SM XGC55 2020

XGC55 CRAWLER CRANE
MAINTENANCE MANUAL
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XCMG, CONSTRUCTION MACHINERY CO., LTD. BUILDING MACHINERY CO.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA

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Preface
Thank you for choosing XGC55 Crawler Crane made by XCMG, Construction Machinery Co.,
Ltd. Building Machinery Co.
This manual describes the correct operation, inspection and adjustment for XGC55 crawler
crane. In order to give full rein to the crane high performance, please read, understand and use
the operating instructions in this manual to ensure safety and high efficiency work for a long
time and take it as the foundation. Besides, this manual contains the detailed information of
important components and system function as reference to choose spare parts.
Only the trained and qualified personnel may work on this crane.
Note: the symbols like “Note”, “Caution” and “Danger” mentioned in this operation
manual will appear. This kind of symbols alerts operators to comply with the correct
operation methods.
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Note: “Note” is often used when illustrating something. When it has economical
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significance to the application of this crane, we use “Note” to explain.
Caution: “Caution” means when operator is operating crane, if he did not obey the
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operating procedure mentioned in this manual, some troubles might happen.
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Danger: “Danger” appears when operating warnings are violated and will cause personnel
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injury or crane damage.

Pay attention to periodic inspections of crane safety devices and don’t use reluctantly the
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devices with any defects and abnormalities. What you shall always keep in mind is SAFETY
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FIRST!
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Please keep the supplied technical documents and operation manual carefully, and operate the
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machine according to instructions in them.

We reserve the right to modify the design without notice for improvement.
The right for explaining the manual belongs to XCMG, Construction Machinery Co., Ltd.
Building Machinery Co.
Notes:
1. Read this operation manual carefully and get familiar with procedure and notes
before operation, otherwise the machine shall not be operated;
2. Do not put hands and other parts of body or clothes into machine clearance, and
keep electrical supply far away from moisture environment. Operators shall wear
safety helmet, gloves and protection glass;
3. Note whether there are persons around the machine before starting, start the
machine when there is no person in the dangerous areas, otherwise never start the
crane.
4. Preserve this manual carefully for reference in future.
XCMG, Construction Machinery Co., Ltd. Building Machinery Co.
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XGC55Crawler Crane Maintenance Manual Contents
Contents
1. Service and Maintenance……………………..…………………..………..……...……….1-1
1.1 Safety notes……………………………………………………….………..……………1-2
1.2 Regular and daily lubrication and maintenance……………….………………....………1-5
1.3 Key notes on crane maintenance………………………..….……………...…..….…….1-6
1.4 Crane maintenance measurements……………………..…………………..……………1-6
2. Maintenance List…………………………..…………………………..…........….…....…..2-1
3. Power system………………………………..………………..…..……..…........….…....…..3-1
3.1 Engine……………………………………………………………..……..…….…………3-2
3.2 Fuel system………………………………………..……………..……..…….…………3-2
3.3 Cooling system…………………………..………………………..……..…….…………3-6
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3.4 Air intake system…………………………………………..……..……..…….…………3-9
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3.5 Visual inspection on exhaust system…………………………....……..…….…………3-11
3.6 Check and replace engine oil……………..……………………..……..…….…………3-12
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3.7 Notes on engine maintenance……………..……………………..……..…….…………3-12
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4. Slewing Bearing…………………..…..……………………………..……..…….…………4-1
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4.1 Maintenance of slewing bearing………………………….……..……..…….…………4-2

4.2 Check slewing bearing………………………..…………………..……..…….…………4-3
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4.3 Check slewing bearing bolt ………………………..……………..……..…….…………4-3

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4.4 Check bolt moment ……………………………………………..……..…….…………4-3

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5. Slewing Reducer……………………..……………………………..……..…….…………5-1
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5.1 Check oil level…………………………………………………..……..…….…………5-2

5.2 Change oil………………………………………………………..……..…….…………5-2
5.3 Check connection bolt…………………………………………..……..…….…………5-3
5.4 Check parts………………………………………………………..……..…….…………5-3
6. Main Hoist Winch……………………..……………………………..……..…….…………6-1
6.1 Main hoist winch………………………………………………..……..…….…………6-2
6.2 Check oil level…………………………………………………..……..…….…………6-2
6.3 Replace lubricating oil…………………………………………..……..…….…………6-3
6.4 Lubricate rope reeving drum shaft………………………………..……..…….…………6-3
6.5 Check and fix connection bolt…………………………………..……..…….…………6-3
6.6 Check components………………………………………………..……..…….…………6-4
7. Aux. Hoist Winch…………………..………………………………..……..…….…………7-1
7.1 Aux. hoist winch…………………………………………………..……..…….…………7-2
Service and Maintenance XGC55Crawler Crane Maintenance Manual
7.2 Check oil level…………………………………………………..……..…….…………7-2

7.4 Lubricate rope reeving drum shaft………………………………..……..…….…………7-3
8. Main Luffing Winch………………………………………………..……..…….…………8-1
8.1 Main luffing winch………………………………………………..……..…….…………8-2
8.2 Check oil level…………………………………………………..……..…….…………8-2
9. Travel Gear…………………………..…..…………………………..……..…….…………9-1
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9.1 Check oil level of travel reducer………………………………..……..…….…………9-2
9.2 Replace travel reducer oil………………………………………..……..…….…………9-2
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9.3 Check and lubricate crawlers……………………………………..……..…….…………9-3
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9.4 Adjust crawler tensioning device………………………………..……..…….…………9-4
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9.5 Check reducer connection bolts…………………………………..……..…….…………9-5

9.6 Check travel gear components…………………………………..……..…….…………9-5
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10. Hydraulic System………………………………………………..……..…….…………10-1

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10.1 System inspection……………………………………………..……..…….…………10-2

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10.2 Hydraulic oil tank……………………………………………..……..…….…………10-2

10.3 Check and replace hydraulic oil………………………………..……..…….…………10-7
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10.4 Check hydraulic system for leakage…………………………..……..…….…………10-7

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10.5 Check pressure hose…………………………………………..……..…….…………10-7

10.6 Change pressure hose…………………………………………..……..…….…………10-8
10.7 Notes on the adjustable elements of hydraulic system………..……..…….…………10-8
10.8 Notes on hydraulic system maintenance…………………..……..…….…………10-9
11. Electrical system………………….………………………………..……..…….…………11-1
11.1 Daily inspection of electrical system…………………………..……..…….…………11-2
11.2 Daily inspection on electrical control system…………………..……..…….…………11-2
11.3 Daily inspection on LMI………………………………………..……..…….…………11-2
11.4 Battery maintenance…………………………………………..……..…….…………11-3
11.5 Preventative measures for cable fire…………………………..……..…….…………11-3
11.6 Check after the thunderstorm…………………………………..……..…….…………11-5
11.7 Fuse……………………………………………………………..……..…….…………11-5
XGC55Crawler Crane Maintenance Manual Contents
12. Air Conditioner……………………..……………………………..……..…….…………12-1

12.1 Check air conditioning device………………………………..……..…….…………12-2
12.2 Daily maintenance of air conditioner…………………………..……..…….…………12-3
12.3 Notes on use…………………………………………………..……..…….…………12-4
12.4 Heating………………………………………………………..……..…….…………12-6
12.5 Common trouble shooting……………………………………..……..…….…………12-6
13. Operator’s Cab……………………..……………………………..……..…….…………13-1
13.1 Check wiper…………………………………………………..……..…….…………13-2
13.2 Refill water into the spray bottle of the windshield glass washer…..…….…………13-2
13.3 Check the sliding door………………………………………..……..…….…………13-2
13.4 Check pilot control……………………………………………..……..…….…………13-2
13.5 Check rotary brake……………………………………………..……..…….…………13-2
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13.6 Check switch, button and handle……………………………..……..…….…………13-2
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14. Others………………………………..….………………………..……..…….…………14-1
14.1 Inspection and maintenance of hoist hook block…………………………………14-2
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14.2 Lubricate boom pin shaft and sheave bearing……………..……..…….…………14-4
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14.3 Wire rope……………………………………………………..……..…….…………14-5

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14.4 Lifting device………………………………………………..……..…….…………14-16

14.5 Inspection and maintenance of pendants (rod) ………………………………………14-23
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15. Use and Replacement of Oil and Grease………………………..……..…….…………15-1

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15.1 Overview……………………………………..…………………………….…………15-2
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15.2 Recommended list of common oil grease…………………………….…….…………15-5

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15.3 Lubrication and oil replacement………………………………..……..…….…………15-7

15.4 Lubrication and maintenance for crane in non-normal working conditions…………15-11
16. Crane Inspection…………………………………………………..……..…….…………16-1
16.1 Visual inspection……………………………………………..……..…….…………16-2
16.2 Regular inspection……………………………………………..……..…….…………16-3
16.3 Winch theoretical service life………………………………..……..…….…………16-11
16.4 Inspection in special operating environment………………..……..…….…………16-17
16.5 Crane storage………………………………………………..……..…….…………16-17
17. Common Trouble and Trouble Shooting………………………..……..…….…………17-1
17.1 Common trouble and trouble shooting of hydraulic system………..…….…………17-2
17.2 Common trouble and trouble shooting of mechanical drive………..…….…………17-4
17.3 Common trouble and trouble shooting of engine……………..……..…….…………17-6
17.4 Common trouble and trouble shooting of electrical system………..…….…………17-17
17.5 Common trouble and trouble shooting of LMI and display…………………………17-21

17.6 Common trouble and trouble shooting of electrical aux. function……….…………17-22
17.7 Common trouble and trouble shooting of air conditioning system….…….…………17-25
17.8 Screw connection and hydraulic piping tightening recommended moment…………17-26
18. Hydraulic System Diagram……………………………………..……..…….…………18-1
18.1 Domestic configuration………………………………………………………………18-2
18.2 Linde configuration……………….…………………………………………………18-3
18.3 Mix-and-match configuration…………………………………………………………18-4
19. Electrical System Diagrams……………………………………..……..…….…………19-1
20. Addendum………………………………………………………..……..…….…………20-1
21. Memorandum……………………………………………………..……..…….…………21-1
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XGC55Crawler Crane Maintenance Manual Service and Maintenance
1. Service and Maintenance
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1-1
1. Service and Maintenance

1.1 Safety notes
Preventative maintenance is necessary to ensure that the crane is always in good condition.
Caution
Lower down boom onto the ground, stop the engine, carry out all the locking
operation and plug the switch key or disconnect battery line, in case the crane is
started accidentally during crane maintenance.
Not observing the above rules may result in serious personal injury or even death.
1. Notes on crane maintenance
● Stop the crane on firm and even ground (make sure the ground has enough bearing
ability), or take measures to prevent crane movements (such as fix crawler shoes with
special steel plates), place a warning sign: “crane in inspection”.
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● Wear safety uniform, goggles and other safety equipment required for maintenance
work.
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● Use ladders and safety belts while working high above ground (higher than 2m).
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● Keep all platforms and ladders on handles, pedals and engine hood free of dust, snow
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and ice.
● Prevent dust and dirt from entering into the system during hydraulic system inspection or
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maintenance work.
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● Only professional personnel can carry out the inspection and maintenance work,
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especially for electrical system, hydraulic system, engine and all brakes.
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● Follow the signalman’s instructions if the crane needs to be moved for maintenance.
● After the inspection is completed, the crane must grant the renewed authorization before
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operation.
2. Inspection and inspection table
● The inspection below table is formulated according to the general condition of the crane,
operation condition and weather condition shall also be taken into consideration.
● This inspection table includes most of the inspection items, other items can be added if
the repair personnel think necessary.
● Other matters about inspection and maintenance please contact our after-sales
department.
Caution
During inspection process, if any item(s) needs to be repaired or adjusted
immediately, please carry out the work immediately.
3. Maintenance and spare parts
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● Maintenance
If any item(s) needs to be repaired or adjusted immediately, please carry out the work
immediately.
If the crane needs to be repaired immediately, please contact our after-sales department.
● Spare parts
Please use our spare parts and lubricant recommended by us in order to guarantee crane
performance.
Consumables, such as filter elements, shall be replaced periodically according to the
requirement to prevent failure due to delay.
If undetermined problem is found during inspection or maintenance work, please contact
our after-sales.
4. Notes on crane care
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● No alteration, addition or change shall be done without the permission from the
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manufacturer, otherwise it will endanger the crane!
● Use clean lubricating grease
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Keep the house or warehouse storing lubricating grease clean, do not let dirt or water
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entering into the container.

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Make sure that the lubricating grease is free of water.

● Suitable space and assistant equipment are needed for lubrication and maintenance work.
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● Before replacing a single component or large component assembly, place them firmly on
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assistant equipment, and make sure it is free of any risk or damage.

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● Make sure suitable assistant equipment that can operate normally and have enough
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bearing ability (such as hoist cables, tapes and chains)! It is forbidden to stand, walk or
work under the hanging load.
● If safety devices need to be removed for maintenance work, they must be re-installed
and inspected immediately after maintenance work, fasten the loose screws, and make
sure no tools are left on the device.
● Keep the crane body clean
It is easier to detect oil leakage, cracks, loose connectors and other problems on clean
crane body, especially keep grease nozzle, vent hole and oil dipstick free from dirt.
Do not spray water onto electrical elements or joints.
After the crane is cleaned, check all fuel lines, engine oil and hydraulic circuits for
leakage; check joints for loose, cracks and damage!
Notes
After cleaning, lubricate crane transmission pin shaft and swing connectors
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immediately.
The indoor ornaments, console and panel, floor and mat in the cab can only be
cleaned by warm water containing detergent.
Do not use corrosive cleaning agent.
● Oil stain
Clean the oil stain after replacing fuel, hydraulic oil, lubricating grease and filter elements
to prevent fire.
● Set warning sign
Place “crane in maintenance” warning sign on key switch while carrying out inspection
and maintenance work.
● Precautions against fire
Waste with oil stain or other combustible contents shall be stored in safety place.
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Be familiar with the location of the fire extinguisher and master its use.
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Keep the crane clean, especially remove combustible material. Clean the crane thoroughly
after maintenance work on hydraulic system, engine and fuel system. Remove all residual
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lubricating grease, fuel or cleaning agent.
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● Prevent over-lubricating, which is not only a waste but also harmful:

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The lubricant will seep into the friction surface, causing operation failure;
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The lubricant drops on catwalk may cause injury due to slip;

The too high oil level will cause lubricating oil foaming and too high temperature, which
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will cause oil overflow from the tank;

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Injection of excessive lubricating oil will cause shaft sleeve be pushed out due to too stiff
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or too much pressure.

● Rotating parts
There is danger of crush hazards while inspecting engine fan belt, winch gear and slewing
gear. Stop the engine for inspection.
● Water and oil temperature
It is extremely dangerous to drain water, oil or replace filter element while the engine is
just stopped, the above work shall only be done until the temperature drops down. When
the oil temperature is too low, raise the temperature to 20℃－50℃, then drain the oil.
● Internal pressure. Release the residual energy in hydraulic and fuel system before
inspection and maintenance work to avoid injury.
Release the pressure before removing pipe line, joints or other parts with internal pressure
(such as hydraulic system, compressed air system and fuel system, etc.), then carry out
inspection and maintenance work.
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● Oil waste and used filter element

Put the oil waste into container, and dispose of it as industrial waste.
While replacing oil or filter elements, check if there are metal scraps or other foreign
particles.
● Prevent dirt
The opened hydraulic oil pipe line and hydraulic parts shall be protected with blocks or
seals to prevent dirt.
● Clean joint surface
While removing “O” ring or other washers, clean the seal surface and replace with new
seals. Apply a thin layer of oil on seals before installation work.
● Crane electrical devices shall be checked or inspected periodically. Check the locking
connection and all electrical wires, joint connection and wiring board for damage. Repair
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or replace immediately if there is any damage. Only the qualified electrical worker or
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trained personnel, under the supervision of qualified electrical worker, can carry out the
maintenance work on electrical system or working agent according to the electrical
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requirement.
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● Only use the original fuse with specified current strength! Shut down the crane
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immediately if there is power failure.

● Notes on welding work
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Shut down crane power (turn the key switch to “OFF” position)
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Disconnect battery power line (-).

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Do not continuously apply voltage above 200V.

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Place earth connect within 1m around welding point.

