutch improperly adjusted (2)(6)
Clutch fails (2)(6)
Pressure regulating valve defects (2)
Shift fork reversely installed (2)(8)
Synchronizer spring damaged (2)(7)
Synchronizer Lubricating oil quality is bad (2)(8)
damaged Different oil mix used (8)(6)
Operation and use method improper (1)
Influenced by shaft distortion, gear away from counter position (2)(4)
Bearing damaged (2)
Splitter counter shaft front bearing inner race drops (2)
Oil level too low (8)(4)
Oil level too high (8)(4)
Lubricating oil quality is bad (2)(6)
Overheated
Gearbox working slant angle too big (2)(6)
Oil changing not in time (2)(6)
Different oil mix used (2)(6)
Start with too high gear (1)(2)
Main shaft distorted
Impacting load too heavy (1)(2)

6-20
 Troubleshooting
STC500S3

Table 6-2.4 Common faults and troubleshooting on gearbox

Condition Cause Troubleshooting

Splitter counter shaft front bearing inner race drops (2)
Oil level too low (2)(4)
Lubricating oil quality is bad (2)(4)
Bearing burnt
Oil changing not in time (2)(4)
Different oil mix used (2)(4)
Vent hole plugged (10)
Oil level too high (6)
Housing has casting defects (2)(4)
Oil leakage Rear oil seal damaged (2)(4)
Retaining screw loose or thread slipping (6)(7)(14)

Code meaning in remedy:

1) Driver adopts correct driving method

2) Replace parts
3) Loosen retaining screw and retighten with
proper torque
4) Search for damages caused by this
5) Use sand paper to grind the surface
6) Readjust as per requirements
7) Install the missing parts
8) Check air pipe
9) Troubleshoot the interference of fastening
parts
10) Troubleshoot the interference to the
components
11) Recheck gear countering condition
12) Wash components
13) Apply a thin layer of silicone oil lubricant
14) Apply sealing agent

6-21
Troubleshooting
STC500S3

c. Refer to Table 6-2.5 for common faults and

troubleshooting on power takeoff device

Table 6-2.5 Common faults and troubleshooting on power takeoff device

Condition Cause Troubleshooting

Oil seal or liner worn out at some position Replace
Glue application not even at some of the Wash, clean and reapply glue
Oil leakage
contacting surface correspondently
Lock bolt loose Tighten lock bolt
Install seal ring or replace air
Air line leakage
pipe
Shift fork positioning screw loose or ruptured Tighten or replace
Power takeoff
Piston positioning screw loose Tighten positioning screw
device can’t be
Shift fork drops out of engaging sleeve fork groove Reinstall
put into gear or
Support spring damaged, invalid Replace
out of gear
Shift fork or engaging sleeve deformed Replace
Return spring deformed or invalid Replace
Indicator lamp switch and piston interferes Adjust position
Appear serious pitting or tooth broken Replace
Abnormal noise Appear serious pitting, roller pin or roller worn out Replace
Shaft fine pitch threaded bolts loose or damaged Retighten or replace
Indicator lamp switch wiring terminal damaged Replace
Indicator lamp switch wrong installation position
Indicator lamp
makes mandril fail to touch contactor or always Add gasket or remove gasket
switch invalid
touch
Indicator lamp switch mandril speed changed Replace
Hydraulic pump Accelerate to improve air
Air pressure insufficient
power takeoff pressure
device drive shaft
Air pipeline plugged Check and replace air circuit.
doesn’t spin and
makes abnormal
Solenoid valve has problems Replace solenoid valve
noise

Dismantle power takeoff

device cylinder seat, replace
Nut pressing shift fork loose or dropped
Hydraulic pump with new locking plate, and
power takeoff tighten nuts.
device drive shaft
can’t stop After dismantling power
Screws on power takeoff device piston rod loose takeoff device cylinder rear
cap, tighten the screws.

6-22
 Troubleshooting
STC500S3

d. Refer to Table 6-2.6 for common faults and

troubleshooting on drive shaft

Table 6-2.6 Common faults and troubleshooting on drive shaft

Condition Cause Troubleshooting

Free joint cross shaft, needle roller bearing is badly Check, replace machine
worn, cross shaft axis rubbed out of groove, and radial elements (replace drive shaft
clearance between cross shaft and bearing is too large. assembly as far as possible)
When flange and shaft tube are being welded, tilt or
Replace drive shaft assembly
drive shaft curves.
Drive shaft
Drive shaft assembly parts wearing results in imbalance
makes noise Replace drive shaft assembly
transmission

Drive shaft spline tooth and slip yoke key groove wearing Replace drive shaft assembly

Assembling position of drive shaft two ends get changed, Reassemble as per technical
constant speed transmission condition broken requirements

Intermediate support bearing seat rubber spacer gets

Replace
damaged
Intermediate
Tighten as per required
support shaft Retaining bolts for intermediate support get loose
torque
makes noise
Intermediate support bearing assembly lacks of oil or
Lubricate assembly
damaged

6-23
Troubleshooting
STC500S3

6.2.1.5 Brake system

Refer to Table 6-2.7 for common faults and

troubleshooting on brake system

Table 6-2.7 Common faults and troubleshooting on brake system

Condition Cause Troubleshooting

Excessively high / low Improper adjustment of rated

Adjust the adjusting screw of
operating pressure of pressure of the pressure regulating
the pressure regulating valve
the system valve

The adjusting screw of the pressure

No pressure regulating regulating valve is excessively
Adjust and clean
and loading off fuctions tightened or vent holes on the valve
are blocked

One-way valve of air outlet of

pressure regulating valve is
damaged, or there’s foreign matter
Closing pressure of between valve and valve base;
pressure regulating taper spring bearing end piece Inspect and clean.
valve is relatively low jumps out; vent holes on the upper
cover of pressure regulating valve
are blocked; vent holes on the case
are blocked.
Air source

Seal parts of exhaust valve are

Air leak at pressure
damaged or there’s foreign matter Inspec, clean or replace
regulating valve outlet
between valve and valve base.

Poor sealing or burt-out of intake Disassemble, inspect and

Air charging of the
/ exhaust valve blades of air replace intake / exhaust valve
system is slow, or fails
compressor blades.

Valve is blocked by oil stains or seal

Disassemble and clean the
rings on piston of blow-off valve
Automatic blow-off valve valve, or replace the seal ring.
breaks and occurs air leak.
fails
Control pipeline or connector is
Inspect and clean
blocked by foreign matter.

The pressure regulating valve

The dryer fails to Disassemble and inspect the
fails or seal parts of water drain
exhaust air in a kick- pressure regulating valve, or
valve damage; poor sealing due to
back way clean and replace sealing parts.
existence of foreign matter.

One of the four loops Disassemble, inspect, clean or

Stuck or damaged.
fails to charge air replace

6-24
 Troubleshooting
STC500S3

Table 6-2.7 Common faults and troubleshooting on brake system

Condition Cause Troubleshooting

Contact surfaces between upper

Main brake valve leaks chamber, lower chamber intake
Disassemble, inspect, clean or
air when stepping on valve and piston of main brake valve
replace
brake pedal occur foreign matter of damages of
seal.

Intake valve and seal parts of upper

or lower chamber of main brake
Main brake valve leaks valve are damaged, or seal ring
Disassemble, inspect, clean or
where without stepping between intake valve stem and
replace
on brake pedal case is damaged, or there’s foreign
matter between valve and valve
base.

Connection between brake pedal

and main brake valve connecting Inspect and adjust the
lever is too “tight” that the brake connecting parts.
pedal has no free travel.

The clearance between intake valve

seal parts of lower chamber of main
Disassemble, inspect and clean
Main brake loop

brake valve and piston of middle

chamber is blocked.

Pipeline section of front brake loop

Disassemble, inspect, clean or
is blocked by oil stains; spring of
replace
The brake is too tight. frong compartment fails.
Brake air chamber
Problems occur to brake mechnical
won’t reset or resets too
parts: rusting of brake camshaft;
slowly
deformation of brake camshaft or Inspect, repair or replace
breaking-off of release spring of
brake shoe.

Air returning of upper chamber of

main brake valve, load regulating
Disassemble, inspect and clean
valve and relay valve is not smooth;
part of brake pipeline is blocked.
Manual brake valve occurs air leak
or middle / rear axle spring energy
Inspect and repair
storage brake compartment occurs
air leak.

Control air holes of upper and

Poor front damping Disassemble, inspect and clean
middle chambers of main brake
effect the main brake valve
valve are blocked.

6-25
Troubleshooting
STC500S3

Table 6-2.7 Common faults and troubleshooting on brake system

Condition Cause Troubleshooting

Poor seal between air intake valve

and valve base, or there’s foreign
Air leakage of manual Replace air intake valve seal
mateer between valve and valve
brake valve parts.
base, or air intake valve seal parts
Parking brake and emergency brake loops

are damaged.

Air charging of manual The overflow valve between middle

Disassemble, inspect and
brake air cylinder takes / rear brake loop and manual brake
adjust the overflow valve.
too long loop functions abnormally.

Piston seal ring of spring energy

Disassemble, inspect, repair or
ir leakage of spring storage chamber is damaged, over-
replace the brake air chamber
energy storage chamber pulled; over pull of air chamber and
on a press machine.
cylinder.

Seal parts of the air intake valve of

Replace seal parts of the air
brake valve is damaged, or there’s
intake valve or clean the valve
Air leakage of manual foreign matter between valve and
and valve base.
brake relay valve valve base.

Poor sealing between exhaust valve

Inspect and replace.
and the piston.

Contact area between brake shoe

and brake drum is smaller than 70% Inspect and replace.
Braking fault of the total area.

The friction wafer is dirty (with oil Clean away the stains and dry
stains, etc) or too damp. the friction wafer.

Large brake clearance differential

Adjust clearances of left / right
between left and right side causes
brake
Braking disalignment unsynchronized of initial brake.

Different brake moment between Adjust brake clearance, brake

left wheel and right wheel. pressure, etc.

Front wheel swings when Brake drum of the front wheel is out
Grind the brake drum.
slightly step on the brake of round.

Use motor exhaust brake as

The brake drum heats up when
Frequently use of traveling brake. little as possible; use traveling
driving in mountainous area
brake as little as possible.

6-26
 Troubleshooting
STC500S3

6.2.2 Hydraulic system

(1) Steering oil pump

Refer to Table 6-2.8 for common faults and

troubleshooting on steering oil pump.

Table 6-2.8 Common faults and troubleshooting on steering oil pump

Condition Cause Troubleshooting

Oil pump rear cap seal ring

Check or change seal ring
damaged
Oil pump
leaks Framework oil seal of oil
Check and change framework oil seal
pump drive shaft end leaks

Oil pump
Oil viscosity is too low and
pressure is Check oil and replace hydraulic oil of proper viscosity
easy to leak
insufficient
Steering oil tank lacks of oil Add certain amount of hydraulic oil
Oil pump flow
Oil pump suction pipe
is not enough Check oil pipe and remove the plugging
plugged
Insufficient oil in tank Add certain amount of hydraulic oil
Check oil suction parts whether there’s air leakage. If
Oil pump Air enters oil pump
leakage occurs, replace seals, and tighten joints
noise is
Oil suction not smooth, and
seriously Check oil filter and pipeline whether they are smooth
pipeline resistance too strong
loud
Abnormal wearing inside oil Check inter parts of the oil pump and replace wearing
pump elements

6-27
Troubleshooting
STC500S3

6.2.3 Electrical system

6.2.3.1 Battery

Common faults of the battery include: cracking

of cell case, cracking of sealing compound,
corrosion or loosening of post terminal, plate
sulfurousness, falling off of active material,
corrosion of plate grid and short-circuiting of
plate, etc. See Table 6-2.9.

NOTICE

In battery power cord disassembly, first

disassemble the cable of negative (-)
electrode. In battery power cord assembly,
first assemble the cable of negative (-)
electrode. Do shut off all switches in
disassembling or assembling battery
power cord. Otherwise, electric elements
may be damaged. Do not reversely
connect positive and negative plates of
the battery.

6-28
 Troubleshooting
STC500S3

Table 6-2.9 Performance, causes and troubleshooting on battery

Fault Item Description

A layer of white crystal is produced on battery plate, which can not

be converted into PbO2 and Pb during charging. This chemical
phenomenon is called “sulfurousness”. When sulfurous battery
discharges, voltage drops abruptly and reaches final voltage in a
Characteristics
short time. Thus, capacity of battery is reduced. When charging,
of fault
voltage of battery rises quickly, causing rapid temperature rise of
electrolyte. But due to slow increase of density, bubble occurs too
early, even if at the moment when charging begins.

Long-term inadequate charge or having not been re-charged after

discharge of battery causes part of PbSO4 on the plate dissolves
in the electrolyte. Higher environmental temperature leads to
higher solubility. When environmental temperature drops, solubility
decreases. Dissolved PbSO4 separates out and crystallizes on the
plate again, completing sulfurousness.
Low level of battery electrolyte causes contact of upper plate with
the air and oxidation of the plate. The electrolyte flows upside and
Plate down during driving of truck, partially contacting with oxidized part of
sulfurization the plate and generates large-crystal PbSO4 hardened layer. Upper
Causes of fault
plate is thus sulfured.
Long-term over discharge or deep discharge of low current generates
PbSO4 in orifices of the active material in deep location of the plate,
making it difficult for regular charge.
Incomplete initial charge of new battery causes insufficient reduction
of active material.
Density of electrolyte is too high or external temperature change is
too abrupt.

Slightly sulfurousness of battery can be eliminated by long-term

charging at low current. Severe sulfurousness can be eliminated by
Resolution
adopting the method of def-sulfurousness charging. Batteries which
suffer extreme sulfurousness should be no longer used.

6-29
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STC500S3

Table 6-2.9 Performance, causes and troubleshooting on battery

Fault Item Description

In general, it refers to falling off of active material PbO2 on positive

Fault plate, causing reduction of battery capacity. Brown material can be
characteristics observed from liquid filling hole during charging. The electrolyte is
turbid.

High charing current and high temperature of electrolyte makes the

active material expand, loose and easily fall off.
Frequent charge of the battery: large amount of gas breaks away
Falling off
from plate gap and produces pressure in the gap, causing the active
of active Causes of fault
material to fall off.
material
Frequent discharge at low temperature with high current causes
flexural deformation of the plate and falling off of the active material.
Jolting and shaking during driving of the truck.