No seals or shafts between welding point and earth point.
If welding work is carried out in the vicinity of a LMI or controller, remove them to
prevent damage.
Clean the dirt and flammable material on and around the crane before welding, burning
and grinding, to ensure adequate ventilation and prevent danger of explosion!
1.2 Regular and daily lubrication and maintenance
Please make a “■”mark on maintenance table for lubricating and maintenance work before
regular and daily lubrication and maintenance.
Please carry out lubrication and maintenance work on specified parts.
Such as: the “■”mark on the operating hour item of 250 means the corresponding work shall
be done every 250h; the same with operating hours such as 250h, 500h and 750h, etc.
The following notes about maintenance intervals comply with all cranes subjected to operation
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and environmental condition. For special operation, the interval must comply with the actual
operating condition.
Note
For major maintenance work, such as: “every 1000 operating hours”, other
maintenance and service work shall also be done, the working intervals are smaller and
comply with the larger maintenance work.
The above example means other intervals less than “every 500 operating hours” shall be
done at the same time.
1.3 Key notes on crane maintenance
Purpose to crane maintenance:
● Preparation work before operation
● Keep performance ability
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● Avoid downtime
● Lower repair cost
● Maintain crane operation value 务
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1.4 Crane maintenance measurements
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1. Inspection on crane condition

The crane operator takes a visual inspection on crane condition with specified “intervals”
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according to the “lubricating and maintenance plan”, such as:

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● Check oil level and lubricating oil quality

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● Check display and monitor device

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● Check airbag and filter system for cleanness and function

● Check hose and pipeline for leakage or damage
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● Check shafts for sufficient lubrication and abnormal clearance

● Check installation condition of drive system (reducers, engines, pumps and valves, etc.)
and wire rope lubrication, and existence of dirt or wear.
The above regular visual inspection can detect damage earlier, and repair in time to prevent
crane stop during operation.
2. Preventative maintenance
● The preventative maintenance includes some measurements in “maintenance list”.
● Inspection on crane condition can find wear, damage or defective earlier and repair these
problems as soon as possible.
● Avoid crane stop and repair during crane operation.
● The work involved in crane inspection includes the visual and function inspection of
superstructure and chassis equipment assy. and the expected value/actual value of the
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measurable variables.
● The inspection work must be done by trained professionals.
3. Requirement on crane inspection and maintenance documentation
● Correct visual and function inspection and inspection results shall be recorded in “crawler
crane inspection document”.
● Compile a report on the above inspection, which is the basis for any possible repair work.
The correct inspection, periodic repeat and documentation are the key factors in success
inspection.
● Check safety device, such as over-release limit device, angle indicator, backstop bracket
and other safety devices.
● Compare the difference between the inspected value and actual valve of electrical system
and hydraulic system.
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● Check the function of electrical system and hydraulic system.
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● Check fuel and hydraulic oil for leakage.
● After the engine is started, check the indication values and functions of displays (or
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meters).
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● Check the nitrogen loading pressure of accumulator.

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● Check the noise level and vibration level of the transmission device.
● Check for missing bolts, nuts, pins and pin shafts, check spare parts for cracks and
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damage, etc.
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● Check connection pins, pendants and open pins for damage or loose.
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● Check shafts for damage and wear.

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● Check crane equipment for damage and wear.

Check wire rope for damage and wear.
Check hook block for damage and wear, if the hook block can work normally.
Check if hoist cables and chains and assistant parts can work normally, check crane for
damage and wear.
● Check brake and clutch, verify brake performance.
While the crane is working, the min. moment the brake of hoist and luffing system can
bear is 33% higher than the torque the drum transfers to brake.
Check if the second brake system can bear the same moment as that of dynamic brake
system.
When the dynamic brake is disabled, at least the second brake can function properly to
prevent free fall.
When the power is cut off, the brake can move freely.
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● Under the state of emergency, speed reduction shall not cause damage to structure, wire
ropes, drums and gears.
● Make sure there is no unauthorized alteration or change, such as counterweight change,
improper boom repair, etc.
For further maintenance information, please contact our after-sales department.
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XGC55Crawler Crane Maintenance Manual Maintenance List
2. Maintenance List
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2-1
Maintenance List XGC55Crawler Crane Maintenance Manual
2. Maintenance list
Item Content Consu Interval (working hour)
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1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*
1 Power system
1.1 Engine Fuel oil Details refer to engine manufacture’s Operation Manual
Check engine oil quantity ■
Replace engine oil ■
Replace engine oil filter ■
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Pump and engine, engine Scre
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installation bolt w
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1.2 Fuel oil system
Check fuel pre-filter and water ■
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drainage
Replace fuel filter element ■
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Clean fuel tank filter mesh ■
Fuel oil system-check pipe line ■
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Check fuel quantity and refill fuel ■
1.3 Cooling system
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Cooling system-check liquid level ■
Check and clean cooling system ■
Cooling system-replace coolant 公 ■
■
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Replace water filter
Clean outside of radiator
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(position1)
Clean inside of radiator (position1) ■
Check fan, belt and tensioning
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device
1.4 Air intake pipe line
1*－ once a day before operation 2*－ once a week 3*－ once a month 4* － at least once a year
5*－each time before raising boom, for boom and jib parts according to the requirement
6*－ please observe the requirement in the notes in this chapter about this maintenance interval.
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XGC55 Crawler Crane Maintenance Manual Maintenance List

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1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*
Clean and check air filter element ■
Check air intake system visually ■
Clean air filter ■
Replace air filter Replace immediately if the resistance is beyond the limit
1.5 Air exhaust system
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Visual inspection on exhaust
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system
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2 Slewing bearing
2.1 Lubricate the inside of slewing
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bearing
2.2 Lubricate the tooth surface of
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slewing bearing
2.3 Visually check slewing bearing
■
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connection bolt
Check the pre-tightening force of First
■
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slewing bearing connection bolt time
4 Slewing reducer
4.1
4.2
Slewing reducer-check oil level
Slewing reducer- replace oil
■ 公 ■ ■
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4.3 Slewing reducer- check brake ■ ■
4.4 Check slewing gear connection bolt ■ ■
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4.5 Visually check slewing reducer

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gear
5 Main hoist winch
5.1 Main winch reducer- check oil level ■
5.2 Main winch reducer-replace oil ■
5.3 Main hoist winch-lubricate shaft ■ ■
5*－ each time before raising boom, for boom and jib parts according to the requirement
2-3

mables
1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*
5.4 Main hoist winch - check brake ■ ■
5.5 Main hoist winch - check
■ ■
connection bolt
6 Aux. hoist winch(tower jib
luffing winch)
6.1 Aux. winch reducer- check oil
■
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level
6.2 Aux. winch reducer-replace oil ■
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6.3 Aux. hoist winch - lubricate shaft ■ ■
6.4 Aux. hoist winch - check brake ■ ■
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6.5 Aux. hoist winch - check
■ ■
connection bolt
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7 Main luffing winch
7.1 Main luffing reducer- check oil
■
level
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7.2 Main luffing reducer-replace oil ■
7.3 Main luffing winch - check brake ■ ■
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7.4 Main luffing winch - check
■ ■
connection bolt
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8.1
Travel gear
Check travel reducer oil level 公 ■
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8.2 Replace travel reducer lubricating
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oil
8.3 Lubricate crawler connection pin
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of the crawler assy.
8.4 Maintain hydraulic oil cylinder ■ ■
8.5 Adjust crawler tensioning device ■ ■
8.6 Check connection bolt ■ ■
Upper guide roller installation
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bolt
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XGC55 Crawler Crane Maintenance Manual Maintenance List

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1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*
Crawler lower roller installation
■
bolt
9 Hydraulic system
9.1 Hydraulic oil tank-check oil level,
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oil color
9.2 Hydraulic oil tank-return oil filter First
■ ■
element time
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9.3 Hydraulic oil tank- clean suction oil First
■ ■
filter time
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9.4 Hydraulic oil tank-replace air filter ■ ■ ■
9.5 Servo system-replace pipe line First
■ ■
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filter element time
Check hydraulic tank ■ ■
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9.6 Replace hydraulic oil First
■ ■
time
■
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Hydraulic tank water drainage
9.7 Check hydraulic system for leakage ■
9.8 Check pressure hose ■ ■
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9.9 Replace pressure hose At least every 6 years
Hydraulic system-tighten hydraulic
■ ■
9.10
piping
Hydraulic system-check the
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pressure of accumulator
10 Electrical system
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10.1 Check lighting system ■

10.2 Check limit switch ■ ■
10.3 Check battery maintenance ■
10.4 Preventative measurement against
■ ■
cable fire
11 Maintenance and inspection of
air conditioner
2-5

mables
1* 2* 3* 50 100 150 200 250 500 1000 1500 2000 3000 4* 5* 6*
11.1 Check A/C equipment At least once a year when the cooling period starts
11.2 Maintenance of air conditioner The beginning, middle and end of cooling period
equipment
12 Operator’s cab
12.1 Wiper-check function ■
12.2 Check front glass cleaning device ■
Cab installation bolt ■
部
13 Others
13.1 Lubricate boom pin shaft ■
务
13.2 Lubricate hook block ■
13.3 Wire rope ■ ■ ■
业
Lubricate wire rope ■
Clean wire rope ■
■ ■
外
13.4 Sheave block
Check sheave block shaft ■
Check sheave block ■
海
Counterweight tray connection pin ■
14 Crane inspection
司
14.1 Visual inspection ■
14.2 Periodic inspection ■ ■
Check large steel structure
Check winch
公 ■
■
■
■
销
Check hook block ■ ■
营
2-6
XGC55 Crawler Crane Maintenance Manual Power System
3. Power system
部
务
业
外
海
司
公
销
营
3-1
Power System XGC55 Crawler Crane Maintenance Manual
3. Power system
3.1 Engine
Please refer to engine maintenance instructions and notes provided by engine manufacturer.
Fig. 3-01 engine outline
部
The following must be observed during motor cleaning and starting period:
务
1. Under installation state, do not spray water directly to motor and engine.
2. For disassembly, the shaft port is downward for cleaning.
业
Danger
外
Burn and scald danger. Observe the regulation that wait 60min for crane to cool down
海
after it is stopped before maintenance work.

司
3. Check the start condition each time before starting the engine.
4. Visually check engine connection bolt and damping rubber pads each time before starting
公
engine, or carry out daily inspection. All fixing bolts must adopt anaerobic fastening glue,
销
usually it does not need to be tightened, and visual check is enough. Loose, brake or
营
broken bolts must be replaced.

Use crane according to operation instructions and load capacity chart, periodically fastening
bolts according to the requirement, which can avoid bolt fatigue damage.
3.2 Fuel system
Fig. 3-02 flow chart of fuel system

3-2
Notes on fuel system:

Please use light diesel oil complied with GB252-2000.
● Drain out the water in the oil-water separator each time before starting the crane.
● Replace filter element periodically.
● Check oil tank vent and oil tank periodically.
Note
Please use light diesel oil complied with GB252-2000, and carry out periodic
maintenance according to the maintenance instructions provided by crane
manufacturer. The engine manufacturer shall not warranty for engine fuel system
problem due to fuel quality.
The above example means other intervals less than “every 500 operating hours”
shall be done at the same time.
部
务
Fuel system:
1. Fuel tank with filter
业
2. Fuel filter
3. Fuel pump
外
4. Injection pump
5. Injection nozzle
海
6. Oil return nozzle

7. Oil return to tank through orifice
司
8. Oil return circuit to oil tank

公
9. Oil drain screw plug

销
营
Fig. 3-03 fuel system

3.2.1 Oil-water separator water drainage
● Drain out water in the oil-water separator each time before starting the crane every day.
● Open the water drainage switch by hand, counterclockwise rotate the drainage valve,
drain out water and sediment in the filter water basin, until clean fuel flows out, then close
the discharge valve clockwise (Fig. 3-04).
Note
The water drainage switch shall not be screwed too tight, otherwise the thread will
be disabled.
3-3
3.2.2 Replace oil filter
Fuel pre-filter
Water draining port
Oil draining plug
部
Fig. 3-04 fuel pre-filter Fig. 3-05 replace fuel filter Fig. 3-06 fuel tank oil drain plug
Process of fuel filter replacement (Fig. 3-05)
务
业
● Use a clean cloth to wipe fuel filter outside surface.
外
● Put a container right below the fuel filter, unscrew the filter and drain the fuel in the pipe
line.
海
● Dispose the replaced fuel filter according to local environmental regulations, and use a
司
clean cloth to clean area around fuel filter.

公
● Apply a thin layer of oil on the O-ring of the new filter, and replace with new filter.
● Tighten the filter until it touches the filter base, then continue to tighten 3/4 circle.
销
● Install and tighten oil drain screw.

营
● Start the engine to check for leakage.

Note
The filter element replace interval depends on fuel pollution degree. Fuel block will
cause fuel supply decrease, engine power decrease and difficult to start. The filter
element must be replaced when the engine power is dropped sharply.
Prepare the spare filter element all the time, since filling the tank with polluted fuel
will block the filter.
Use the fuel filter recognized by engine manufacturer and replace it periodically,
otherwise it will cause high pressure pump and injector damage.
Please refer to the maintenance instructions and notes described in the instruction
manual provided by engine manufacturer.
3-4
3.2.3 Fuel tank inspection

● Drain water and residue in fuel tank periodically, and this work can only be done when
the fuel tank is almost empty. When there is a little amount of fuel in the tank, prepare a
suitable container, open the oil drain plug on fuel tank drain assy., drain out water and
residue in the tank. Clean the sealing ring and tighten oil drain plug (as shown in Fig.
3-06).
● Periodically check the air vent hole of fuel filling port to prevent it to be blocked by dirt
or other foreign particles.
● Periodically check fuel tank, and clean in time once the tank is dirty. Clean the oil tank in
time when there is dark green or brown silt deposition on tank wall or exposed on other
surfaces, black or brown “ribbon-like” things suspended in the water of oil tank bottom,
and the tank smells like smelly egg (H2S).
部
3.2.4 Inspection on fuel system pipe line
务
Check engine fuel system once a year in addition to visual inspection (e.g. check oil level).
业
Check the following parts:
 The joint parts shall be tight, no oil leakage.
外
 When use some parts repeatedly, check the connection between hose and hose joint to
海
ensure its tightness. Use another hose clamp to clamp the hose or replace the whole hose
司
if the tightness is not certain.

Note
公
The pipe line, hose and joints damaged due to mechanical effect, thermal effect or
销
other effects must be replaced.

营
Make sure there is sufficient distance between all pipe lines, hoses and engine parts
(e.g. turbocharger), and there is no friction among them.
3.2.5 Fill fuel
It is recommended to fill fuel after the operation is finished very day, to reduce sediment. The
fuel is injected into the fuel tank through fuel pump filler.
Note
The filling pump shall not be idle.
Caution
Do not light fire around fuel.
Do not smoke while filling oil, otherwise it will cause fire, resulting in loss of property
and casualties.
3-5
3.3 Cooling system

3.3.1 Cooling system inspection
● Use antifreeze under any circumstances.
● Check coolant level every day before starting the crane, refill coolant when the level is
below the inspection hole in the expansion tank.
● Use the appointed coolant. Unqualified coolant will damage (corrode) the engine, such as
water pump leakage. Do not refill cold coolant while the engine is still hot, refill coolant
with the same quality while the engine is cooled to a temperature below 50ºC, otherwise it
will damage the engine castings; do not refill mineral water or mix with antifreeze of
other brand.
● Periodically check water tank (radiator) and fan, clean immediately if there is leaves, dirt
or other debris in the radiator, otherwise it will affect radiation function.
部
● Periodically check drive belt (fan, generator).
Visually check drive belt for wear and crack every day before starting the crane.
务
The transverse crack does not affect the performance, when there is longitudinal crack,
业
replace the belt.
外
● Only use coolant filter recognized by engine manufacturers, replace filter element
periodically.
海
The coolant shall contain a certain amount of DCA4 to prevent cylinder liner cavitation
司
and cooling system corrosion.

公
Coolant refilling port

销
营
Water drainage port
Fig. 3-07 cooling process Fig. 3-08 replace coolant

3.3.2 Coolant inspection
Visually check if the water level is on the inspection hole of expansion tank, if not, add
coolant.
3-6
Caution
Do not open the radiator cap while the engine is still hot, since coolant has high
temperature and high pressure while the engine is on operating temperature.
Slowly open the cap with a thick cloth or gloves, remove the cap when the sound and
liquid flow stops.
Not observing the above regulation will result in serious personal injury accident.
3.3.3 Refill coolant
Coolant refilling process:
● Slowly open the filling cover to release cooling system pressure.
● Visually check if the water level is on the inspection hole of expansion tank, if not, add
coolant.
● Inject qualified coolant through expansion tank filling port into the water tank.
部
● Start the engine while the radiation and expansion tank is full with coolant, slowly idle for
about 5min, the coolant level will drop.
务
业
● Turn off the engine, take down the key, and then refill coolant until it reaches to the
inspection hole on the expansion tank.
外
● Cover the cap.