Lead-acid battery with falling-off of active material with small amount

REsolution of deposits can be reused after deposits are removed; if deposits are
in large amount, replace the plate and electrolyte.

Grid of positive plate is corroded and the plate is rotten. The active
Chracteristics of
material is deposited between partitions in a block and output
fault
capacity of battery is reduced.

The O2 produced from frequent over charge of the battery at the

positive plate causes oxidation of the grid.
Causes of fault High density and temperature of the electrolyte and long-time
charging accelerates corrosion of the plate.
The electrolyte is impure.

Corrosion of
For batteries which are slightly corroded: if impurities exist in
plate grid
electrolyte, pour out the electrolyte and clean with distilled water for
several times. Refill with new electrolyte. The battery can be used
again after charging.
Resolutions For batteries which are corroded rather severely: if density of
electrolyte is excessively high, adjust it to the specified value. The
battery can be used without re-charge.
For batteries which are corroded severely: the plate should be
replaced if the grid cracks or the active material fall off in blocks, etc.

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STC500S3

Table 6-2.9 Performance, causes and troubleshooting on battery

Fault Item Description

Positive and negative plates of battery directly contacts or are lapped

by other conducting material and cause plate short-circuiting. For
Characteristics batteries which exist plate short-circuiting, the charging voltage is
of fault extremely low or at zero. Temperature of electrolyte increases rapidly
while density increases slowly. There’s few bubble occurring at the
end of charging.

Breakage of partitions causes direct contact of positive and negative

Short-
plates.
circuiting of
The active material falls off in large amount. The deposition connects
the plate
Causes of fault the positive and negative plates.
Inflection of plate group.
Conducting material falls into the battery.

Disassemble and inspect the battery when plate short-circuiting

occurs.
Resolutions
Replace broken partitions, eliminate deposited active material and
align or replace flexural plate group, etc.

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STC500S3

Table 6-2.9 Performance, causes and troubleshooting on battery

Fault Item Description

Self discharge is the phenomenon that electricity quantity

Characteristics automatically disappears when there is absence of load to the
of fault battery. If a full-charge battery loses over 2% of the capacity in every
24 hours within 30 days, it’s called fault self discharge.

The electrolyte is impure. Potential difference exists between

impurities and plate and between different impurities which deposit
on the plate, causing local discharge through the electrolyte.
After long-term storage, sulfuric acid in the batter sinks, leading to
forming of potential difference between upper and lower part of the
Causes of fault plate and causing self discharging.
Electrolyte overflows from the battery and accumulates on surface of
battery cover, forming a closed circuit between positive and negative
Self post terminals.
discharge Plate active material falls off. Too much lower deposits causes plate
short-circuiting.

For batteries with slight self discharge, pour out the electrolyte after
normal discharge and clean with distilled water for several times.
Refill with new electrolyte and charge the battery; for batteries with
Resolutions relatively severe self discharge, completely discharge the battery,
pour out electrolyte, take out plate group and partitions. Clean with
distilled water and reassemble the battery. The battery can be used
after filling new electrolyte and re-charge.

Original positive plate and negative plate of the single-cell battery

Characteristics
exchanges. Battery voltage drops rapidly and can not be used any
of fault
more.

Reversed Failed single-cell battery hasn't been found in time (e.g. plate short-
polarity of circuiting, active material falling off, etc). When discharging, due to
single-cell Causes of fault small capacity, the single-cell batter is discharged to zero at first.
battery During later discharge, discharging current from other single-cell
battery charges the battery and reversed its polarity.

Resolutions Replace new plate for polarity-reversed single-cell battery.

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STC500S3

6.2.3.2 Electrical instrument and sensor on

chassis

Chassis electrical instrument includes: oil

pressure gauge, water temperature gauge,
fuel gauge, trocheameter, speed indicator, and
voltmeter, etc. Common faults and diagnosis
are as followed :

1.Oil pressure gauge

(1) No indication

1) Faults:

No indications on the oil pressure gauge when

the engine runs at different speed.

2) Causes:

a.Power cord of oil pressure gauge is

disconnected.

b.Inner elements of oil pressure gauge are

damaged.

c.Oil pressure sensor is damaged.

d.Lubricating system of the engine fails.

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STC500S3

3) Fault diagnosis and troubleshooting:

Turn on ignition switch. Disassemble the guide

wire from one end of oil pressure sensor and
conduct instant earthing test. If pointer of oil
pressure gauge moves immediately from 0
to 1.0MPa, the gauge functions well. Then,
disassemble the sensor and reassemble the
disassembled guide wire. Plug an iron nail
without pointed head into oil hole of the sensor
for tip layering membrane test. Movement of
pointer of oil pressure gauge indicates ideal
state of the sensor but engine lubricating
system fails. Otherwise, it must be fault of the
sensor.

Pointer of oil pressure gauge still stands when

earthing test is conducted on one end of the
sensor. Connect one end of testing lamp to
power wiring terminal of oil pressure gauge,
conduct earthing test on the other. Fault
of testing lamp indicates disconnection of
power supply circuit and faults on oil pressure
gauge or the circuit between the gauge and
the sensor. Conduct earthing test on the
outlet wiring terminal end of oil pressure
gauge. Normal movement of pointer indicates
disconnection of guide wire of the sensor.
Otherwise, the gauge is damaged.

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 Troubleshooting
STC500S3

(2) After ignition switch is on, the gauge

indicates the maximum pressure value.

1) Faults:

After ignition switch is on and before starting

of the engine, pointer of oil pressure gauges
moves toward the maximum valve.

2) Causes:

a Earthing between oil pressure gauge and

guide wire of the sensor.

b Internal earthing of oil pressure sensor.

3) Fault diagnosis and troubleshooting:

U n d e r t h i s c o n d i t i o n , t u r n o ff i g n i t i o n
switch immediately to avoid burning out
of the pressure gauge. During inspection,
disassemble guide wire on one end of sensor
and turn on ignition switch for test. If the
pointer stops moving, there must be short-
circuiting inside the sensor. The sensor
should be replaced; if the pointer still points
to the maximum valve. Inspect and repair the
location where the guide wire from pressure
gauge to the sensor gets short-circuited and
earthed.

Besides, inaccurate indication of oil pressure

gauge is mainly caused by mismatching
of sensor resistance and instrument. It’s
recommended that the maintaining staff
replace the assembly with the instrument
sensor specified by the manufacturer.

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STC500S3

2. Fuel gauge

(1) Pointer of fuel gauge always points to full

scale.

1) Faults:

After ignition switch is turned on, no mater

how much oil is in the tank, the pointer of fuel
gauge always points to “1” (full scale).

2) Causes:

a.The guide wire connecting fuel gauge with

sensor is disconnected.

b.Internal disconnection of the sensor.

3) Fault diagnosis and troubleshooting:

Turn on ignition switch. Disassemble wiring

terminal guide wire of fuel gauge sensor for
earthing test. If the pointer returns to zero,
sensor is disconnected inside. If the pointer
does not return to zero, use fuel gauge outlet
wiring terminal for earthing test. If the pointer
returns to zero, it indicates that the guide
wire connecting fuel gauge and sensor is
disconnected.

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 Troubleshooting
STC500S3

(2) Pointer of fuel gauge always points to no

oil.

1) Faults:

After ignition switch is turned on, no mater

how much oil is in the tank, the pointer of fuel
gauge always points to “0” (no oil).

2) Causes:

a.Internal earthing of the sensor.

b.Sensor floater is damaged.

c.Fuel gauge connecting wire is reversely

connected.

d.Power cord of fuel gauge is disconnected.

3) Fault diagnosis

If similar fault occurs to the newly replaced

fuel gauge, inspect whether the guide wire
is reversely connected. Inspect whether
the wiring terminal of fuel gauge power is
electrified with testing lamp. If the power cord
is normal, disassemble upper guide wire of the
sensor. If the pointer points to “1”, it indicates
that earthing inside the sensor exists or the
float is damaged. Disassemble and inspect the
sensor.

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STC500S3

3. Solenoid water thermometer

(1) Pointer of the water thermometer does not

move.

1) Faults:

After ignition switch is turned on, no matter

how water temperature changes, the pointer
always stays.

2) Causes:

Power cord of water thermometer is

disconnected.

b.Water thermometer is damaged.

c.Water temperature sensor is damaged.

Guide wire connecting water thermometer and
the sensor is disconnected.

6-38
 Troubleshooting
STC500S3

3) Fault diagnosis and troubleshooting:

Turn on ignition switch. Use a 2-5W lamp of

the truck as testing lamp. One end is earthed,
and the other connects with wiring terminal
water thermometer sensor. If pointer of water
thermometer moves for indication immediately,
the water thermometer is normal but sensor
is damaged. If the pointer still remains, use
one end of the testing lamp for earthing and
connect the other to wiring terminal power. If
the testing lamp is on, connect it to the outlet
wiring terminal of the water thermometer and
earth the other. If pointer of water thermometer
moves normally, the meter is normal one
section of sensor guide wire between water
thermometer and sensor is disconnected. If
the pointer still remains, the meter is damaged.
If the testing lamp is still off, the fault must
be caused by disconnection of power supply
lines.

6-39
Troubleshooting
STC500S3

(2) The pointer points to maximum

temperature after the ignition switch is on.

1) Faults:

After ignition switch is turned on and before

or right after starting of the engine, pointer
of water thermometer points to maximum
temperature.

2) Causes:

a. Certain section of the guide wire between

water thermometer and sensor is earthed.

b. Internal earthing of the sensor.

3) Fault diagnosis and troubleshooting:

Turn on ignition switch. Disassemble the wiring

terminal guide wire of fuel gauge sensor for
earthing test. If pointer of water thermometer
returns to original place, internal earthing of
the sensor must exist. Otherwise, disassemble
and inspect whether earthing exists at the
section of the guide wire connecting water
thermometer and sensor.

6-40
 Troubleshooting
STC500S3

4. Electronic trocheameter

Out-of-service is a common fault for electronic

trocheameter.

Faults:

1)Pointer of trocheameter does not move

during truck traveling.

2) Causes:

a. Sensor fails.

b. Instrument fails.

c .Circuit fails.

3) Fault diagnosis and troubleshooting:

Disassemble trocheameter sensor and linker

of instrument connecting wire bundle. Rotate
the sensor rapidly with hand. Measure the
resistance of the sensor at the wire bundle end
of the instrument. Check whether alternative
changes exist between 0 and ∞. Alternative
changes indicate fault of instrument. Replace
with new instrument and keep the selected
parametric interval consistent with the old
gauge. If there is no alternative changes,
disassemble the linker of the connecting wire
bundle of the trocheameter sensor. Measure
the resistance at both ends of the sensor
from sensor side. Check whether alternative
changes exist between 0 and ∞. Alternative
changes indicate circuit fault. Inspect the
circuit. Otherwise, it must be fault of the
sensor. Replace it with a new one.

6-41
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STC500S3

5. Engine speed indicator

Out-of-service is a common fault for engine

speed indicator.

Faults:

The engine runs normally, while pointer of the

indicator does not move.

2) Causes:

a.Fault of the sensor.

b.Instrument fails.

c.Circuit fails.

3) Fault diagnosis and troubleshooting:

Disassemble the speed indicator and

measure its resistance. If the resistance is
beyond the range of 350Ω-500Ω, sensor
may be damaged. Replace it with a new.
If the resistance is within the above range,
disassemble the linker of connecting wire
bundle of speed indicator. Measure the
resistance at both ends of the sensor from
the side of wire bundle. If the resistance is
beyond the range of 350Ω-500Ω, circuit may
fail. Inspect the circuit. On the contrary, it
should be fault of the speed indicator. Replace
with a new speed indicator. Make sure that
the selected parametric interval of the new
indicator should be in consistent with that of
the replaced one. Follow the requirements
for installation of speed sensor of flywheel
housing. Tighten the sensor into proper
position. Rotate back for 1/3 turn, 0.5-1mm
from the bottom. Too large distance reduces
accuracy of measurement while excessively
small distance will cause damage to the
sensor.

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STC500S3

6.2.3.3 Auxiliary electrical parts of chassis

electrical system

Auxiliary electrical devices of crane chassis

electrical system include: wiper, windshield
washer, automatic window lifter, radio player,
cigar lighter, unlocked door alarmer, etc. The
following are common faults for wiper and
windshield washer as well as methods for fault
diagnosis and elimination.

(1) Wiper
Common faults for the wiper include: out-of-
service at all gears, out-of-service at a certain
gear and the wiper blades fails to stop at
proper position, etc.

1) The wiper is out of service at all gears.

a.Faults:
After ignition switch is on, no matter which
gear the wiper switch is at, the wiper fails to
work.

b.Main causes:
Wiper fuse burns out.
Wiper motor or switch fails.
Mechanical transmission part fails.
The circuit is disconnected or the connector
loosens.

c.Diagnosis and troubleshooting

Firstly, check whether the fuser is burnt
out, the connector is loose or the circuit is
disconnected. Then, check whether the switch
works normally. Finally, check motor and the
mechanical transmission part.

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Troubleshooting
STC500S3

2) The wiper is out of service at a certain gear.

a.Faults:
After ignition switch is on, the wiper is out of
service at some gears (low gear, high gear
or neutral gear) while works normally at other
gears.

b.Main causes:
Wiper motor or switch fails; intermittent
relay fails; the circuit is disconnected or the
connector loosens.

c.Diagnosis and troubleshooting

If the wiper does not work at high gear or
low gear, check lines for the gears. Check
the switches and motor brush. If the wiper
does not work at neutral gear, check the
neutral gear of wiper switch, the lines and the
intermittent relay.

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 Troubleshooting
STC500S3

3) The wiper fails to return to the original

position.

a.Faults:
When the switch is off or under intermittent
operation, the brush blade fails to stop at the
bottom of the windscreen.

b.Main causes:
Automatic stop device is damaged; wiper
switch is damaged; the wiper arm is improperly
adjusted; the circuit is incorrectly connected.

c.Diagnosis and troubleshooting

Inspect whether wiper arm is correctly
mounted; whether the switch circuit is correctly
connected. Check contacting of the contact
and the slide plate of the automatic stop
device.

6-45
Troubleshooting
STC500S3

(2) Windshield washer

1) Main faults include:

All nozzles or some of them fail.