海
Note
司
Danger of burn and scald!

公
Make sure the engine is cooled for 60min before the above work.
销
Open the engine cooling system cap until the engine is cooled down, otherwise the
system is under pressure and it will cause accident. Remove the radiator cap before
营
cleaning coolant elements!

The coolant shall be replaced as soon as possible if necessary (e.g. for repair),
replace the coolant at least once every two years.
Make sure that no air bag is formed while refilling the cooling system, air in the
system will cause engine damage.
3.3.4 Clean radiator and replace coolant
Notes on radiator cleaning and coolant replacement:
● Use medium pressure (to prevent radiator plate damage) to spray compressed air or water
to radiator, until there is no attachment on radiator plate.
● If the coolant temperature is unusually high in normal temperature, the cooling system
may be contaminated. In this case, the cooling system must be thoroughly cleaned,
remove grease in the pipe line, decalcified and rust.
3-7
● Do not use water with mineral, otherwise the engine cylinder body will scale, nor use
softened water.
● Pause for some times during coolant filling process to let the coolant level stabilize, and
even if there is air inside, the air will escape.
● The coolant shall be mixed with anti-corrosion antifreeze (see engine operation manual).
Antifreeze will have no side effect to refined coolant.
● For detailed information, please refer to engine manufacturer’s operation instructions.
Coolant replacement process (see Fig. 3-08):
● Stop the engine.
● Slowly open the cap to release cooling system pressure.
● Prepare a suitable coolant container.
● Open the drain plug on radiator to discharge coolant.
部
● Drain the coolant in engine and radiator.
● Screw the drain plug after the cooling system is drained empty.
务
● Add new coolant to the cooling system, until it reaches to the inspection hole on
业
expansion tank.
外
● Start the engine, slowly idle for about 5min, the coolant level will drop.
● Stop the engine, check coolant level and refill if necessary.
海
3.3.5 Drive fan belt inspection

司
Engine fan belt is consumable and its service life is usually one year or 1000 hours. The
公
engine manufacturers will not guarantee after one year or 1000 hours.
销
Replace the belt according to the maintenance manual provided by engine manufacturer.
Check fan belt tension, press the middle position of fan belt (about 100N) with fingers,
营
deflection of 10mm-15mm is normal.

Stop the engine before checking the belt, otherwise it may result in serious personal injuries.
Fig. 3-09 fan belt inspection and replacement
3-8
3.4 Air intake system

3.4.1 Air intake system process
Notes on air intake system:
● Check air intake pipe line for leakage or crack, or loose clamp before starting the crane.
● Periodically discharge dust in filter dust collector.
● Visually check the air intake block alarm every day. If the plug is blocked, clean the air
filter element, and replace if necessary. Please use specified filter element and safety filter
element, otherwise it will cause engine premature wear.
Air intake port Air drainage port
部
务
业
turbocharger
外
海
Fig. 3-10 air intake (drainage) system flow chart Fig. 3-11 engine air intake (drainage) pipe line
司
3.4.2 Check air filter element

公
It is recommended to prepare the spare part. And use these spare parts while cleaning other
parts.
销
Process of air filter inspection:

营
● Pull out the filter element.

● Visually check for damage.
● Wipe the element gently.
● Clean the inside of the filter shell, as shown in Fig. 3-12.
● If there is no damage, put back the filter element; if there is damage, replace with a new
one.
Note
When use compressed air to clean the filter element, wear protective gloves and
clothing. The max. air pressure is 5bar.
Do not beat or tap the filter element, do not use damaged filter element.
3-9
Fig. 3-12 process of air filter element inspection

3.4.3 Clean and replace air filter element
Process of air filter element cleaning and replacement:
● Stop the engine, loosen the fixing clamp, and remove the filter cover from filter body.
部
● Pull out the clogged filter element.
● Clean and check filter element, replace the filter element if necessary.
务
● Before installing new and clean filter element, the seal and seal strut inside the air filter
业
body shall be thoroughly cleaned again.
外
● Insert new and clean filter element into the air filter body.
● After the maintenance work is finished, set the maintenance indicator (arrow) back to the
海
original position.
司
Note
公
Do not repair the air filter while the engine is running.

销
The filter element must be replaced after it was cleaned for 5 times or it is
contaminated by rust.
营
The filter element must be replaced after it is used for 2 years.
Air filter
Fig. 3-13 air filter Fig. 3-14 take out the filter element
3-10
3.4.4 Clean the air filter

Air filter cleaning:
 If the air filter cannot be cleaned by compressed air, then the dirt can be removed by
gently shaking the filter.
Pat the filter element outer surface repeatedly to remove the dirt (Fig. 3-15(A)). Do not
damage the filter element.
 Use compressed air, the max. pressure is 5bar.
Use dry compressed air to blow the air filter surface (Fig. 3-15(B)), then blow the inside
surface (Fig. 3-15(C)).
 Clean the sealed support surface (Fig. 3-15(D)).
部
务
业
外
海
Fig. 3-15 the clean air filter

司
3.4.5 Check air intake pipe line and pipe clamp

 Check air intake pipe for crack, deformation, check pipe clamp for looseness. Replace air
公
intake pipe line if there is phenomenon shown in Fig. 3-16. Fix the pipe clamp if it is
销
loose, and replace the pipe clamp if necessary.

营
 Even a small amount of dirt in the engine will cause serious wear of piston rings. Make
sure the air intake system is clean and without leakage.
Fig. 3-16 check air intake pipe line and pipe clamp
3-11
3.5 Visual inspection on exhaust system

● Check the exhaust system for leakage.
● Do not lay pipe line or cable around the thermal radiation danger zone near the exhaust
system.
3.6 Check and replace engine oil
3.6.1 Check oil level
Check engine oil level before operation.
Clean the dipstick, insert it and check again. If the oil level is within the scales, there is no
problem.
Note
Oil level inspection must be done while the crane is on even support ground,
otherwise the result may not be correct.
部
3.6.2 Replace engine oil
Engine oil replacement process
务
业
● Use a clean cloth to wipe the surface around engine oil filler cap, remove the filler cap.
● Place a container (25L or larger) under the oil drain plug of engine oil pad, unscrew the
外
oil drain plug, to drain the engine oil.

海
● Remove the engine oil filter, discard it, and use a clean cloth to wipe area around engine
司
oil filter seat.

● Apply a thin layer of engine oil around the O ring of the new filter, and install the new
公
filter.
销
● Tighten the filter by hand, until it touches the base seat of the filter, and then continue to
营
tighten 3/4 circle.

● Install and screw oil drain plug.
● Refill the right amount of engine oil into the filler according to the engine oil
specification and amount recommended by this manual.
● Mount on the engine oil filler cap.
● Start the engine and check for leakage. Stop the engine, and take off the key. Plug oil
dipstick and recheck oil level a few minutes later.
Caution
Do not open the oil drain plug while the engine oil is still hot, otherwise there is
danger of burn.
Not observing this may cause serious personal injuries.
3-12
3.7 Notes on engine maintenance

The following requirements shall be emphasized for engine maintenance in order to guarantee
normal engine work:
● Check before starting the engine:
1) Coolant level.
2) Fuel level.
3) Engine oil level.
4) Air filter for block.
5) Water in fuel filter.
6) Engine hand throttle on idle position.
7) Connection pipe line.
8) Cable and connector of battery, battery.
部
9) Crack, deformation and loose connection in fan.
● Drain out the water in water oil separator daily
务
业
Open the water outlet on the bottom of the water-oil separator, drain out the water
completely and then close the port.
外
● Notes on daily maintenance:

海
1) Check engine oil level and coolant level;

司
2) Check for leakage

3) Check parts for looseness or damage
公
4) Check drive belt for wear or damage;

销
5) Check diesel engine appearance change;

营
● Check if the water is drained out in the water-oil separator.
3-13
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Slewing Bearing
4. Slewing Bearing
部
务
业
外
海
司
公
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营
4-1
Slewing Bearing XGC55 Crawler Crane Maintenance Manual
4. Slewing bearing
4.1 Maintenance of slewing bearing
Pay attention to the running condition of slewing bear, if there is noise, impact or sudden
increase in running speed, stop the crane immediately and check and solve the problem, open the
slewing bearing to check if necessary.
● The slewing bearing needs to be lubricated every 50 operating hours under normal
working condition.
● Sufficient new grease shall be refilled before and after the crane is out of service for a
long time.
● Refill the lubricating grease into the ball track until it oozes out from the seal every time.
● Slowly rotate the slewing bearing while lubricating the grease, so the grease will be filled
● Often check the sealing condition of the seal, replace the seal immediately if there is
部
damage in sealing tape, and reset immediately if the sealing is off.
● Adopt oil pipe line lubrication.
务
● Remove debris on tooth surface every 250 operating hours, and coat with grease.
业
Danger
外
There is danger of being dragged into the slewing pinion while carrying out the
海
maintenance work.
司
Danger of crushing and shearing.

公
Make sure that when the engine is started for slewing and luffing operation, no
maintenance personnel is in the danger zone among boom, turntable and slewing
销
bearing or between car-body and slewing, except the crane operator (in cab).
营
The slewing bearing shall not be exposed directly in the sun. Never use water to
clean the slewing bearing in case water comes into the ball track. No hard object shall
be close or into the meshing area.
Crane operator and lubricating operator shall always have eye contact or language
communication.
Grease type refers to the related chapters of “fuel oil, lubricating oil, lubricating grease,
coolant and its quantity”.
4-2
XGC55 Crawler Crane Maintenance Manual Slewing Bearing
Fig. 4-01 maintenance of slewing bearing

4.2 Check slewing bearing
● Safety and tightness of connectors
● Condition, function and noise
部
● Stable start and stop
● Effectiveness of rotary locking device.
务
业
4.3 Check slewing bearing bolt
Check visually the bolts on slewing bearing each time before hoisting operation, or at least
外
every 100 hours. Eliminate bolt damage or material fatigue in the following cases:
海
● Use the crane according to the operation instructions and load capacity chart.
司
● Periodically check bolts according to the requirement.

Check bolt crack.
公
No severe corrosion, eliminate light rust deposition before installation work.

销
Before screw each bolt, apply anaerobic glue (1243) on all thread surface of connection bolt.
营
Check bolt top surface and thread for crack before screwing each bolt.
Note
If the slewing bearing is replaced, then all bolts must be replaced.
4.4 Check bolt moment
Make sure there is enough preload force. Check bolt preload force after the bearing is
operating for 100 hours, and then check every 500 operating hours. Replace bolt 7 years or 4000
operating hours later (whichever first comes).
Position Installation position Specification Moment (N.m) SAP
1 Turntable, car-body M24×170，class 10.9 940-1120 170400275
4-3
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Slewing Reducer
5. Slewing Reducer
部
务
业
外
海
司
公
销
营
5-1
Slewing Reducer XGC55 Crawler Crane Maintenance Manual
5. Slewing reducer
5.1 Check oil level
Stop the crane on flat ground, draw the oil dipstick or unscrew the oil filling plug, if the oil
level reaches the oil dipstick marking or visible on the oil plug hole, the oil is sufficient.
Note
If oil leakage is found during oil level inspection, suspend the operation and open the
system for inspection.
Slewing motor Hydraulic motor fixing bolt
Dipstick Reducer installation bolt
Slewing reducer Dipstick Oil filling plug
部
Oil drain plug
Turntable
务
Slewing bearing
业
Car-body
外
Fig. 5-01 check slewing reducer structure and oil level

海
5.2 Change oil

司
Non-working state for oil change.

Drain oil out while it is still hot, i.e., change oil after the engine is running for a long time.
公
Slewing reducer oil change process is as the following:

销
● Unscrew reducer oil filling plug.

营
● Place oil container.

● Unscrew oil drain plug.
● Drain the oil into the container.
● Install the oil drain plug.
● Refill the new oil (about 7L) through oil filling port, until the oil is beyond oil level
inspection hole.
● Install the oil filling
● Clean the reducer surface, and wait for about 10min to check the surface for leakage.
Note
Dispose the used oil in a green way.
5-2
XGC55 Crawler Crane Maintenance Manual Slewing Reducer
5.3 Check connection bolt

● All connection bolts shall use anaerobic fastening glug (1243 thread locker & sealant),
usually it does not need to be screwed again. Check visually.
● Loose, fractured or defective bolts must be replaced.
Note
This work can only be done by trained expert. Accidents might happen if the brake
is not complete.
Installation Moment Anaerobic

Position Specification SAP
position (N.m) fastening glue
Slewing reducer M16×60,
1 193-257 ● 805000040
- turntable class 8.8
Slewing reducer
部
M12×40,
2 78-104 ● 805000045
- car-body class 8.8
5.4 Check parts
务
业
● Check connection components for safety and tightness.
● Check operating status, function and noise.
外
● Stable start and stop.

海
● Check pipe line and bearing seat for leakage.

司
公
销
营
5-3
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Main Hoist Winch
6. Main Hoist Winch
部
务
业
外
海
司
公
销
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6-1
Main Hoist Winch XGC55 Crawler Crane Maintenance Manual
6. Main hoist winch

6.1 Main hoist winch
Main hoist winch is on turntable, near swing center (Fig. 6-01), used for main hoist under
boom working condition and fixed jib working condition, reeved with Φ20 wire rope.
Main luffing winch Aux. hoist winch Main hoist winch
部
Fig. 6-01 winch position
务
业
Note
Danger of dragging.
外
Be extremely careful when carrying out maintenance, inspection and installation

海
work, there is danger of being dragged or pulled between winch and winch wire rope!
司
This work can only be done by trained expert. Accidents may happen if the brake is
公
not thorough.
6.2 Check oil level
销
The oil must reach oil level plug position.

营
Process of oil level inspection:

● Place the crane on even ground and boom is horizontal (0º).
● Unscrew the oil level plug.
● If the oil level is visible, then the oil is sufficient. Otherwise lack of oil (Fig. 6-02).
Note
If there is sign of oil leakage, suspend the operation and open the system for
inspection. This work can only be done by trained expert.
6-2
XGC55 Crawler Crane Maintenance Manual Main Hoist Winch
Air hole
Refilling screw plug
Oil level screw plug Oil draining screw plug
Fig. 6-02 oil level inspection

6.3 Replace lubricating oil
部
Unload the load before replacing oil (Fig. 6-02).
Oil replacement procedure:
 务
业
Unscrew reducer oil filling plug.
 Place the container.
外
 Unscrew the oil level plug.

海
 Unscrew the oil drain plug.


司
Drain the oil into the container.

 Screw the oil drain plug.
公
 Refill the new oil through the oil filling port, until the new oil oozes out of the inspection
销
port.
营
 Screw the oil filling plug.

 Screw the oil level plug.
Note
Drain oil out while it is still hot, i.e., change oil after the engine is running for a long
time.
6.4 Lubricate rope reeving drum shaft
Lubrication method: inject lubricating grease through the oil filling port on the rope reeving
drum end that does not install reducer.
6.5 Check and fix connection bolt
All connection bolts shall use anaerobic fastening glug (1243 thread locker & sealant), usually
it does not need to be screwed again. Check visually.
6-3
Main Hoist Winch XGC55 Crawler Crane Maintenance Manual
Loose, fractured or defective bolts must be replaced. Specific requirement see the table below:
1 Main hoist reducer- M12×65, 78-104 ● 805000086
left strut class 8.8
2 Main hoist reducer- M20×60, 376-502 ●
805000145
right strut class 8.8
3 Main hoist M24×55, 651-868 ● 805000282
winch-turntable class 8.8
Connection bolt
Connection bolt between main hoist
between main hoist reducer and right strut
reducer and left strut
部
务
业
Connection bolt
between main hoist
外
reducer and turntable

海
Fig. 6-03 lubricate connection bolt and shaft base

司
6.6 Check components

公

销

营
6-4
XGC55 Crawler Crane Maintenance Manual Aux. Hoist Winch
7. Aux. Hoist Winch
部
务
业
外
海
司
公
销
营
7-1
Aux. Hoist Winch XGC55 Crawler Crane Maintenance Manual
7. Aux. hoist winch

7.1 Aux. hoist winch
Aux. hoist winch is in turntable, behind main hoist winch (Fig. 6-01), used for hoist operation
under boom single top working condition and fixed jib working condition, reeved with Φ20 wire
rope.
Note
Danger of dragging.
not thorough.
7.2 Check oil level
部
务
业
外
海
Note
司
公

销
营
Air hole
Oil level screw plug Oil draining screw plug

7-2
XGC55 Crawler Crane Maintenance Manual Aux. Hoist Winch

 Unscrew reducer oil filling plug.
 Drain the oil into the container.
port.
部
Note
务
业
time.
外
7.4 Lubricate rope reeving drum shaft

Lubrication method: inject lubricating grease through the oil filling port on the rope reeving
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drum end that does not install reducer.

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1 Aux. hoist reducer- M12×65, 78-104 ● 805000086
left strut class 8.8
2 Aux. hoist reducer- M20×60, 376-502 ●
805000145
right strut class 8.8
3 Aux. hoist M24×55, 651-868 ● 805000282
7-3
Aux. Hoist Winch XGC55 Crawler Crane Maintenance Manual
Connection bolt
Connection bolt between aux. hoist
between aux. hoist reducer and right strut
reducer and left strut
Connection bolt
between aux. hoist

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7-4
XGC55 Crawler Crane Maintenance Manual Main Luffing Winch
8. Main Luffing Winch
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8-1
Main Luffing Winch XGC55 Crawler Crane Maintenance Manual
8. Main luffing winch

8.1 Main luffing winch
Main hoist winch is in the rear of turntable (Fig. 6-01), this winch is used for boom luffing and
reeved with Φ20 wire rope.
Note
Danger of dragging.
not thorough.
8.2 Check oil level
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外
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Note
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Oil level screw plug

Oil draining screw plug

8-2
XGC55 Crawler Crane Maintenance Manual Main Luffing Winch
 Unscrew reducer oil filling plug.

 Drain the oil into the container.
port.
Note
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time. 务
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外
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1 Main luffing M12×65, 78-104 ● 805000086
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reducer- left strut class 8.8

2 Main luffing M20×60, 376-502 ●
805000145
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reducer- right strut class 8.8

3 Main luffing M24×55, 651-868 ● 805000282
8-3
Main Luffing Winch XGC55 Crawler Crane Maintenance Manual
Connection bolt Connection bolt between

between main luffing main luffing reducer and
reducer and left strut right strut
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Connection
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between main luffing
外

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8-4
XGC55 Crawler Crane Maintenance Manual Hydraulic System
9. Travel Gear
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10-1
Hydraulic System XGC55 Crawler Crane Maintenance Manual
9. Travel gear
9.1 Check oil level of travel reducer
oil refilling port
oil level inspection port
oil draining port
Fig. 9-01 reducer oil level inspection

Inspection process:
● Check reducer for abnormal sound.
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● Stop the crane on flat ground, if the oil reaches the level inspection port, then the oil is
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sufficient (oil refilling capacity is about 9L after it is emptied).
● Refill lubricating oil through oil filling plug if necessary.
外
● Screw the oil level plug.

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Note
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There may be danger for crawler travelling or turntable slewing. Be extremely

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careful while carrying out maintenance, inspection and lifting work within this area.
Turn off the engine before carrying out operation on travel gear.
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If there is oil leakage while checking oil level, suspend the operation and open the
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reducer for inspection.

9.2 Replace travel reducer oil
The process is as follows:
● Unscrew oil drain plug and oil level plug, drain the oil into a suitable container.
● Before refilling the new oil, clean the gear with warm and clean oil to remove worn
material and foreign body.
● Screw the oil drain plug, unscrew the oil filling plug to refill the new oil. If the lubricating
oil reaches the oil check port, then the oil is sufficient (oil filling amount is about 9L since
it is empty)
● Check the cleanness, and then screw the oil level plug.
● After refilling the oil, wait for about 2min, and then check oil level again.
10-2
Note
Dispose the waste oil in a green way.
Use special tool for oil refilling.
time.
9.3 Check and lubricate crawlers
Lubricate crawler shoe connection pins, and check crawler tightness when noise occurs.
Lack of lubrication on crawler shoe connection pins, improper tensioning of crawler shoes and
dirt on crawler will usually cause operation noise and premature wear of crawler shoes; therefore,
regularly check the following items:
● Crawler travel gear (wear, lubrication on crawler shoe connection pins and tensioning of
crawler shoes).
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● Crawler upper roller or upper guide roller (wear, lubrication and function of rollers).
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● Crawler driving gear (wear and lubrication of reducer).
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● Crawler dirt condition (when the crawler is dirty, the wear on crawler moving parts will
be very serious, which will cause increase of resistance on driving gear.).
外
● Lubrication of crawler connection pins (spray lubricant on the connection pins of crawler
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upper part, drive the crane forward until the lower part is on the guide roller, then spray
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lubricant on this part.).

● Crawler connection pin bolt (for looseness, if it is loose, it will fall out, causing pin flee
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out, then crawler shoe ear and pin shaft broken).

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Check each time before operation, and at least check once a day after the crane travels for a
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long distance.
Fig. 9-02 crawler shoes and crawler shoe connection pins
10-3
9.3.2 Lubrication of crawler pin

Lubricate crawler connection pins in crawler assy.
Spray lubricant on the crawler pins on the connecting position on crawler upper part; then
move crane forward until the lower part is on the upper roller, then spray lubricant on this part.
Note
Lubricate crawler shoe connection pins before cleaning crawler and tightening
crawler assemblies.
Please check connection pin lubrication and lubricate crawler shoe connection pins
if necessary each time before crawler operation.
Clean immediately if the crawler is dirty.
9.3.3 Lubrication of guide roller, lower roller and upper roller
Lubricate guide roller, lower roller and upper roller after 1500 working hours of new crane,
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and then lubricate every 800 working hours.
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9.3.4 Maintenance of chassis hydraulic cylinders
For cranes working in corrosive environment (near ocean, chemical plants or steel plant), coat
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acid free grease on the chromium surface of the exposed piston rod to prevent corrosion.
外
9.4 Adjust crawler tensioning device

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9.4.1 Check crawler tightness

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As shown in Fig. 9-03 and Fig. 9-04.

Clean crawler shoes before checking crawler tightness.
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Fig. 9-03 four rollers and track frame

Stop the crane on flat ground for crawler tightness adjustment. Move the crane forward
slightly, so the loose part is concentrated on the upper part of the drive sprocket, and easy for
adjustment.
10-4
Fig. 9-04 crawler tightness

Crawler tensioning adjustment procedures:
1. Remove cover plate and bolts.
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2. Use mechanical lifting jack to push the pushing rod, during this process, the guide roller
sliding block will move forward, and then there will be clearance between sliding block
and adjusting shim.
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Note: this process shall be done by two operators working together. If the lifting jack
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stroke is not sufficient, add tightening shims between lifting jack and pushing rod to
increase stroke.
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3. After adjusting crawlers to appropriate tightness, retract lifting jack and then install the
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cover plate and bolts.

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9.5 Check reducer connection bolts

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Check the assembly bolts of travel reducer, drive roller, lower roller and upper roller, and
retighten them if necessary. Remove loose, broken or defective bolts and replace with new ones
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if necessary. Tightening torque see the table below:

Table 9-01 tightening torque
Position Size Bolt standard Torque（N·m）
Reducer assembly bolt M24×85 GB/T5782-2000 940～1120
Driver roller assembly bolt M24×165 GB/T5782-2000 940～1120
Lower roller assembly bolt M20×110 GB/T5782-2000 376～502
Upper roller assembly bolt M16×40 GB/T5782-2000 193～257
9.6 Check travel gear components

● Safety and tightness of connection components.
● Status, function and noise.
● Uniformity of the tightness of the left and right crawler.
10-5
10. Hydraulic System
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10-6
10. Hydraulic system

10.1 System inspection
● Check before starting the crane: make sure the hydraulic suction pipe butterfly valve is
open, check hydraulic oil level in the oil tank, check if the hydraulic quick connector is
tight.
● After the crane is started, check for abnormal noise, vibration, heat, suffocation or leakage,
etc.
● Pilot pressure shall be 2.8 Mpa-3.5Mpa.
● Idle movement of mechanisms, including: lifting/lowering of main winch, aux. winch
(aux. luffing winch) and main luffing winch, travel forward/backward, and swing
left/right, etc..
10.2 Hydraulic oil tank
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10.2.1 Check oil level
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Check oil level by the oil level gauge on hydraulic oil tank.
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Stop the crane on flat ground, if the hydraulic oil level is between the max. and min. arrow of
oil level plate, then the oil level is correct, as shown in Fig. 10-01.
外
Check oil quantity in the tank before starting the crane, if the oil level is dropping too fast,
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there is leakage on pipe line or hydraulic components, so screw pipe connector or replace
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hydraulic components. Besides, when the hydraulic oil temperature is too low (below 20℃), the
oil will flow slower, so too rush operation may damage the hydraulic components; when the
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hydraulic oil temperature is too high (above 80℃), the hydraulic oil will deteriorate more
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quickly, which will shorten the life of hydraulic components. Therefore, do not hoist load after
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the crane is started under low temperature, preheat thoroughly, and go into normal operation
state until the oil temperature reaches 20℃.
Note
Danger of burn.
Pay special attention to the hydraulic system components under the engine hood,
there is danger of high temperature.
Ensure there is enough cooling time, or wear safety uniforms. Prevent oil spray.
10-7
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Fig. 10-01 hydraulic oil tank structure
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10.2.2 Replace oil return filter element

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Oil return filter is installed on the top of hydraulic tank. replace filter element very 2000h
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Filter element replacement method:

 Unload the crane and stop the engine;
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 Make sure the system is in no pressure state and is cooled to appropriate temperature
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before replacing filter element;


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Unscrew the cover on top of the oil return filter, pull out the oil return filter out of the tank,
and replace filter element;
 Screw the filter cover. Prevent filter element skew while installing it.
10.2.3 Replace oil suction filter element
Oil suction filter is installed on the top of hydraulic tank, and the filter outlet is connected with
the oil suction flange in tank. Replace oil return filter element every 2000h.
 After removing the filter cover fixing bolt, pull out the oil suction filter out of the tank,
screw anticlockwise the filter cover with connecting rod from nut on top of bypass valve
and replace filter element (the new filter element has bypass valve and O ring);
10-8
 Reinstall the filter element back to tank and fix filter cover with bolt;
 Check if the O ring on the bottom of filter element is appropriately installed, when the
filter element is installed into the tank, the oil suction flange filter bottom and inside the
tank shall be aligned correctly.
Note
 When the hydraulic is in working temperature, if the filter element alarm light
is constantly on, the filter element shall be replaced.
 If the sealing pad is damaged, it must be replaced.
 Prevent removed bolts, shims or other foreign matters into the tank during
filter element replacement process.
filter cover filter element positioning seat
filter cover assy.
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O ring seal pad
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connection rod
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filter element
bypass valve
外
O ring
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filter element
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oil tank structure

bypass valve
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Fig. 10-02 oil return filter structure Fig. 10-03 oil suction filter structure
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10.2.4 Change pilot filter element

Pilot filter element is installed on the outlet oil circuit of pilot gear pump, and is used for oil
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filter of pilot system. When differential pressure reaches 0.15Mpa, the filter element 2 light on
cab panel is on, indicating the oil suction filter element need to be replaced.
 Unscrew the screw plug on the filter body bottom and drain out the hydraulic oil, unscrew
the shell body anticlockwise, replace filter element and then reinstall the filter;
Note
 There is oil flow direction arrow sign on pilot filter body, the hydraulic oil flow
direction must be the same with the sign.
10-9
Table 10-01 filter element models

No. SAP Filter element model Qty. Position
1 803183245 JX-800×180 1 Oil suction filter element
2 803084457 HC2296FKS18H50YT 1 Oil return filter element
3 803084455 HCG300FKN4Z 1 Pilot filter element
10.3 Check and replace hydraulic oil

10.3.1 Check hydraulic oil
Table 10-02 inspection of foreign material in the hydraulic oil and oil deterioration
Inspection Foreign Lab
Judgment method
content material container
Dust and
Test tube or a
metal After the engine is started, take out a sample from
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transparent
powder the hydraulic oil tank or pipe, compare with new oil
container,
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from of its opacity.
new oil
outside
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After hydraulic oil emulsion, there is water
Foreign
accumulated on the bottom after the oil is heated.
外
material
Test tube or a Take out the oil emulsion sample, insert the braised
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transparent iron bar or drop the emulsion oil onto the heated
Moisture
container, iron plate, it will emit a sharp thorned sound.
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new oil Before starting the engine, unscrew the oil drain
valve and take out the sample, observe the water
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sediment.
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Test tube or a Inject the oil sample from the oil hydraulic tank or
Deteriorati transparent pipe into the container, compare color and odor
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on container, with new oil, the oxidized oil will become dark
new oil brown, deteriorated oil will emit foul smell.
Table 10-03 check hydraulic system after starting the engine
Inspection
Check method Judgment Purpose
content
Feel by putting hand on oil Find hydraulic system
Hydraulic oil tank, pilot pressure is Normal temperature abnormality earlier,
temperature 2.5MPa~4.0MPa while the +30℃ to +80℃ improve the service life
engine speed is 1000rpm of hydraulic components
Oil leakage Visual inspection No oil leakage Find oil leakage earlier
Pump Feel by hand(surface 5℃ higher than oil Find motor abnormality
temperature thermometer) tank temperature earlier
Find abnormal change in
Feel by hand, feel (sound Abnormal sound and hydraulic oil, air in
Pump noise
volume, sound quality) noise change pump, pump wear and
filter blockage.
10-10
Motor
Feel by hand, feel (sound Abnormal sound, Find motor abnormality
temperature
volume, sound quality) noise change earlier
and noise
Note: the hydraulic oil cannot be used permanently, so check and replace hydraulic oil
according to the degree of impurities or deterioration.
10.3.2 Replace hydraulic oil
Replace hydraulic oil no matter how long the crane is working if there is something wrong in
the hydraulic oil; if the hydraulic oil is contaminated or deteriorated for a short time, fine out the
cause and then change the oil.
Note
The crane must be placed horizontally while replacing hydraulic oil.
Refill oil if there is lack of hydraulic oil during maintenance process, the new oil shall be the
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same model with the oil in the tank, refill the oil until it reaches to the specified quantity.
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Hydraulic oil replacement method:
● Drain the hydraulic oil into a suitable container through the ball valve under the tank
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bottom.
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● Clean hydraulic tank and seal the ball valve.

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● Unscrew the upper cover of the air filter, refill the new oil through filter mesh until it
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reaches the standard oil level.

Note
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Oil level shall not be below the lower mark (min. filling oil level) even if all cylinders
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are extracted; otherwise the hydraulic pump may be damage.

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Use specified hydraulic oil, prevent dust and sand into the tank. Clean oil tank and
filter. If the new oil is not the same model with the original oil, open the round cleaning
cover plate and thoroughly clean the oil tank with soft cloth, and replace all the
hydraulic oil in pipe line and hydraulic components.
10.3.3 Drain out the water in the hydraulic tank
Due to environmental influence, there may be water in hydraulic oil, so timely drain out water
in the tank to prevent premature hydraulic oil deterioration and emulsion. Drain water once a
month, and once a week for area with high humidity.
The water drainage method:
Stop the crane horizontally, after 24 hours, open the ball valve in the oil tank, the oil drainage
amount each time is about 4L, and more if there is too much water in the tank, but refill the
hydraulic oil to the specified position in oil tank.
10.3.4 Hydraulic oil replacement cycle
10-11
For new cranes, replace hydraulic oil after 1000 hours or half a year; then every 2000 hours or
once a year.
10.3.5 Low temperature operation
Carry out the following temperature rising operation to ensure the safety of the hydraulic
system when the ambient temperature is below 0℃.
● Start the engine, idle for 7min-10min, then increase the speed to 1000rpm-1200rpm, do
not carry out any operation on crane, run for 30min-40min or longer with no load to raise
the hydraulic oil temperature, and let hydraulic oil temperature reach higher than 20℃.
● After the above heating operation, carry out normal operation, and adjust the heating time
according to the local environment temperature. The movement of handles and pedal
valves shall be slow, and pay close attention to the operating condition of the system.
Operating the crane with hydraulic oil temperature below 20 ℃ may damage the
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hydraulic components.
10.4 Check hydraulic system for leakage
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Check the hydraulic system for oil leakage before starting the crane every day. If there is oil
业
leakage, let professionals handle this, please do not operate the crane with leaking hydraulic
外
system.
10.5 Check pressure hose
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Regularly check hose for leakage. During visual inspection, change the defective hose
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immediately even with the slightest damage.

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The possible hose defectives are as follows:

● Damage, cut and wear of the outer hose layer.
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● Hose hardening, cracking and burn.