2) Causes:
Washer motor or switch is damaged; the circuit
is disconnected or the connector loosens; low
level of cleaning agent or fall-off of connecting
pipes; the nozzle is blocked.

3) Diagnosis and troubleshooting

If none of the nozzles works, firstly confirm
whether the washer motor is in operation.
Next, check whether level of cleaning
agent and the connecting pipe are normal.
Otherwise, check whether circuit of washer
motor and the connectors are disconnected or
fall off. Finally, check whether the switch and
motor work normally. Faults of some nozzles
are caused by block of the nozzle or fault of
liquid-transferring branch pipe.

6-46
 Troubleshooting
STC500S3

(3) Electric door window

Common faults of the electric door window

include: non-working of window lifter, fault of
lifting and lowering of some door windows or
the door window can only be regulated in one
direction; abnormal noise in lifter operation.

1) Electric window lifter does not work.

a.Main causes:
The fuse is burnt out; the connecting guide
wire is disconnected or relevant connector
loosens; the window lifter switch is damaged;
motor is damaged; earthing wire rusts and
loosens.

b.Diagnosis and troubleshooting

Check whether the fuse is disconnected; check
whether connections of all the connectors are
firm; check electrification of power cord and
voltage; whether earthing of the earthing wire
is normal and reliable. Finally, check whether
damages occur to switch and motor. Replace
the broken parts.

6-47
Troubleshooting
STC500S3

2) A door window can not be regulated or can

only be regulated in one direction.

a.Main causes:
The door window switch or motor is broken;
the guide wire at the position is disconnected
or the connector loosened.

b.Diagnosis and troubleshooting

Firstly, check the window switch; electrify
and check the door window motor; overhaul
or replace when fault occurs. If the motor
works normally, check disconnection of the
connecting wire. If the door window can only
move in one direction, it is probably caused
by fault of switch or disconnection of the guide
wire. Inspect the guide wire firstly, then the
switch.

3) Abnormal noise in lifter operation

a.Main causes:
The door window switch or motor is broken;
the guide wire at the position is disconnected
or the connector loosens.

b.Diagnosis and troubleshooting

This type of mechanical faults is usually caused
by improper mounting position or inaccuracy
of installation. Readjust, tighten and align the
screws in corresponding positions.

6-48
 Troubleshooting
STC500S3

(4) Fault inspection and diagnosis of the

cooling system

Common faults of air conditioning system

include:
Fault of the cooling system, obvious drop of
cooling effect, violent vibration of compressor,
louder noise, freezing of evaporator, etc.

1) Complete fault of the cooling system

Causes:

a.Fault of the clutch. Fault of clutch such as

loosen belt, poor attracting, energized coil
breaking off, burning out, etc, may cause
attracting fault of the clutch and can not drive
the compressor to operate normally.

b.Leaking out of coolant can not realize the

cooling effect even when the compressor is in
operation.

c.Inductio/exhaust valve of the compressor is

broken. Coolant can not circulate in normal
way. Coolant can not circulate normally.
Test the pressure at the high/low ends of the
cooling system with a pressure measuring
gauge. The pressure of the two ends is close
or even equal.

6-49
Troubleshooting
STC500S3

d.The cooling system is blocked: coolant can

not circulate or flow, thus the system loses
cooling ability. Complete blocking usually
occurs at the drying reservoir or expansion
valve.

e.If working medium in thermo-bulb of the

expansion valve leaks out, the system can’t
realize cooling effect either. Leaking out of
working medium in thermo-bulb eliminates
the active force over the inner membrane of
expansion valve. Two active forces below push
the membrane upwards, driving the push rod
and closing the expansion valve. This can cut
off the coolant entrance to evaporator. Clean
up impurities in expansion valve. Extract air
from intake of valve with pressured nitrogen.
If air can’t be extracted in both directions, it
indicates that working medium in the thermo-
bulb has leaked out. Replace with a same type
expansion valve to restore cooling of system.

f.Fan motor circuit breaks or burns out. No air

flows through the evaporator and no cooling
air is blown out from air conditioner.

g.Freezing of evaporator freezes. Impeded

by ice layer, coolant in heat transfer tube of
evaporator can not extract any heat. Thus,
cooling effect can not be realized either.
Evaporator freezing is usually accompanied
with liquid impact.

In addition, circuit faults such as safety

fusing, abnormal temperature control and line
breaking can also impair normal operation and
cooling of truck air conditioning system.

6-50
 Troubleshooting
STC500S3

2) Poor effect

Under following conditions, truck air conditioner

cooling system can not achieve desired
cooling effect.

a. Compressor clutch slips, slows down

rotation speed of compressor.

b. Short in amount, leakage or too much of

coolant.

c. Rotation speed of air blower is relatively low.

Air blow rate and limits cooling ability is thus
reduced. Blocking of air filter, air flow passage
of evaporator and air supply line reduce air
flow rate and limit cooling ability.

d. External new air port of air bellows are all

open. Too much fresh air causes excessive
fresh air heat load, forcing long-term operation
of air conditioner and lower temperature drop
inside the truck.

e. Poor ventilation of condenser. Block caused

by excessive dust deposit, crushing down of
heat radiation fin and other factors impairs
heat radiation effect and raises condensation
pressure. Cooling effect drops as a result.

f. Air in the system causes increase of

induction and exhaust pressure. Nebulous
foam can be observed from the liquid level
observing device.

Air in the system is caused by no vacuuming

or incomplete vacuuming before charging of
coolant.

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Troubleshooting
STC500S3

g. Inner parts of the system are dirty or

blocked. When impurities and sludge exist
in the system, block will occur to the drying
reservoir or expansion valve. Even if the above
positions are not completely blocked, cooling
ability drops as well. Block of drying reservoir
causes obvious temperature differential to its
front and rear pipes; blocking of expansion
valve causes frost at the expansion valve. Air
induction pressure drops or even becomes
vacuumed. At this moment, the drying
reservoir should be replaced, or disassemble
and clean the expansion valve.

h. Improper adjustment of temperature

control or idle controller occurs error. If the
temperature control is adjusted too low while
the fan is working at low gear, cooling air can
not be exhausted.

i. Excessive opening of thermo expansion

valve. Excessive opening of expansion valve
impairs throttling effect. Low pressure value
can not meet the requirement. In addition,
too much coolant entering into the evaporator
may cause some of the coolant return to the
compressor in liquid form. Performance of the
fault is that induction port of the compressor
is colder than the evaporator, accompanied
with liquid impact. Under this circumstance,
tighten adjusting nut of expansion valve half to
two turns and readjust the low pressure value
to normal range. Normal cooling process is
recovered.

j . R e d u c ti o n o f c o m p r e s s o r e ffi c i e n c y.
After being used for while, due to frictions
between different parts, volume efficiency of
compressor will drop. This can cause great
difference between actual displacement and
theoretical displacement. Circulation of coolant
inside the system and greatly impairs cooling
ability. The compressor must be replaced
under this circumstance.

6-52
 Troubleshooting
STC500S3

3) Cooling compressor vibrates violently with

louder noise.