营
● Crack, damage and severe corrosion on connector.

● Connector or hose leakage.
● Winding, broken, twisted and flattening of hose.
● Foam, softening of the outer layer of hose.
If the above phenomenon is found, screw or repair or replace according to requirement.
Note
Replace the defective hydraulic pipe lines and joints connected to the engine due to
mechanical, thermal and other effects.
Make sure that all pipe lines, hoses and hot engine components (such as exhaust
system) are far from each other, and that they do not have friction.
10.6 Change pressure hose
Hydraulic hoses shall be replaced periodically even if they are not damaged, including the
10-12
hoses stored for over 2 years.

According to our experience, the recommended longest service cycle for mobile crane is:
● For difficult hoisting and unloading work..................................................... about 1 year
● High working temperature and frequent operation cycle............................ about 3 years
● For normal hoisting and unloading work..................................................... about 6 years
● For installation work, do not frequently use the max. output power..........about 10 years
The suction hose from the tank shall be checked visually for torn and damage once a month,
and change timely if necessary.
Hydraulic hose types are as follows (Fig. 10-02):
1SN: hydraulic rubber hose with one layer of steel
2SN: hydraulic rubber hose with two layers of steel
4SP: hydraulic rubber hose with four layers of winding steel wires (middle pressure)
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4SH: hydraulic rubber hose with four layers of winding steel wires (super high pressure)
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外
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Fig. 10-02 type and outer appearance of hydraulic hoses

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10.7 Notes on the adjustable elements of hydraulic system

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Table 10-04 notes on the adjustable elements of hydraulic system

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Name Adjusting pressure (MPa) Remarks

Main valve (main overflow valve) 32
Main valve (secondary overflow valve) 10
Pilot valve 9 Adjusted only by
Pilot relief valve 3 professionals
Swing valve (main overflow valve) 20
Oil radiation control valve 15
Control and adjustment device of other
Forbidden to adjust
pumps and motors
10.8 Notes on hydraulic system maintenance
The service life and function of hydraulic machinery and hydraulic components is closely
related to the rationality of use and maintenance. Pay attention to the following aspects for your
crane’s long and safe operation:
● Read the instruction manual carefully to thoroughly understand crane hydraulic system.
10-13
● Carry out daily maintenance and periodic maintenance on hydraulic system according to
the requirement. Incorrect maintenance is very harmful to the system!
● Correctly use hydraulic oil, refill clean hydraulic oil according to the requirement.
● Regularly replace hydraulic filter element to guarantee long and normal use of the
hydraulic system.
● Protect the cleanliness of the hydraulic system when replacing hydraulic components,
hydraulic hoses or filling hydraulic oil.
● Clean environmental—clean the dirt near hydraulic components or hose joints carefully
when removing the hydraulic components or hydraulic hoses to ensure that no dirt comes
into the hydraulic system. Do not open the hydraulic system components or hoses without
protective measures in windy, rainy and snowy weather.
● Pay attention to the degree of contamination and humidity of hydraulic oil, avoid any dirt
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into the hydraulic oil tank, keep the cleanliness of hydraulic oil. Oil must be filtered
beforehand, use movable filter oil trolley with precise filtering device to refill oil.
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● Strictly check new components or hydraulic hoses for cleanness, there shall be
业
anti-corrosion oil in the new elements, check elements for damage during transport.
外
● Although cylinder rod outer appearance quality is excellent, its surface is very susceptible
to corrosion in corrosive environment. If the crane is out of service for more than one day,
海
apply acid free grease on the exposed surface.

司
● Make sure the pressure bearing oil pipe (pump to main valve, main valve to motor) be
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replaced once every 2 years.

● After maintenance on hydraulic system, check the following items before starting the
销
crane:
营
Is the oil tank cleaned and refilled with sufficient hydraulic oil according to the
requirement?
Is the pipeline cleaned and installed?
Is the precision of the filter consistent with requirement of the system?
Refill oil on pump and motor shell oil if necessary.
Refill oil and exhaust air on oil pump and motor shell if necessary (the crane is used for the
first time, or used after a long time park, or after major maintenance).
10-14
XGC55 Crawler Crane Maintenance Manual Electrical System
11. Electrical system
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11-1
Electrical System XGC55 Crawler Crane Maintenance Manual
11. Electrical system

11.1 Daily inspection of electrical system
Please check the following items after all wiring is completed, and the crane gets power with
engine not ignited:
● Check beacon light for normal start.
● Check working light and indoor light for normal start.
● Check cab air conditioner for normal start.
● Check meter light for normal start.
● Check radio for normal start.
● Check monitoring system for normal start and display.
● Make sure the emergency switch is functional.
● Make sure if the wipers are functional.
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● Make sure if the throttle is on the min. position.
11.2 Daily inspection on electrical control system
● Check anemometer for display and change;
务
业
● Check stroke switch, that is, use hand to touch the switches, and the operator in the cab to
外
observe if the indicator light or controller port changes;

● Make sure the display of the control system is normal.
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● Check boom angle display.

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● Make sure the oil level sensor display is normal.

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● Make sure the oil temperature sensor display is normal.

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Check the following while the engine is starting:

● Make sure the engine oil pressure display is normal.
营
● Make sure the revolving speed display is normal.

● Make sure the water temperature sensor display is normal.
● Make sure the oil temperature sensor display is normal.
11.3 Daily inspection on LMI
Please check the following items after all wiring is completed, and the crane gets power with
engine not ignited:
● First make sure if the set working condition is consistent with the actual working
condition.
● Make sure if the angle sensor and the tension sensor is normal, namely, negative value
display is normal.
● Make sure if the percentage display of main luffing pendant tension is normal.
11-2
Note
If any abnormality is found on LMI display, please timely solve the problem before
raising boom, please contact the service personnel if the problem cannot be ruled out.
11.4 Battery maintenance
As electricity power supply for the crane starting, electrical control system, lighting and
auxiliary electrical equipment, all its technical performance complies with GB5008-2005.Carry
out maintenance on the battery to maintain normal state.
There is battery charge status display on battery cover. When the indicator displays green, the
battery is functional; when the indicator displays black, charge the battery timely; when the
indicator displays white, replace the battery immediately.
● Battery will lose power for various reasons, charge the battery timely, to prevent the
battery performance degradation caused by sulfate.
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● Overcharging is strictly forbidden during use or charging process, to prevent premature
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battery failure due to excessive water loss, grid growth or salt off.
业
● For battery that is already installed on the crane and has been used for a long time, if the
crane is not used for a long time (generally more than 15 days), please remove the battery
外
and store it in dry and ventilated place, and charge the battery every 3 to 6 months
海
(depending on if the indicator displays black).

司
● The battery shall be stored in a dry, clean and well ventilated place, the environmental
temperature shall be 5℃ -25℃; the battery shall be more than 2m from thermal source;
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not exposed in direct sunlight. It will seriously affect battery performance if the ambient
销
temperature is too high.

营
● Gas will be produced during battery charging process, so periodically check the battery
vent hole, to prevent battery explosion caused by exhaust hole clog.
11.5 Preventative measures for cable fire
11.5.1 Causes to fire
(1) Electrical components or electrical system failure
Electrical component or system cable fire is not entirely caused by technical failure; much of it
is due to careless or circuit operation failure. Therefore, when replacing components, the use of
original components is very important.
After the use of non-original components, the impact on electrical system such as thermal
effect is often ignored because of investigation difficulty, and this will easily lead to circuit
failure.
Electrical power can only be identified only by its effects. One of them is thermal effect.
(2) Fuse failure
11-3
The circuit with electricity will slightly heat, and it will be very hot when high electricity
comes through, which may cause fire. Install fuse in the middle of the circuit to prevent this
occasion. When electrical power exceeds the max. permissible value, the fuse can automatically
cut off the power.
Fuse (safety wire) failure is the main cause of cable fire.
(3) Failure due to other causes
● Use prohibited or defective cable or cable connector (cable is not long enough).
● Use prohibited or defective consumables or operating elements (relays, motors, switches
and lights, etc.).
● Fuse connector overload.
● Install battery that does not meet the design requirement (too large size battery box,
short-circuit risk due to positive pole earthing).
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● Water in equipment, earthing or short circuit.
● Inspection and maintenance not according to the maintenance manual, electrical equipment
aging.
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业
The above points may singly or jointly lead to burning and cable fire.
外
Note
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The cable fuse can protect electrical cable in case of shortcut.

No fuse bridge connection, even it is very simple.
司
Do not use fuse greater than a specified value (high current value) in any case.
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11.5.2 Prevention method

销
Effectively prevent the above situation according to the following methods:

● Regularly inspect/check crane electrical device.
营
● Promptly eliminate hidden troubles, such as connection looseness, hot cable, etc. At the
same time, timely find the causes and eliminate them.
● Check all electrical devices and wiring, remove and replace them in time if oxidization
and hidden trouble is found.
● Use the original spare parts with specified strength and original fuse.
● If there is a power failure, immediately stop the crane.
● Do not change the electrical system under any circumstances.
● Carry out a thorough maintenance and inspection at least once a year by crane electrical
professional.
Note
This work can only be down by qualified electrical workers or specialized
technicians under the supervision of a qualified electrical worker.
11-4
11.5.3 Components that must be checked

Table 10-01 component inspection
Parts name Inspection content
Generator Spare parts
Starter, auxiliary diesel engine starting Operation and insulation condition
device, the lighting device
Power line circuit, collector
Switch, relay, fuse Prevent electricity parts directly contact
Battery Prevent electricity parts indirectly contact
11.6 Check after the thunderstorm
After the thunderstorm, check the electrical devices before operation to see if the crane can
work, especially the following parts:
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● Force sensor.
● Angle sensor.
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业
● Limit switches.
● Anemometer.
外
● Lantern.
海
If there are signal transmission problem in the above devices after the thunderstorm, please
司
lower down the boom, check if surge protector in boom connector box is damaged, and replace it
公
if it is damaged.
In addition, the surge protector on this crane has a certain service life, and it can be damaged
销
after several lightning or one strong lightning, so it needs to be checked regularly, and replaced
营
immediately once it is damaged.

● Winch, especially check the rolling bearing for damage.
● Slewing bearing, slowly rotate the rotary device, pay attention to abnormal sound,
especially inside the slewing bearing.
11-5
11.7 Fuse
Table 10-02 fuse position (Rexroth hydraulic component system)
Code Value/amp. Parts position Note
F0A 50 Distribution box Main power 1
F0B 50 Distribution box Main power 2
F0C 40 Distribution box Air conditioner
F0D 30A Distribution box Engine ECU
F0E 30A Distribution box Fuel system protector
F1 15 Distribution box Key switch
F2 20 Distribution box Main pump and pilot pressure
F5 10 Distribution box Monitoring system
部
F6 15 Distribution box Oil defueling pump
务
F7 20 Distribution box Indication light, charger
F8 20 Distribution box Engine control
业
F9 20 Distribution box Travel, swing sound and light alarm
外
F10 10 Distribution box Bypass, pilot

海
F12 10 Distribution box Free swing

F14 10 Horn power
司
Distribution box
F15 10 Distribution box Winch high speed, free fall
公
F16 10 Distribution box Limit switch

销
F17 10 Distribution box Pressure switch, oil temperature

营
F18 20 Distribution box Preheat device

F21 10 Distribution box Controller, display
F22 10 Distribution box Integration panel
F23 10 Distribution box Anemometer, tension sensor
F24 10 Distribution box Spare
F26 30 Distribution box IO_moudle
11-6
XGC55 Crawler Crane Maintenance Manual Air Conditioner
12. Air Conditioner
部
务
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外
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公
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12-1
Air Conditioner XGC55 Crawler Crane Maintenance Manual
12 Air conditioning device

12.1 Check air conditioning device
This crane adopts vapor compression type air conditioner, which consists of a compressor,
condenser, dry bottle, thermal expansion valve and evaporator (Fig. 12-01).
部
务
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Fig. 12-01 air conditioning system and its composition
外
(1) Evaporator
The evaporator let the liquid refrigerant expand by going through the expansion valve,
海
absorbing the heat inside the cab, and give cold air into the cab by evaporation cooling fan.
司
(2) Temperature sensor

公
The temperature sensor senses the out/return air temperature of the evaporator chamber to
销
control the movement of compressor clutch, so as to maintain the indoor temperature in a set
range, and prevent evaporator from icing.
营
Note: the sensor shall be on the specified location (position designed by air-conditioner
manufacturer).
(3) Expansion valve
● The expansion valve lower the pressure of the high temperature and high pressure liquid
refrigerant to a low temperature and low pressure spray evaporating refrigerant into the
evaporator (i.e.: separate the high-pressure side and low-pressure side of the refrigerant).
● Automatically regulate refrigerant flow.
● Control refrigerant flow to prevent liquid impact and abnormal heat.
(4) Warm air
The warm air is a heat exchanger by injecting the hot engine cooling water into the heater
element, and heat the cab by the cold air in the cab.
(5) Filter mesh of the internal and external air
12-2
Block foreign particles such as dust while inhaling the internal and external air.
Clean or replace the filter regularly.
(6) Compressor
The compressor gets power from engine belt drive, obtains low temperature and low pressure
cold agent, change it to high temperature and high pressure gaseous refrigerant by compression,
and send to the condenser.
(7) Condenser
Radiate by using engine water tank fan, transform high temperature and high pressure gas
refrigerant to high temperature and low pressure liquid refrigerant.
(8) Drying bottle
The drying bottle filters the impurities of liquefied refrigerant the bottle in the condenser by
absorbing moisture in the system, and store the refrigerant.
部
12.2 Daily maintenance of air conditioner
务
The service life of the air conditioner in the engineering vehicle largely depends on user’s
业
proper maintenance.
Note
外
Carry out regular inspection and maintenance on pipeline and other devices no
海
matter whether the air conditioner is used or not.

司
If the air conditioner is not used for several months, operate the air conditioner once a
month, each time for about 10minutes, in order to keep the normal operation of the
公
system.
销
Refill antifreeze into the heater system in winter to prevent filter element crack from
营
cold.
Items of routine maintenance are as follows:
● Check and clean the condenser, require heat sinks clean without blockage. Use cold water
or compressed air to clean, do not use hot water or hot air.
● Check the refrigerant quantity in the cooling system by observing the window of the
liquid storage. Under normal circumstances, there is no bubble in the observation window,
and there are a small amount of bubbles while the engine speed changes.
● Check the tightness of compressor driving belt.
● Check hose appearance and joint tightness.
● Check cooling system power connection for power or short circuit.
12-3
Table 12-01 table of air conditioning system regular maintenance and interval
Maintenance period
System components Maintenance work
Monthly 6 months Annually
■
Coolin Refrigerant Check pipe line for wear and intact
g pipe
system ◆
Joint Check for leakage (oil stain)
■
Condenser Check condition of the radiator
◆
Liquid Check use condition or change
accumulator
●
Refrigerant Check coolant condition through
the observing window
◆
Air conditioner Check for the installation condition
部
body of the body (no looseness)
◆
务
System seal Check car-body and air conditioner
sealing
业
■
Compr Electromagnetic Check clutch movement
外
essor clutch
◆
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Belt Check belt for intact and tightness

◆
Fixing bracket Check installation and fixing
司
condition
公
●
Compressor Check running noise
销
running
■
营
Electri Electrical wire Check wire wear and intact

■
cal Joints Check contact and intact
■
system Control switch Check contact and intact
12.3 Notes on use
12.3.1 Safety notes
● Refrigerant R134a is a strong volatile chemical substance; contact with skin will cause
frostbite, so wear gloves when using refrigerant R134a.
● Immediately wash with water if the refrigerant comes into eyes. Wear protective glasses
and gloves in order to protect eyes, and do not rub eyes with hands or handkerchief.
● Refrigerant R134a has high-pressure, so there shall be no fire, or flammables around the
area, do not place the refrigerant container in dry hot place. Make sure the storage
temperature is below 52℃.
(Note: storing the refrigerant in dry hot place may cause crack or explosion.)
12-4
The surrounding environment shall be clean and dry, if moisture and foreign matter is
mixed into the refrigerant, it may damage the air conditioning system.
● Prepare a refrigerant leakage detector to check refrigerant leakage. Collision of
Refrigerant R134a with the flames of the perceptron will produce toxic gas, therefore, pay
attention to personnel safety protection.
● Use Refrigerant R134a when loading the crane. Other refrigerant will cause damage to the
air conditioning system.
● The refrigeration oil PAG100 in the compressor can quickly absorb moisture in the air,
pay attention to the following points:
(1) When removing air conditioner parts, cover with caps immediately in order that the air
conditioning system will not absorb moisture in the air.
(2) Do not remove the block cap before the assembly is complete.
部
(3) In order to protect the air conditioning system, preventing it from absorbing moisture in
务
the air, all the parts shall be completely connected to form a closed loop as soon as
业
possible.
● If there is sudden refrigerant leakage, ventilate the operating site immediately before
外
accepting service.
海
12.3.2 Notes on parts installation and replacement

司
● Completely empty the refrigerant before removing the connection parts.

● In order to prevent foreign substances and dust, use plug cap to cover the connector when
公
the air conditioning parts is packaging.

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● Do not open the sealing cover before installing new parts.

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● The connecting parts shall be resealed before connection.

● Check and adjust belt tightness.
Apply a pressure of 10kg in the middle of the belt to check belt tightness.
Belt tightness degree: new belt: 10mm-11mm old belt: 11mm-12mm.
Unscrew the nuts and readjust the belt if it does not comply with the above requirement.
● Refill refrigeration when changing air-conditioning accessories or checking the
refrigerant.
12.3.3 Notes in use
● Keep providing fresh air into the cab for long-term use.
● Do not set the temperature too low.
● In order to lubricate the compressor, operate the air conditioning equipment 10min at least
once a month.
● When the air conditioner filter is blocked, the air volume will be reduced, and the power
12-5
will drop. So check the filter once every 3 months, clean or replace the filter if necessary.
(1) The inner filter element- remove: gently lift the filter hook, take out the filter for
cleaning or replacement.
(2) The outer filter element- remove: loosen the upper and lower hitch, take out the outer
filter for cleaning or replacement.
12.4 Heating
12.4.1 Heating from air conditioner
Use engine cooling water for cab heating.
The cooling water flow sent to the cab heating system is controlled by a thermostat.
The warm air volume is regulated by 3 gear blower switch.
12.4.2 System emission
The water circuit for auxiliary heating is within the engine circuit; so when emptying the
部
engine cooling water, the water in the heating system will also be emptied.
Carefully empty the water in the system; the fastest way is to empty water in the engine and
heating system at the same time.
务
业
Note
外
Shut off the main switch of the battery only after the heater stops.
海
If carry electrical arc welding on the crane, remove the positive and negative battery
cable of the battery from the vehicle and the crane, in order to protect the heating
司
control device. Connect the positive cable to the vehicle’s earth wire.
公
Only after the heating device stops running can the main switch of the battery (on the
销
battery case) be turned off. In summer, the auxiliary heating device should be operated
once a month, about 15-20minutes each time.
营
12.5 Common trouble shooting

Table 12-02 air conditioner common troubleshooting
Trouble Phenomenon Cause Measurement
Refrigeration Abnormal 1. Water in the system will cause ice Change liquid
intermittent stop or start block in expansion valve accumulator, empty
operation of again
refrigeration 2. Thermostat disorder Adjust by filling
dielectric
3. Poor earth connection Check and repair
4. Poor contact of control switch Check and repair
5. Poor contact of relay Check and repair
Increase in Abnormal 1. Too loose belt Adjust or replace
noise sound from 2. Loose compressor strut Adjust
the system 3.Loose evaporation fan wheel Adjust
4. Clutch slip Repair or replace
5. Wear inside the compressor Repair or replace
12-6
Insufficient Heating wind 1. Valve not open Open valve

heating not hot 2. Block in pipeline Repair
enough 3. Not high temperature of heating Open when the
medium temperature goes up
4. leakage in pipeline Repair or change
No Evaporator 1. Compressor clutch
refrigeration fan is normal, a. Coil open or short circuit Replace
the b. Clutch slip Repair or change
compressor 2. Thread end disconnection Check and connect
does not work 3. Belt break Replace
4. Pressure switch movement
a. Too much refrigerant leakage
Check leakage,
supplement
b. Charge too much refrigerant Release a certain
amount
c. Switch damage Replace damaged part
5. Thermostat damage Replace damaged part
部
Evaporator 1. Too much refrigerant leakage Check leakage,
fan is normal, supplement
the
compressor 务
2. Refill too much refrigerant Release a certain
amount
业
works 3. Compressor damage Repair or replace
外
Bad cooling The 1. Poor earthing Check and repair

effect compressor 2. Fuse broken Check and replace
海
does not work 3. Power switch damage Check and replace

Evaporator 1. Fan damage Replace
司
fan is not 2. Fuse broken Replace

operational, 3. Wind volume switch damage Replace
公
the 4. Speed regulation resistance Replace

compressor damage
销
works
Insufficient 1. Import and export block Remove the
营
evaporator air obstruction

volume 2. Air outlet port block Remove the
obstruction
3. Evaporator frost Repair
Evaporator 1. Loose belt Adjust
fan normal 2. Insufficient coolant due to leakage Check leakage,
supplement
3. High high pressure and low
pressure
a. Condenser heat sink block due Clean
to dirt
b. Condenser fan stop Repair or replace
c. Charge too much coolant Release a certain
amount
d. Air in the system, pressure Check, release and
gauge jitter supplement
e. Too much opening of Adjust or Replace
expansion valve
12-7
4. High high pressure and low
pressure
a Expansion valve block due to Clean or replace
dirt
b Liquid accumulator block due Replace
to dirt
c High pressure pipeline block Repair or replace
5. Cooling system valve open Repair or close
Bad cooling Normal 6. High high pressure and low low
effect evaporator pressure
fan a. Insufficient coolant due to Check and
leakage supplement
b. Too small expansion valve Adjust or Replace
opening degree
c. Low pressure pipeline block Repair or replace
d. Evaporator block Repair or replace
Bad cooling Evaporator fan 7. Low pressure low pressure, high
effect normal pressure and low
部
a. Compressor failure Repair or replace
务
Note: the use of air conditioning refers to Air Conditioner Manual.
业
外
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公
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12-8
XGC55 Crawler Crane Maintenance Manual Operator’s Cab
13. Operator’s Cab
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务
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外
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公
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13-1
Operator’s Cab XGC55 Crawler Crane Maintenance Manual
13. Operator’s cab
Sprayer
Wiper
部
务
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Sliding door
外
海
司
13.1 Check wiper

公
Please check wiper once a weak.

销
Note
Refill a suitable amount of antifreeze into the water depending on the temperature
营
before winter.
It is strictly prohibited for wiper to dry scrape (i.e. swing without water spray),
because too much dray resistance will burn the wiper motor.
13.2 Refill water into the spray bottle of the windshield glass washer
Check water nozzle position and water level in spray bottle.
Note
Often refill water into the spray bottle, and add a small amount of cleaning agent.
13.3 Check the sliding door
If the crane is operating near the ocean or in humid area, please open the sliding door once
every week, in case the sliding door is not easy to open due to the humidity.
13.4 Check pilot control
Check pilot control and brake pedal for damage, observe if the movement is smooth.
13-2
XGC55 Crawler Crane Maintenance Manual Operator’s Cab
13.5 Check rotary brake

In order to ensure the normal work of the rotary brake, check rotary brake and the operating
handle before operation.
13.6 Check switch, button and handle
Check each switch, button and handle before operation.
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外
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公
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13-3
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公
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外
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务
部
XGC55 Crawler Crane Maintenance Manual Others
14. Others
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外
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公
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14-1
Others XGC55 Crawler Crane Maintenance Manual
14. Others
14.1 Inspection and maintenance of hoist hook block
14.1.1 Inspection of hoist hook block
Monthly check hook block for distortion, wearing and corrosion. The checking items are as
follows:
1） Crack on the surface: no crack is allowed on the surface of the hook head.
2） Distortion:
a. Check hook head’s opening degreeα 2 or measuring length y (see Fig.14-01), the value
shall not exceed 10% than the actual dimension of unused hook head; no visible
permanent distortion on hook shank, nut and side plate.
Hook neck
部
务
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Mark
GB/T 100512
外
Mark
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Measurement length y
司
公
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Fig. 14-01 hook block inspection

b. Check the tensional deflection of hook head. The torsion angleα (see Fig. 14-01) shall not
exceed 10°.
c. No plastic deformation is allowed on the hook handle. If any plastic deformation is
observable with eyes, please contact our service department.
3) Wear: the wear allowance △S of the hook head(see Fig. 14-01) shall not exceed 5% of the
basic dimension.
4) Corrosion: the thread of hook head shall not corrode;
5) Don’t weld hook head flaws.
6) Pin shaft: no deformation or crack;
7) Check for deformation, looseness or missing hook bolts;
8) Check hook reeving rope for corrosion or wear. The reeving of hoist rope shall be carried
14-2
out strictly according to the reeving diagram in the Operation Manual.

9) Sheave inspection
Inspection items:
 Check all sheaves for crack, dents and other similar damages, and replace sheave
immediately if there is such damage;
 Check all sheaves for wear, replace sheave immediately if it exceeds the max. wearing
degree;
The max. wearing degree standard (see Fig. 14-11):
Max. length of bottom surface “X” is 3mm; “X” equals the difference between new bottom
surface and actual bottom surface.
Max. length of side surface “Y” is 5mm; “Y” equals the length between new rope and sheave
surface.
部
10) Inspect bearing:
Monthly check bearing, and inspection items include:
 务
业
Lubricating grease.
 Bearing end sealing.
外
 Spring retaining ring.

海
 Operation noise and swing resistance.

司
 Bearing clearance.
Danger
公
Please replace the bearing immediately if there is defective on the bearing of the
销
corresponding sheave.
营
Please replace the retaining ring immediately if there is defective on it.

Danger: if one of the above phenomena appears, it may cause serious accident, please
immediately contact our service department.
14.1.2 Lubricate hook block
14.1.2.1 Lubricating position
Lubricate sheave rope groove, sheave bearing and hook head bearing, beam. The lubrication
cycle refers to the instructions in the “maintenance list”.
14-3
Fig. 14-02 hook block lubrication

Danger
部
Danger of being dragged.
务
Be careful when carrying out maintenance, inspection and installation work, there
is danger of being involved or dragged between sheave block and wire rope.
业
14.1.2.2 Lubricate sheave bearing
外
Lubricate bearings through oil cup (Fig. 14-03):

海
Sheave structure wearing degree bearing lubrication

司
Sheave body bearing ring

Sheave Steel rope
公
Oil cup
销
营
Fig. 14-03 sheave wearing and bearing lubrication

14.2 Lubricate boom pin shaft and sheave bearing
Lubricate pin shaft between turntable and boom pivot.
Lubricate pin shaft between turntable and gantry pivot.
Lubricate pin shaft between gantry and luffing sheave group pivot.
Lubricate pin shaft between connection insert, boom single top and fixed jib pivot.
Lubricate connection pin shaft between boom sections.
Lubricate bearing of boom head hoist sheave block.
Lubricate bearing of boom head guide sheave block.
Lubricate bearing of boom single top hoist sheave block.
Lubricate bearing of fixed jib head hoist sheave block.
Lubricate bearing of fixed jib head strut guide sheave block.
14-4
Lubricate bearing of gantry sheave block.

Lubricate bearing of luffing sheave block.
Note
Lubricate all connection pin shafts in the corresponding pin shaft holes before
crane assembly.
部
务
业
Fig. 14-04 lubrication of boom pin shafts and sheaves
外
14.3 Wire rope

海
Note
Wire rope includes main/aux. hoist rope, luffing rope, boom luffing cable and jib
司
cable, etc.
公
Be careful of the wire rope on hoist winch, boom or other jibs and hook block, there
销
is danger of scratch and abrasion!

营
Danger
The outburst steel wire on wire rope is very dangerous.
The prominent steel wire may cause damage, so wear gloves for self-protection.
Danger of being dragged.
Be careful when carrying out maintenance, inspection and installation work, there
is danger of being involved or towed into the following equipment.
14.3.1 Lubricate wire rope
In the manufacturing process, lubricate the wire rope thoroughly, which will not only keep the
wire rope from rusting, but also improve the coefficient of friction of the wire steel inside the
wire rope, between wire rope and sheave block or between wire rope and drum. The effect of
initial lubrication can only last for a short time, so regular and repeated lubrication according to
the specific working condition is very necessary, especially on the bending parts. The service life
14-5
of wire rope will be shortened if it is not be lubricated before operation, so pay close attention to
condition of wire rope.
The effect of lubrication and repeated lubrication on service life of the rope refers toFig.14-05.
X: bending number interval (%)

Y: tension stress (N/mm2)
A: lubrication and repeated
lubrication
B: lubrication
C: degrease
Fig. 14-05 effect on rope service life with different lubrication methods
Often apply oil during operation to extend the service life of wire rope and prevent wire rope
部
from rusting.
Note
务
Lubricate the wire rope from the start, not after damage has been found.
业
Comply with all existing standards or national regulations.
外
海
司
公
销
Use brush Use cotton gauze Use cotton gauze

Fig. 14-06 ways of applying oil on wire rope
营
14.3.2 Clean wire rope

Often clean the outside of the dirt wire rope, especially for wire ropes in highly corrosive
environment, or near material with strong chemical activity.
14.3.3 Check wire rope
The wire rope is a kind of basic consumable with service life. Many properties of wire rope
will change over its entire service life. For example, the breaking force will increase at the
beginning, but it will rapidly decrease after it is beyond some max. value.
The reason for breaking force decrease is the increase of the percentage of metal loss caused
by wear and corrosion, which is produced by rope strand breaks and structural changes.
14.3.3.1 Interval
Standard ISO 4309 recommends daily visual inspection on wire rope and the tightness
condition of wire rope end, to prevent any possible damage. In addition, the regular safety
14-6
operation inspection shall be done by trained professionals.

After the wire rope bears huge load or expected invisible damage, correspondingly reduce
inspection interval (once several hours if necessary). Carry out this inspection when the wire
rope is to be sued after a long time, before the crane is started after it is disassembled and
transported to a new place, after an accident, damage the related condition.
14.3.3.2 Inspection scope
The life of wire rope depends on the operating condition of the crane, hoist wire rope must be
regularly inspected very strictly, replace the wire rope immediately once damage is found.
14.3.3.3 Inspection
● Daily inspection: check on all visible parts of the wire rope each working day, in order to
detect damage and deformation in time, special attention shall be paid to the fixing parts
between wire rope and the crane, report if any significant change is found, find the cause
部
and solve the problem timely.
务
● Regular inspection by supervisors [inspection requirement on general parts and rope end
业
position (except rigging)].
The following point shall be considered to determine inspection period:
外
a. National regulations on the crane.

海
b. Crane type and working environment.

司
c. Crane working class.

d. Test results of several beforehand inspection.
公
e. Wire rope use time.

销
● Special inspection on general parts and rope end position (except rigging)
营
a. Carry out an inspection on wire rope when damage on wire rope and (or) its fixing
end causes accident or the wire rope is removed and installed for use again.
b. Check wire rope before using the rope when the hoisting gear is out of service for
more than 3 months
● For wire rope that is used independently or used on sheave block of synthetic material,
metal material or embedded with synthetic sleeves, when obvious broken steels or wear is
found, there may be much more broken steels inside the wire rope. Therefore, formulate a
wire rope inspection schedule according to the past usage data, not only consider the
routine inspection, but also consider the detailed wire rope inspection records.
Special maintenance shall be done to the maintenance on the partial rope segment of dry
lubricant or deterioration. The discard standard for wire rope of special lifting equipment
shall depend on the exchanged information between lifting equipment manufacturer and
steel wire rope manufacture.
14-7
● Inspection on general part:

Although the wire rope shall be fully checked, but the following parts shall be paid
special attention to:
a. The start and end part of wire rope moving and fixing.
b. Rope segment that goes through sheave block and wind around sheave. Pay special
attention to this segment during repeated operation.
c. Rope segment locate on the fixed sheave.
d. Rope segment of wearing due to external factors.
e. Internal inspection on corrosion and fatigue.
f. Rope segment in thermal environment.
● Check rope end (except rigging)
a. Check on the rope segment from the fixing end, because the fatigue (broken wire)
部
and corrosion on this segment is very dangerous. Also check on deformation or wear
on the fixing device itself.
b.
务
Carry out similar inspection on the rope end fixing device of pressing or forging rope
业
hoop, and check if there is crack in the rope clamp material and if there is possibility
外
of slide between rope loop and wire rope.

c. Check the inside rope segment and broken wire in the rope end of the removable
海
device (wedge joint, cable clamp, clamp plate, etc.), and to ensure tightness of wedge
司
joint and wire rope clamp, also check if the rope end device is completely in
公
accordance with requirements of relevant standards and procedures.