Caused for violent vibration of compressor:

a. Excessive pulling of belt or misaligned

assemble of belt pulley causes an additional
vibration moment during operation. This may
produce violent vibration of compressor and
louder noise.

b. Clutch Slipping. Clutch slipping means:

the clutch sucker is not firmly connected with
the belt pulley and relative motion occurs.
This causes friction and collision between two
steel parts, producing both violent vibration
and extremely loud noise. Slipping of clutch
might be caused by fault of a certain part
which makes exhaust pressure rise too high,
causing overload to compressor. It also
may be that reduction of current passing
through clutch electromagnetic coil causes
inadequacy of suction force. As a result, clutch
sucker is not firmly connected with the belt
pulley. In addition, excessive loosening of the
electromagnetic clutch may also cause violent
vibration.

c. Excessive amount of coolant When there is

excessive amount of coolant, large amount of
liquid drops enter the cylinder and producing
liquid impact effect, causing violent vibration
and extremely loud noise.
Others factor may cause excessive loud noise
also include:
Damage of induction / exhaust valve blades;
piston knocking; loosening of compressor
bracket screws; loosening of conveying belt;
poor lubrication of belt idler pulley; loosening
or wearing of blower motor of the air bellows,
etc.

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Troubleshooting
STC500S3

4) Freezing of evaporator

Freezing of evaporator is mainly caused by

excessive lower temperature of evaporator
surface (below 0 ℃ ). Causes are listed as
followed:

a. Fault of the thermostat. Thermostatic switch

is mouted on the evaporator or inside the air
bellows to control start-up and shut-down of
the compressor. As temperature of evaporator
increases, thermostatic switch contact
closes off and connects the circuit between
clutch and battery. Cooling of compressor
is thus stopped. When thermostat fails, the
compressor can not stop. Continuous cooling
makes temperature of evaporator surface
even lower. When temperature drops below
0℃ , water content condensed from flowing air
will freeze. Replacement of failed thermostat
can eliminate the fault.

b. If thermo-bulb and the capillary tube are

incorrectly mounted, the thermostat can
not accurately sense the temperature of
evaporator surface. The above fault may occur
as well. Re-install the parts in a correct way.

c. If the temperature is set too low while

the blower is operating at the low level, the
evaporate may also freeze. Low temperature
brings large cooling output, while low fan
speed of the blower slows down flow rate of
the air. Air flow rate is thus reduced. When
air is too cold, condensed water will freeze.
The fault can be eliminated by rotation speed
increase of the blower.

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STC500S3

(5) Fault inspection and diagnosis of air

conditioning heat supply system

Heat source of air conditioning non-

independent heat supply system is the cooling
heat water. As a result, fault of heat supply
system is related to fault of motor cooling
system. If water temperature of motor is too
low, the heat supply loses heat source and
fails to supply heat to internal of the truck.

Causes of shortage of heat supply to the

system:

If the thermostat of motor cooling system is out

of service or fails, temperature of motor will be
too slow to supply heat to internal of the truck.
The following faults may cause loss of motor
cooling hot water and shortage of heat supply
to the truck.

1) Leakage of hose. Rupture of water tank

hose, heating hose or loosening of hose chuck
causes loss of cooling hot water.

2) Leakage of water tank, water pump shaft

seal and sealing gasket may also cause loss
of hot water.

3) Loosening of motor cylinder cover or

deflection of cylinder cover causes loss of
cooling hot water.

4) Improper water tank cover, shortage of

sealing or other faults causes overflow of
cooling hot water.

5) Rusting of system causes leakage or block

of internal water tank and reduces hot water
flow rate.

6) Leakage of heat exchange tube of the

heater or leakage of hot water valve may
reduce heat supply of the system.

6-55
Troubleshooting
STC500S3

(6) Fault inspection and diagnosis of air

conditioning control system

1) The blower fails to start after power is on.

Cause of fault: fuse blowing out or bad contact
of line switch; fault of program switch or
damage of blower.

2) Neither the blower nor the compressor

works
Cause of fault: the 25A fuse burns out or
the circuit of air conditioning system is
disconnected. The blower may be able to
operate at high speed only with maximum
heat supply or defrosting. Reason: loosening
of auto-relay connector or fault of relay.

6-56
 Troubleshooting
STC500S3

6.2.3.4 Chassis electrical circuit

Common fault for chassis electrical circuit:

1) Open circuit fault

In electrical circuit, two points which should
have been connected are disconnected.
Electric current fails to form a loop. Electrical
devices can’t work normally, namely open
circuit fault.

2) Short circuit faultIn electrical circuit, two

points which should have been disconnected
have short circuit. Current is conducted to
other electrical circuit or bypasses some
electrical elements. Electrical devices fail to
work normally, namely short circuit fault. Earth
fault is a type of classical short circuit fault.

3) Poor contact (contact resistance is too

large)
Due to wear and dirt, two points contact poorly
in electrical circuit. The contact resistance
surpasses allowed range. Electrical devices
work unreliably, namely poor contact fault.

6-57
Troubleshooting
STC500S3

Diagnosis and overhaul method for chassis

electrical circuit fault:

1) Intuitive method
Without using any instrument or gauge,
overhaul personnel inspect and troubleshoot
by intuition. Intuitively inspect the electrical
devices in chassis electrical system by
listening, touching, smelling, and looking with
human sense organs, and then tell out the
fault position. For experienced maintenance
personnel, they could not only discover some
obvious fault by intuitive inspection, but also
find out some complicated fault to improve
overhaul work efficiency.

2) Fuse inspection method

When there is fault for chassis electrical
system, firstly check whether the fuse is
normal. Some fault is only caused by short-
time overload. Overload can make fuse
burnout or in protection state. e.g.: During
traveling, some electrical device stops
suddenly, and the fuse protector in this sub-
circuit burn out. It means this return circuit is
overloaded or circuit earth fail.

There are three types of commonly used

protection devices for chassis electrical
circuit: one is bi-metal circuit breaker; one is
fuse protector; and another is fuse link. The
protection devices are equipped between main
power source and fuse protector box. It is
located nearby battery, functioning to protect
main power.
For fuse replacement, use fuse with same
specification.

6-58
 Troubleshooting
STC500S3

3) Lamp trial method

Use 24V lamp as temporary trial lamp to
inspect the circuit whether it’s open or short
circuited.

NOTICE

Never use lamp trial method to test ECU of

the vehicle to avoid damage to it.

4) Replacing method
Replacing method is usually used in situation
where failure cause is very complicated.
Respectively troubleshoot potential cause:
replace the thought-to-be damaged part with a
new one. If fault disappears, the replaced one
is damaged indeed. If not, equip the original
one and try others till the real fault is found
out.