销
d. The weaving annular buckle type rope end shall be only on the end of the joint, to
prevent the protruding rope end from injuring hand. Visually check on the broken
营
wire for other parts.

e. If the broken wires is on or near rope end device, shorten the rope and reuse it, and
the wire rope length must meet the requirement of minimum number of laps around
the drum.
14.3.4 Replace wire rope
Replace rope according to condition of broken wire, wear and corrosion, replace the rope
immediately and do not use it any longer if one of the following occasions occur:
● Broken wire: more than 10% broken wire in one lay length (except filled steel).
● Broken rope: when broken wires occur on or near rope end, even few broke wires means
the stress is very strong on this part, cut off the broken parts and reassemble the rope if
rope length permits.
● Local concentration of broken wire: if the broken wires are concentrated in a rope length
14-8
less than 6d (d: wire rope diameter) or in any one of the strands, even if the number of
broken wires rarely.
● Increase of the broken wire rope: after the wire rope is used for a period of time, the
broken wire occurs, and the number gradually increases and the interval decreases.
● Broken strand: decrease of rope diameter due to rope core damage when the whole rope
strand breaks.
● The reduction of elasticity: rope diameter decrease, wire rope lay elongation, wire rope
pressing with each other, and lack of space between the rope wires, this phenomena is
called elastic reduction. Wire rope with this phenomena shall be immediately discarded
even there are no broken wire, since it will cause sudden break under the influence of
heavy load because the wire rope will not bend easily.
● Corrosion: when the steel cable diameter decreases more than 7% due to external wear or
部
corrosion, it will decrease wire rope static breaking force, and reduce operation stability.
务
● Wear: wire rope wear can be internal wear or external wear. The cause of internal wear is
业
the rubbing movement between cable strand and cable when the rope is bent downward or
upward; cause of external wear is the movement between wire rope and sheave, or drag of
外
the wire on the ground.

海
● Insufficient or lack of lubrication and dust will aggravate wear. If the wire rope diameter
司
decrease by 10% or more compared with the nominal diameter, replace the wire rope even
there is no fracture.
公
● Deformation: wire rope deformation is visible wire rope structure change. Deformation
销
usually results in looseness in the deformation zone.

营
Table 14-01 wire rope exterior deformation

Deformation Figures Description Notes
type
Spiral If deformation
X has reached 1/3
deformation
d or more (d is
wire rope
nominal
diameter) ,
replace the rope
Spherical Spherical will occur Replace the
if the cable external wire rope if this
deformation
bearing shaft loose or formation occurs.
the outer strand is
longer than the inside
14-9
strand. Compared with
inner cable or rope
strand, the slide of the
position of outer cable
or rope strand, the
longer part will turn to
somewhere.
The One strand of cable or a Replace the wire
cluster of cables rope if the wire
formation of
protruding out of the rope changes a
cable loop wire rope structure, lot due to the
prominent like hair and formation of
facing the side of the cable loop.
sheave.
One loose If there is one loose If the cable is
cable or rope, the load loosened due to
部
cable or rope
will be transferred to rust and wear, the
务
strand the outer cable of the wire rope shall be
rope or strand, which replaced. If the
业
means that they do not looseness is
bear their assigned caused by other
外
tension, resulting reasons,

海
overloading on other determine

cable or rope strand. If whether to
司
the wire rope moves on replace the wire

公
the sheave, it will cause rope according to

increased bending the situation.
销
tension, resulting in
cable premature rupture.
营
Knot The knot is repeatedly Replace wire

thickened in a long rope with
period. In these parts multiple knots.
the inserted objects
often poke out of the
wire rope, wire rope
strands are piled up,
forming an arch,
resulting in cable
rupture.
14-10
Shrinkage Shrinkage refers to the Replace wire

reduction of the rope with
diameter of the steel multiple
wire rope in the short shrinkage.
direction of extension,
the wire rope end parts
must be carefully check
the fastening part in
front of the non
shrinkage, the shrinkage
is hard to find.
Flatten Flattening is wire rope Flattening will
permanent deformation cause increase in
caused by pressure loss. cable brake.
部
Bending The bending fracture of Replace wire
wire rope is caused by rope with one or
fracture
务
directly pull small holes multiple bending.
业
rope loop of the wire
rope, wire rope does not
外
offset this deformation

by rotating around its
海
axis.
司
Bend Wire rope bending is Please replace the

caused by large external bended wire rope
公
effects. immediately.
销
营
Crimp type Crimp type deformation Replace wire

is caused by pulling rope with crimp
deformation
bearing wire rope on the type deformation.
marginal side.
Others (A) Increase rate of Replace the wire
permanent elongation. rope immediately.
(B) The rope diameter is
decreased, including
that caused by rope core
damage.
Fatigue is the main cause of wire rope damage on some occasions, in addition to the above
items. Internal broken wires still exist even the defects cannot be detected from the outside.
Therefore, replace the wire rope when no defects are detected from the above inspection and the
wire rope has reached the replacement period, working for 2000 hours.
14-11
14.3.5 General notes on operation and installation

14.3.5.1 Transport
Wire rope may be damaged even during delivery period: the rope surface will be damaged if
the forklift fork moves under the shaft or into the rope strand. No direct contact between wire
rope and hook or fork truck when transporting bundles of wire rope or coiled wire rope. Use
lifting tape, and the best way is to use the rod of the central axis of (Fig. 14-07).
部
务
业
Fig 14-07 wire rope transport Fig. 14-08 rope braking by lateral pulling
14.3.5.2 Rope storage
外
The wire rope shall be stored in a dry, cool, shaded and clean place. The wire rope shall not be
海
placed directly on the ground, but on the pallet. If the wire rope is not stored inside the house, at
司
least cover the rope to avoid moisture. The plastic film has good rainproof function, but
condensed water may form under the film, therefore the rope maybe permanently damaged
公
because of rust. This can be solved by adding a layer of burlap cloth in the middle.
销
The general rule is that the FIFO when storing a large amount of spare parts, and this also
营
applies to the use of wire rope, which can avoid the situation that the rope is not be used until
many years later.
14.3.5.3 Rope installation
Make sure the rope is reeved onto the system from shaft or bundled rope, so that all rope is to
be reeved and not damaged from outside.
The best way to prevent rope twisting is to pull out the rope using pallet or from the ground.
The ground shall be clean, since wire rope will be damaged if there is sand or soil in rope grease
or between the sheave and the wire rope.
The better way to wind rope on the rotating shaft is to use pallet or bracket. Please do not roll
wire rope roll on the ground, because this method actually has no good effect.
In any case, it is prohibited to transversely pull rope from a reel or bundles of wire rope (Fig.
14-06), because resistance will form from rope to the torque acting on rope, forming a ring.
When the wire rope is under load, the ring is pulled together to form a knot, producing
14-12
unrecoverable deformation. The wire rope knot is extremely unsafe, and cannot be used and must
be replaced.
14.3.5.4 Setup program
The best way to install the wire rope varies from system to system, so choose the most
appropriate method according to typical working condition schedule, that is, the method which is
the most unlikely to cause wire rope twisting or damage by contact with the structural parts.
For some devices, it is suggested to firstly remove the old rope, and then install the new rope.
For large equipment rope reeving, use old rope to pull the new rope.
At the beginning of winding wire rope, it is suggested to use thin auxiliary rope to pull the
actual rope.
Consider the rope winding method no matter what method is used. One method is to pull the
rope onto rope winding device, and the other is to directly reeve rope from rope bundles to rope
部
winding drum, and then reeve rope by hand or auxiliary rope reeving device of wire rope. If one
务
wire rope end is not detachably connected, pull the free end (the other end) to go through the
业
rope winding device.
14.3.5.5 Rewinding
外
From point of view of the manufacturing process, each wire rope have bent trend, because the
海
rope is pulled out through the conveying wheel from the basket type stranding machine, the
司
supplied rope will bend toward this direction. When the wire rope is reeved from winding reel to
drum, the wire rope must be winded along this direction. If the rope is rewound along the
公
opposite direction, the rope may rotate between reel and drum, or later rotate in order to achieve
销
the ideal direction, which will both lead to structural change.

营
Fig. 14-09 rope reeving diagram

14.3.5.6 Pull rope using auxiliary rope
● If using removed wire rope or auxiliary rope to pull new wire rope, make sure that these
ropes have been firmly fastened and not twisted. Not twisted rope or triangle strands wire
rope is particularly suitable as auxiliary rope. If the traditional wire rope is used, at least
14-13
make sure that the twisting direction is the same with pulled rope.
● When using old rope to pull new wire rope, the two ends are often welded together. This
kind of connection will make the old wire rope distort during operation, and spread the
distort to the new rope, even cause widespread damage to new rope during the installation
process.
● The connection method that causes fewer problems is to use rope strand or thin rope to
connect the two rings or chain links that are welded on both ends of the rope. This
connection method can be bent, and has satisfying load bearing capacity, and can prevent
twisting transferring from the old to the new steel wire rope (Fig. 14-10). Through the use
of two strands, the rotation number in the strand after installation can display the twisting
degree of the old rope on the device.
● It is better to use rope socket to connect wire rope. The rope socket is a rope strand, it is
部
connected to the wire rope end, and fixed with tape. In the case of loading, the rope socket
will be pulled, and fix rope end by the friction block the rope end (Fig. 14-10).
务
业
外
海
Rope connection part use rope sleeve to connect rope

Fig. 14-10 rope connecting diagram
司
14.3.5.7 Rope reeving with load

公
To correctly wind wire rope to the drum, please wind rope in when the rope is tight, especially
销
when using reel with twisted rope groove. If the lower layer is too loose, the upper layer rope
may be pressed into the lower layer end when bearing a load, which will cause rope damage.
营
Because the pulled rope may even stick in this location, and the winding direction may suddenly
reverse, causing the lowering load suddenly be hoisted up.
A piece of board or brake on the shaft can be used to brake the wheel flange (Fig. 14-11). Wire
rope manufacturers will provide brake rope (hemp rope equipped with steel rope core). In any
case, do not attempt to press wire rope to pre-stress the rope, such as squeezing the rope between
the two planks (Fig. 14-09), which will cause unrecoverable deformation of wire rope due to
structural change (Fig. 14-11).
2%-3% min. breaking force shall be applied to rope for wire rope winding.
14-14
Fig. 14-11 reeving rope with load

14.3.5.8 Spooling in
A certain number of small loading cycles must performed, after the wire rope is installed and
before rope operation. The wire rope shall be “spooled in”, so that each part of the wire rope can
be fixed and can adapt to the new environment.
部
However, the actual situation is often the contrary: after wire rope installation, usually carry
out overloading test, and this load capacity is beyond system permissible value.
14.3.5.9 Wire rope cutting 务
业
Users often need to cut wire rope into parts or shorten the wire rope. There are many ways of
外
cutting steel wire rope.

● Wire rope cutter can be used to cut 8mm diameter rope.
海
● Mechanical or hydraulic cutter can be used to cut wire rope of larger diameter.
司
● It is recommended using pneumatic or electrical angle grinder if there is power supply.

公
Whichever way, the steel wire rope must be carefully connected to the next separation point to
销
prevent the wire rope end wear or lay length change of wire and or rope strand.
The insulating tape cannot prevent the wire rope structure change, use steel wire to bundle the
营
wire rope end.

Steps of cutting wire rope are as follows (Fig. 14-12):
● First mark the separation point with chalk or insulating tape. Put one end of the steel wire
rope length of about 4 times of the diameter along the length of wire rope, then twist
together the steel wire and wire rope at the separation point.
● Tightly wind along about 3 times of wire rope diameter the length of steel wire rope.
● Tension the wound rope with pliers, and twist together with the other end of the wire.
Shorten the twisted wire to the length of approx. wire rope diameter, then gently struck them,
so that the end of the steel wire rope get between the groove of two outer strands to prevent
accidents.
● Cut the rope after preparing the other side separation point.
14-15
Fig. 14-12 rope cutting

14.4 Lifting device
14.4.1 Hoist chain
The hoisting chain is chain assembly including one or several chains and components
connecting the upper and lower parts. According to international standards, connect the load to a
crane or lifting hook of other lifting equipment. There is risk for hoist chain in use: one is lifting
failure, load damage of heavy fall; another is the risk of personnel injury. Therefore, the correct
use and maintenance of hoisting chain is very necessary to avoid accidents, ensure the safety,
部
improve efficiency, prolong service life and reduce production cost.
The hoisting chain has the following types according to forms (Table 14-02):
● Single-limb sling
务
业
● Double-limb sling
外
● Triple-limb sling
● Quadra-limb sling
海
● Ring chain
司
Table 14-02 hoisting chain classification

公
Name Figure
销
Single-limb
sling
营
Main circle
Middle circle (use when necessary)

Extend out (length)
Connection circle
Chain
Hook or other components
14-16
Double-limb
sling Main circle
Extend out (length)

Connection circle
Chain
Triple-limb
sling
部
Main circle
务
Extend out (length)
Connection circle
业
Chain
外
海
司
公

销
Quadra-limb
营
sling
Main circle
Extend out (length)
Middle main circle
Connection circle
Chain
Hook or
other components
14-17
Ring chain
14.4.2 Use and maintenance of hoisting chain
部
14.4.2.1The correct use of hoist chain.
务
First choose correct lifting equipment before lifting load, including number of limbs, the chain
业
diameter, working load limit (WLL), if multiple limb chain is used, know the chain WLL in
different angles.
外
Follow the laws and regulations and the relevant safety standards when using the hoisting
海
chain:
司
● Do not distort or knot.

● Do not drag under load.
公
● Add cushion to avoid damage when the chain is rounding the obtrude angle of the load.
销
● Use chain regulator if necessary to prevent loading impact or imbalance.

营
● When using hook block, the load shall be applied to the lowest position of hook groove,
not directly on hook tip.
● The chain shall not be used in acidic solution and gas environment, which may lead to
chain corrosion or cause brittle chain mechanism and cracks.
If the chain has to be used in such environment, please consult the chain manufacturer.
● Do not have the chain retreat such as zinc dipping, coating, electroplating, pickling,
heating without permission of the chain manufacturer.
● When lifting important or dangerous load, the professional must carry out risk assessment,
and have corresponding adjustment to chain WLL.
Before first use, first confirm that the chain meets the order requirement, and enclose the
inspection certificate, in which the marking and WLL on chain are consistent in the certificate.
Check for damage and wear each time before use, repair and treat according to repair rule if
there is problem. The weight of the load in static state shall not exceed the WLL.
14-18
In order not to distort and overturning, the following requirements shall be complied with:
● When using single limb lifting chain, the contact point shall be vertically above the center
of gravity of the load.
● When using double limb lifting chain, the contact points shall be on both sides above the
center of gravity of the load.
● When using triple or quadra-limb lifting chain, the contact points shall be evenly
distributed above the plane around load center of gravity, and the distribution of the chain
limb shall preferably be uniform.
● When using multiple-limb lifting chain, reasonably choose chain form and contact point,
so that the chain limb angle (β) is within limit range, and all angles are better to be the
same, and angle (β) shall not be less than 15°.
The hook shall match with lifting point, so that the load is correctly within the bowl shaped
部
arc of the hook throat, avoid the hook tip.
务
When using multiple-limb lifting chain, the hook tip must be facing outwards unless using
业
special hook structure under special occasion.
For load without proper lifting point, and the chain has to go below the load for net lifting, the
外
WLL shall be reduced to 80% of the original value.

海
For double net lifting, make sure that the chain will not twist, and the angle (β) is not more
司
than 60°.
Caution
公
Chain WLL is usually based on the uniform bearing of each limb of the chain; for
销
multiple limb chain, if the angles are different, the smallest angle receives the max.
营
force. In extreme cases, the vertical single limb receives all load.
In the following cases, the load can be considered to be uniform, i.e.:
● The load does not exceed 80% of the WLL.
● All chain angles are not less than 15°.
● Angles of all chain limbs are equal or the max. deviation between each other is 15°.
● Aside from the above provisions, chain WLL shall reduce by 50%.
When the chain is in use, the chain is slowly tightened, so the hand and other body parts of the
operator shall be far away from the chain to avoid damage. After the lifting is begun, and the
chain is tightened, and the load is slightly lifted, carefully check if the chain is securely fastened
and the load is in horizontal position; for basket hanging or similar lifting condition, the load
shall be maintained at the central position by friction. For multiple-limb lifting chain, sometimes
not all chain limbs are used at the same time, for two limbs only one limb is used, the WLL shall
be reduced to 1/2of the specified value; for three limbs and four limbs, only two limbs are used,
14-19
the WLL shall be reduced to 2/3 of the specified value; for three limbs and four limbs, only one
limb is used, the WLL shall be reduced to 1/3 of the specified value. The chain limb that is not
used shall be hung back to the main ring to avoid danger during lifting.
14.4.2.2 Storage, inspection and maintenance of the chain
The chain shall be stored on special brackets, and put the lower hook end back to the upper
main ring.
The chain shall be stored in dry and ventilated place, and avoid moisture, to prevent
electrochemical corrosion of the chain, because micro cracks will appear under corrosion pits of
the high strength chain. The chain shall have anti-corrosion treatment when it is not be used for a
certain period. If the chain is hung on hook block without load, the chain hook shall be into the
main ring of the lifting chain. Avoid chain bump and damage during transport, because the
damaged chain is very easy to have stress concentration, resulting in early fracture.
部
Remove the dirt, oil and corrosion before inspection on chain. The cleaning method shall not
damage the basic material, and avoid hydrogen embrittlement, material wear, deformation,
cracks and other surface damage.
务
业
Have periodic and aperiodic inspection on lifting chain for damage and wear. The chain shall
外
be checked by qualified personnel at least once a year; the inspection period depends on use
condition; use instrument or equipment to do a crack inspection once every 3 years. If users have
海
doubts about chain security, immediately stop using the chain, and have qualified personnel to
司
carry out the inspection.