6-59
Troubleshooting
STC500S3

6.3 Schematic Diagrams of

Complete Vehicle

6.3.1 Schematic diagram of brake

system

Fig.6-3.1 Schematic diagram of brake system

6-60
 Troubleshooting
STC500S3

6.3.2 Schematic diagram of hydraulic

system

Fig.6-3.2 Schematic diagram of hydraulic system

6-61
Troubleshooting
STC500S3

6.3.3 Schematic diagram of electrical

system

6.3.3.1 Schematic diagram of electrical

system on superstructure

Fig.6-3.3 Schematic diagram of electrical system on superstructure

6-62
 Troubleshooting
STC500S3

6.3.3.2 Schematic diagram of electrical

system on chassis

103.Y-2.5

101.R.B-1.5
85
31.B-1.0
86
102.W.R-1.0
87

30

104.R-4.0

104.R-4.0
105.W-1.0

106.W-1.0
CN2-03

30.R-10
107.W-4.0

Gear
Terminal
Load capacity (A)
30
87
86

85

108.W.-1.0

110.W-1.0 109.W-1.0

112.W-1.0
113.W-1.0
111.W-1.0

d
123.W-1.0 85

117.W-2.5 116.W-2.5
114.W-1.0
30

87a
86

87

115.W-1.0

30

120.W-1.0
87
121.W-1.0
122.W-1.0

86

85

118.W-2.5
f

119.W-2.5

Fig.6-3.4(1) Schematic diagram of electrical system on chassis

6-63
Troubleshooting
STC500S3

CN2-05
122.W-1.0
115.W-1.0
202.W-1.0

87a

87

86
255.W-1.0

85
30
232.W.B-1.0

109.W-1.0
254.W-1.0

108.W.-1.0
201.Y-1.0
87

86

244.W.B-1.0
85

119.W-2.5
30

221.U-1.0
205.W-1.0

30.R-10
215.W-1.0 229.O-1.0

220.W-1.0 239.G-1.0

218.W-1.0

207.W-1.0

208.W-1.0

219.W-1.0

230.W-1.0

241.W.B-1.0

233.G-1.0
CN2-38

253.G-1.0

227.W.R-1.0

235.W.G-1.0

228.W.B-1.0

226.W.R-1.0

225.W.G-1.0

222.W.B-1.0 204.R-2.5

237.W.G-1.0
31.B-2.5

Fig.6-3.4(2) Schematic diagram of electrical system on chassis

6-64
 Troubleshooting
STC500S3

301.R-1.0

109.W-1.0
108.W.-1.0
305.W.-1.0
109.W.-1.0

119.W-2.5
307.W.-1.0
108.W.-1.0
302.W.-1.0

30.R-10
310.W.-1.0

615.W-1.0
253.G-1.0
309.W.-1.0
518.W-1.0
31.B-1.0
502.W-1.0
31.B-1.0
233.G-1.0
31.B-1.0

31.B-1.0

201.Y-1.0 255.W-1.0
407.W-1.0
221.U-1.0
402.W-1.0
520.W-1.0
602.W-1.0
519.W-1.0
517.W-1.0

513.W-1.0
105.W-1.0
311.W-1.0
403.W-1.0

312.W-1.0
704.W-1.0

418.W-1.0

416.W-1.0

303.W-1.0
302.W-1.0

315.W-1.0 503.W-1.0
123.W-1.0

304.W-1.0
318.W-1.0

316.W-1.0

317.W-1.0

Fig.6-3.4(3) Schematic diagram of electrical system on chassis

6-65
Troubleshooting
STC500S3

109.W-1.0
119.W-2.5
30.R-10
M
75W 404.W-1.0 401.W.R-1.0
M

401.W.R-1.0
87a
402.W-1.0

CN1-02
408.W-1.0

K9
409.W-1.0 30
87

406.W-1.0

CN1-18
403.W-1.0
86

85
87a

410.W-1.0
K10

405.W-1.0
30
87

CN2-43

407.W-1.0
86

85

411.W-1.0

412.W-1.0
414.W-1.0
413.W-1.0 101.R.B-1.0
CN2-31

Reverse indicator 415.W-1.0

416.W-1.0

417.W-1.0
85
86

418.W-1.0
87

30
CN2-19

Travel brake indicator

Horn switch 420.W-1.0
85
86
87

30

422.W-1.0
421.W-1.0
419.W-1.0
423.W-1.0

Fig.6-3.4(4) Schematic diagram of electrical system on chassis

6-66
 Troubleshooting
STC500S3

CN2-34

119.W-2.5
30.R-10
109.W-1.0
502.W-1.0
Inter-axle differential solenoid valve
501.W-1.0

CN2-32
Inter-wheel differential solenoid valve 503.W-1.0

Differential buzzer
504.W-1.0

Left steering lamp 505.W-1.0

B+
CL
CN1-16 CN2-21

Light Light
switch changeover Steering
519.W-1.0

Overtake

Middle
Horn

Right
beam

beam
Small
506.W-1.0

Left
lamp
lamp

High

Low
Big

Combined switch
LL

JK302C-00000
520.W-1.0
507.W-1.0
LR
CR

Right steering lamp

510.W-1.0
522.W-1.0
511.W-1.0

509.W-1.0

508.W-1.0
Danger alarm switch
CN2-20

512.W-1.0
85
86

513.W-1.0
87

30

High beam lamp

87a 86

Low beam lamp

514.W-1.0
85

515.W-1.0
87

30
87a 86

85

Day travel lamp

87

30

524.W-1.0
CN1-03

87a 86

Small lamp 516.W-1.0

85

517.W-1.0
87

30
CN2-04

523.W-1.0
521.W-1.0
85
86

Rear fog lamp

87

30

518.W-1.0

Fig.6-3.4(5) Schematic diagram of electrical system on chassis

6-67
Troubleshooting
STC500S3

622.W-1.0

109.W-1.0
30.R-10
601.W-1.0

CN2-35
602.W-1.0

603.W-1.0
302.W-1.0

605.W-1.0 604.W-1.0

621.W-1.0
Rotate alarm lamp

607.W-1.0

608.W-1.0 606.W-1.0
620.W-1.0

616.W-1.0
609.W-1.0
610.W-1.0

611.W-1.0

612.W-1.0

614.W-1.0 613.W-1.0
85
86
87

113.W-1.0
30

Start signal
114.W-1.0
87a 86

CN2-30 CN2-6

309.W.-1.0
85
623.W-1.0

Vehicle speed
87

signal
30

615.W-1.0
87a 86

618.W-1.0 617.W-1.5
85

Outrigger work lamp

87

30

619.W-1.5

Fig.6-3.4(6) Schematic diagram of electrical system on chassis

6-68
 Troubleshooting
STC500S3

Fig.6-3.4(7) Schematic diagram of electrical system on chassis

6-69
Troubleshooting
STC500S3

E
G
PA
K
AN
BL

6-70
 Specifications
STC500S3

Specifications

7 Specifications
7.1 Basic Specifications.................................................................................................. 7-3
7.2 Technical Parameters of Complete Vehicle............................................................... 7-5
7.3 Performance Parameters of Main Parts.................................................................... 7-7

7-1
Specifications
STC500S3

E
G
PA
K
AN
BL

7-2
 Specifications
STC500S3

7 SPECIFICATIONS

7.1 Basic Specifications

7.1.1 Outline and dimensions of

complete vehicle

Unit: mm

13750
11500 ~ 42500
3650

1395 2750 1450 4000 1350 2250

R4000

Fig.7-1.1 Outline and dimensions of complete vehicle

7-3
Specifications
STC500S3

7.1.2 Outline and dimensions of chassis

Unit: mm
2766

18° 13°
2750 1450 4000 1350 2250
2826

11998

Fig.7-1.2 Outline and dimensions of chassis

7-4
 Specifications
STC500S3

7.2 Technical Parameters of

Complete Vehicle

Refer to Coversion Tables in chapter 1.5

starting from page 1-16 to 1-18 for the
conversion between metric and imperial units.

Table 7-2.1 Main technical parameters for crane in traveling status

Category Item Unit Parameter

Overall length of vehicle mm 13750
Overall width of vehicle mm 2750
Overall height of vehicle mm 3650
Between axle 1 and axle 2 mm 1450
Dimension Wheel base Between axle 2 and axle 3 mm 4000
Between axle 3 and axle 4 mm 1350
Between front wheels mm 2254
Wheel span Between intermediate &
mm 2048
rear wheels
Total mass of vehicle Kg 42000
Weight Load on axle 1 and axle 2 Kg 16000
Axle load
Load on axle 3 and axle 4 Kg 26000
Rated power of Dongfeng Cummins ISLe340
N.m/(r/min) 250/2100
engine 30 (EURO III)
Drive
Rated torque of Dongfeng Cummins ISLe340
N.m/(r/min) 1425/1200~1500
engine 30 (EURO III)
Traveling speed Max. traveling speed Km/h 85
Min. turning radius m 12
Turning radius Min. turning radius of boom
m 15.5
head
Traveling Min, ground clearance mm 342
parameter Angle of approach º ≥18
Angle of departure º ≥13
Braking distance (vehicle speed at 30km/h) m ≤10
Max. gradeability % 40
Fuel consumption/100km l ≤50

7-5
Specifications
STC500S3

Table 7-2.2 Main technical parameters for crane in operating status

Category Item Unit Parameter

Max. rated hoisting capacity t 55
Min. rated range m 3
Swing radius of turntable end mm 4000
Base boom kN.m 1774
Max. hoisting
Longest boom kN.m 840.8
moment
Longest boom + jib kN.m 318
Main Longitudinal m 6.0
Outrigger span
performance Transversal m 7.2
parameters Base boom m 12
Hoisting height Longest boom m 42.8
Longest boom + jib m 58.8
Base boom m 11.5
Boom length Longest boom m 42.5
Longest boom + jib m 58.5
Offset angle of jib º 0,15,30
Luffing time of Luffing up S 80
boom Luffing down S 80
Telescoping time Full telescoping out S 120
of boom Full telescoping in S 100
Max. swing speed r/min 2.0

Max. hoisting Main winch Idle load m/min 130

speed
(Single rope) Auxiliary winch Idle load m/min 130
Operating
Simultaneous
speed S ≤40
extending
parameters Horizontal outrigger
Simultaneous
S ≤20
Telescoping time retracting
of outrigger Simultaneous
S ≤35
extending
Vertical outrigger
Simultaneous
S ≤30
retracting
Power level of exterior operating noise db(A) ≥91
Noise level inside the cab db(A) ≥89

7-6
 Specifications
STC500S3

7.3 Performance Parameters of

Main Parts

7.3.1 Performance parameters of main

parts on superstructure

Table 7-3.1 Performance parameters of main parts on STC500S3 superstructure

Item Parameter
Motor mode: A6V107HD1D
Reducer mode: QJ2.48
Speed ratio: 48.2
Hoisting mechanism
Drum bottom diameter: φ402
Specification of steel wire: 18.35W×7.1960GB8918.96
Maximum pulling force for single rope: 48.8 KN
Motor mode: A2F28W2Z8
Reducer mode: JH17-100-15
Speed ratio: 95
Swing mechanism Swing support mode: 011.45.1600Z5
Raceway diameter of swing support: ф1600 mm
Number of gear module: 14
Gear ratio: 127/13
Mode: PARKER P2145R00D1D/KAWASAKI K3VL140B
Displacement: 145ml/r/140ml/r
Main oil pump
Rated pressure: 28 Mpa
Rated rotational speed: 2000 r/min

7-7
Specifications
STC500S3

Table 7-3.1 Performance parameters of main parts on STC500S3 superstructure

Item Parameter
Luffing: D=280 mm S=3230 mm
Telescoping cylinder I: D=180 mm S=7750 mm
Telescoping cylinder II: D=180 mm S=7750 mm
Cylinder Front vertical outrigger cylinder: D=140 mm S=480 mm
Rear vertical outrigger cylinder: D=140 mm S=645 mm
Front jack cylinder: D=100 mm S=580 mm
Horizontal outrigger cylinder: D=75 mm S=2135 mm
Winch motor mode: A6V107HD1D
Hoisting hydraulic Max. displacement: 107 ml/r
motor Rated pressure: 20Mpa
Rated rotational speed: 4000 r/min
Motor mode: A2F28W2Z8
Displacement: 40 ml/r
Swing hydraulic motor
Rated pressure: 20 Mpa
Max. rotational speed: 3500 r/min
Hydraulic oil tank Volume: 850L

7-8
 Specifications
STC500S3

7.3.2 Performance parameters of main

parts on chassis

Table 7-3.2 Performance parameters of main parts on STC500S3 chassis

Model SYM5425J3
Drive Mode 8×4
Passenger 2
Length (mm) 13750
Width (mm) 2750
Height (mm) 2766
Dimension Between axle 1 and axle 2 1450
parameters Wheel base Between axle 2 and axle 3 4000
Between axle 3 and axle 4 1350
Between axle 1 and axle 2 2254
Wheel track
Between axle 3 and axle 4 2048
Gross weight of chassis (kg) 19400
Load on front axle (kg) 9160
Axle loads
Load on rear axle (kg) 10240
Weight
Gross weight of complete vehicle (kg) 42000
parameters
Load on front axles (kg) 16000
Axle Loads Load on Intermediate and
26000
rear axles (kg)

Model Dongfeng Cummins ISLe340 30 (EURO III)

Maximum power (kW/r/min) 250/2100
Engine
Maximum torque (N·m/r/min) 1425/1200~1500
Permitted volume of fuel tank (L) 300
Model FAST 9JS150TA-B (9-gear Gearbox)
Type Manual
For Gear I, 7.47 ; Gear II, 5.28; Gear III, 3.82;
Gearbox
Gear IV, 2.79; Gear V, 1.95; Gear VI, 1.38;
Speed ratios
Gear VII, 1.00; Gear VIII, 0.73; Low Gear,
12.57 Gear R, 13.14;
Clutch JINNAN ZHONGXIN JL430B3AA1
Traveling brake Pedal brake
Brakes Parking brake Hand brake
Auxiliary brake Engine exhaust brake
Cab SJC61WM104Y

7-9
Specifications
STC500S3

Table 7-3.2 Performance parameters of main parts on STC500S3 chassis

Model SYM5425J3

Front Springs 11
Quantity of leaf springs
Rear Springs 13
Tires 12.00-20-20PR
Electrical system 24V
Maximum speed (km/h) 85
Vehicle Minimum speed (km/h) 2.7
performance Maximum gradeability 40%
Minimum turning radius (m) 24
Braking distance (30km/h) ≤10
Approach angle 18°
Departure angle 13°

7-10
www.sanygroup.com

SANY Mobile Cranes Co.,Ltd.

SANY Industry Town, Economic and Technological Development Zone, Changsha,
Hunan, China 410100

TEL: 0086-21-20271802 FAX: 0086-21-20271702

E-mail: sany@sany.com.cn
Service e-mail: sanyservice@sany.com.cn Service Hotline: 0086-21-20271861