公
Immediately stop using the chain and have it repaired and maintained if the following defects
销
are found:
● The WLL marking or identification mark on chain is blurred.
营
● Deformation on main ring, chain and other accessories. Plastic deformation on chain ring,
the outside length is 3% longer than nominal size, and the inside length is 5% longer than
nominal size.
● Obvious limb length difference of the multi-limb lifting chain.
● The hook has widened signs, such as hook opening size increases significantly. Hook
throat opening size shall not increase beyond 10% of the nominal size.
● The hook bowl wears more than 5%.
● The chain diameter decreases more than 10% due to the wear between chain rings or
between chain ring and other objects(the average value of the two measured values at
right angles to each other) The diameter of the main ring, middle ring, the transition ring
and end ring reduces due to wear > 15%.
● The surface conditions, such as incision, nicks, grooves, cracks, excessive corrosion,
14-20
color change due to heat, chain bending and discoloration due to heat or other defects.
● All the spare parts of the chain must conform to the state or international standards. If one
ring of the chain limb to be replaced, then replace the entire limb. Welding work on the
chain shall be carried out in the factory.
● The chain must be replaced if there is crack, obvious deformation and serious corrosion.
Small defects, such as furrow, gap can be eliminated by careful grinding. The repaired
cross section after grinding is not less than the specified value. If the repaired element is
the element access to mechanical connection, and this element has been tested by the
manufacturer according to the relevant standards, and have inspection certificate, then it
does not need to be going through load test again.
14.4.3 Operation requirement and detection of the sling
● The sling hoisting load shall not exceed the rated load.
部
● The larger the angle between limb and plumb line, the larger the bearing load, if the angle
务
exceeds the limit value, it will result in danger of sudden rupture due to partial overload.
● The angle between chain limb and plumb line shall not exceed 60°(i.e. the angle between
业
the corresponding limb shall not exceed 120°). Fig. 14-13 shows the corresponding
外
relationship between load on limb and angle when the chain is lifting a 10t load.
海
● To prevent the hanging weight lifting overturning or sliding, the hanging point shall be
司
right above the center of gravity, or the angle α between chain limb and horizontal line is
larger than angle β between load center of gravity and the bolt hanging point line and a
公
horizontal line; for multi-limb chain hoisting, in order to ensure lifting stability and
销
balance, the angle between each limb and the plumb line shall not be less than 15°, that is,
营
the angle between corresponding limbs shall not be less than 30°(Fig. 14-12).
Fig. 14-13 sling use requirement

● It is strictly prohibited to use lifting device under shock and vibration conditions, severely
corrosive environment or extreme temperature (below -30℃ or above 200℃), if the
14-21
operation shall be done under the above condition, special order is needed.
Fig. 14-14 wrong using method of chain

● No torsion, twisting or knotting between chain rings, the adjacent rings shall be flexible, as
部
shown in Fig. 14-14 (A).
● It is prohibited to use non-formal connection method, as shown in Fig.14-14 (B).
务
● The load shall be hung at the bottom of the hook groove, not on hook tip. The hook mouth
业
usually shall be outward when lifting heavy load (Fig. 14-15).
外
● The bearing ring shall not directly hang on the crane hook tip or wind on the hook (Fig.
14-15).
海
● When lifting heavy load, the movements of hoist up, lower down and stop shall be slow
司
and steady, pay attention to the balance of the center of gravity of load, avoid impact load,
公
do not hang a load on chain for a long time.

● When hoist load with ring chain, the edges shall be protected with cushion pads, to prevent
销
the ring chain and suspended load damage (Fig. 14-15).

营
● Do not attempt to forcibly pull chain from under the load, or let the load roll on chain.
● The chain shall be handled with care, it is strictly prohibited to throw, drop and drag on the
ground, which will cause chain deformation, surface and internal damage.
14-22
Fig. 14-15 correct use method of chain

Chain detection standard:
● The permissible wearing value shall not exceed 10% of the ring chain bar diameter or aux.
device thickness, the chain shall be discarded if the value exceeds;
● Count from the plane that he main ring does not bend, if the main ring bending degree
exceed more than 10°, it shall be discarded;
● It is prohibited to continue to use the chain if crack, bending or distortion appear on any
part of the chain and clog among ring hinges or stiff obstructed resistance and this
phenomenon cannot be excluded;
● The permanent elongation of chain and single ring shall not exceed 5% of the original
length (Fig. 14-16);
部
务
业
外
海
司
Chain ring inspection hook head inspection

公
Fig. 14-16 inspection on chain and hook head

销
Standard of hook discard

营
● Cracks on hook bearing components.

● Wear or corrosion on dangerous section reaches 5% of the original size;
● The twisting angle of hook body exceeds 10°;
● Hook opening degree increases 10% than the original size (Fig. 14-16).
Caution
Repair or re-process the lifting sling (such as welding, heating, heat treatment,
surface chemical treatment etc.).
Hook anti-fall clip must be able to keep the loose tapes and slings on the hook; tapes,
slings, and aux. device shall not be hung on the clip, and make sure that the anti-fall clip
does not bear any load.
14.5 Inspection and maintenance of pendants (rod)
Pendants (rods) must be checked before assembly.
The inspection must be thorough, including hidden surface and inner hole.
14-23
14.5.1 Inspection contents

● Crack
Regularly pendants (rods) for crack, one surface crack test at least once year, such as test by
magnetic particle. Replace the pendants (rods) immediately if there is crack.
It is prohibited to repair pendants (rods), especially repair by welding.
● Elongation
Check and measure the elongation value of pendant (rod). The max. allowable elongation value
is 0.2% of the whole length(theoretical distance between the connecting pin shaft holes).For
example, the max. allowable elongation 12mm for 6000mm pendants.
● Wear
Check the internal hole and pin for marks of wear and abrasive grinding, including the spring
bracket and open pins used to fix pins.
部
● Paint damage
Regularly check pendants for damage and corrosion. If there is corrosion spots, it must be
务
recoated. No corrosive agents (such as sea water) shall be stored on pendants.
业
● Plastic deformation
外
Do not use pendants (rods) with plastic deformation, immediately replace pendants with plastic
deformation.
海
14.5.2 Inspection
司
The pendants shall be inspected by experts at least once a year.

公
If necessary, check according to job site conditions and actual operation situation. The
销
inspection interval varies with the operating conditions, if the operation is frequent, the inspection
interval shall be shortened.
营
Caution
Do not use damaged pendants, immediately replace the pendants if there is damage,
otherwise it will cause a serious accident.
14-24
XGC55Crawler Crane Maintenance Manual Use and Replacement of Oil and Grease
15. Use and Replacement of Oil and Grease
部
务
业
外
海
司
公
销
营
15-1
Use and Replacement of Oil and Grease XGC55 Crawler Crane Maintenance Manual
15. Use and replacement of oil and grease

15.1 Overview
Regular refilling and replacement of hydraulic oil, gear oil, grease, engine oil and coolant is
necessary to ensure crane normal operation and prolong the service life.
Table 15-01 fuel, lubricating oil, grease and coolant of transmission system
Refilling position Qty.(L) Grease／coolant
Engine 18 Refer to requirement on grease and lubricant in
Cummins (or Weichai) Engine Operation and
Maintenance Manual.
Main hoist winch reducer 3 Industrial gear oil 220LS2(40℃)
Aux. hoist winch reducer 3 Industrial gear oil 220LS2(40℃)
Main luffing winch reducer 3 Industrial gear oil 220LS2(40℃)
Travel reducer 9 Industrial gear oil 220LS2(40℃)
Slewing reducer 7 Industrial gear oil 220LS2(40℃)
Hydraulic system (with tank) 400 Normal temperature: L-M46 anti-wear hydraulic oil
部
High temperature region: L-M68 anti-wear hydraulic
oil
务
Low temperature region: L-HV32 low temperature
业
anti-wear hydraulic oil
Fuel system 400 0# or 10#
外
Slewing bearing 1.6 2# molybdenum disulfide lithium grease

Cooling system 25 Coolant (anti-freezing temperature is -35℃)
海
● The specified capacity is approx. value. In order to obtain the accurate capacity, the
司
maintenance personnel shall carefully check the inspection point, inspection plug, oil
公
dipstick, and observation window.

Table 15-02 grease lubrication table of sheaves and hinge points
销
Refilling position Lubrication Lubrication method Lubrication

interval (hour) grease
营
All sheave shaft, sheave and 250 Grease gun and smear
sheave block 2#molybdenum
disulfide lithium
Boom base pivot shaft 250 Grease gun and smear
grease (in summer)
Fixed jib butt hinge shaft 250 Grease gun and smear
3# molybdenum
Main luffing mast hinge shaft 250 Grease gun and smear
disulfide lithium
Fixed jib strut hinge shaft 250 Grease gun and smear
grease (in winter)
Wire rope 250 Grease gun and smear
Slewing bearing 250 Grease gun and smear
For every
connection pin shaft between
assembly/ Smear
track frame and car-body
disassembly
For every
Boom and pendant pin shaft assembly/ Smear
disassembly
15-2
Notes for grease filling:

● The grease shall comply with the requirements. Lubricating grease is mineral high quality
grease, it shall neither liquefied when the temperature rises nor condensed below freezing
point.
● Clean oil nozzle before refilling oil, keep grease and oil gun clean.
● Use grease with unified brand, do not mix with other brands of oil.
● Smear lubricating oil on wire rope to prevent rope rust.
● The crawler connecting pin shall always be poured with oil (waste oil is also OK).
● The electrical device must not be stained with grease.
部
务
业
外
海
司
公
销
营
15-3
hook beam
部
boom head sheave block
务
业
main/aux. hoist and luffing rope
外
海
hook sheave block and beam

司
公
boom pin shaft

销
营
cable(pendant)pin shaft
luffing winch
aux. hoist winch
main hoist winch

luffing sheave block and shaft
boom base pivot point
guide roller
drive roller swing bearingconnection position between car-body and track frame
Fig. 15-01 main lubricating position
15-4
15.2 Recommended list of common oil grease

Table 15-03 recommendation table of engine fuel
Temperature(℃)
-40 -30 -20 -15 0 10 20 30 40 50
Brand
10#
0#
-10#
-20#
-35#
● Under most operation conditions, using ASTH2 fuel and diesel with min. octane number
40 will be the most economical and get the best performance.
● For area with high altitude or extremely low temperature, use diesel with octane number
more than 40 to prevent flame out and too much smoke.
部
● More use low sulfur fuel, the cloud point at least lower than the min. expected fuel
务
temperature 10℃.
● Cloud point is the temperature that the wax crystal starts to form.
业
● Use common commercial diesel, the sulfur content shall be less than 0.5%.
外
● When refueling, keep oil clean and free of moisture and impurities.
海
Table 15-04 recommendation table of engine oil

Temperature(℃)
司
-40 -30 -20 -15 0 10 20 30 40 50

Brand
SAE15W-40
公
SAE10W-30
销
SAE 5W-30
● It is preferred to use high quality lubricating oil, the recommendation quality grade is CH-4
营
and CI-4.
● High viscosity lubricating oil will improve oil consumption, improve engine operation in
cold weather and maintain lubrication at high operation temperature. In most weather it is
recommended to use SAE15W-40 engine oil.
● Low viscosity oil can be used conditionally, such as SAE10W-30. When the ambient
temperature is lower than -5℃, it can help crane start and provide adequate oil flow.
However, long-term and continuous use of low viscosity oil will reduce engine service life.
Table 15-05 recommendation table of industrial gear oil
Temperature(℃)
-40 -30 -20 -10 0 10 20 30 40 50
Brand
220LS2
15-5
Note
This product is a full hydraulic drive, the quality, viscosity and cleanliness of the oil
is very important for crane normal work. Negligence of the replacement and refilling
of oil will lead to a variety of mechanical failure, and seriously shorten the service life.
Use hydraulic oil, lubricating oil and grease of the same brand; it is strictly
prohibited to mix with different brand of hydraulic oil, lubricating oil and lubricating
grease.
If consumables do not meet these standards, it will cause crane damage, and the
manufacturer assumes no liability even during the warranty period.
Please turn off the engine before lubrication, and wipe oil cup, oil dipstick and the
oil surface to be smeared.
● The temperature in the table refers to the environmental temperature where the crane is,
部
please choose suitable hydraulic oil according to the environmental temperature.
● The application scope of L-HM46 anti-wear hydraulic oil is wide, and it is used for
temperate regions. 务
业
● L-HV32 low temperature anti-wear hydraulic (oil pour point -42°, used in extremely cold
外
regions (-30℃ and below), such as Russia, northeast China and other places.
海
● L-HM68 anti-wear hydraulic oil is commonly used in tropical regions such as the Middle
East and India, etc.
司
● Please choose suitable hydraulic oil according to the working region of the crane. We are
公
responsible to refill appropriate hydraulic oil (paid) before delivery, and the user is
销
responsible for oil replacement after the crane is out of the factory. The user can consult our
customer service staff for correct hydraulic oil specification and trademark.
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● When working under ambient temperature below 0℃, the following temperature raising
operation must be carried out to ensure safe operation of the hydraulic system:
(a) Start the engine, idle for 7min-10min then improve the speed to 1000rpm-1200rpm, do
not carry out any operation to the crane, run with no load for 30min-40min or longer to
rise hydraulic oil temperature until it is higher than 20℃.
(b) Carry out normal operation after the above temperature heating operation is completed,
and at the same time adjust temperature rising time according to the ambient temperature.
In normal operation, the operation movement of handles and pedals shall be slow, and
pay close attention to the operating condition of the system. Hydraulic oil temperature
below 20℃ may damage the hydraulic components.
15-6
Table 15-06 recommended table of hydraulic oil

Temperature(℃)
-40 -30 -20 -10 0 10 20 30 40 50
Brand
L-HM46 anti-wear
hydraulic oil
L-HV32 low temp.
L-HM68 anti-wear
hydraulic oil
● Start the engine with no load after it reaches the lowest start temperature when starting the
crane in cold region, after the no-load operation system reaches the min. operating
temperature, slowly hoist load to keep the system running at the lowest load temperature.
● Real-time measure and check system oil temperature.
● Suitable oil temperature for hydraulic system working is 20℃ -80℃, short time or local
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max. oil temperature shall not exceed 85℃.
务
● When the temperature is close to 80℃, pay special attention to system heat radiation, do
not adjust the working load and frequency too frequently.
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Table 15-07 grease recommendation table
外
Season
In summer In winter
海
Name
2# lubrication grease
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3# lubrication grease
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● The max. working temperature of lubrication grease is 20℃－30℃ lower than its
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dropping point
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15.3 Lubrication and oil replacement

15.3.1 Hydraulic oil
The hydraulic oil tank is filled with hydraulic oil before delivery. Please replace oil
periodically according to the operation requirement.
15.3.1.1Hydraulic oil inspection and replacement interval
● The normal replacement interval of hydraulic oil is 2000 working hours. If the oil has
obviously been polluted, it must be replaced immediately, no matter how long the running
time is.
● Hydraulic oil shall be used for more than 24 months. When the interval is more than 24
months, the oil shall not be used even after filtering.
15-7
Table 15-08 hydraulic oil inspection and replacement interval

Inspection and replacement interval
No. Inspection item Remarks
50 500 2000
Hydraulic
1 Check oil level ● 400L
oil tank
2 Clean oil tank ●
3 Replace hydraulic oil ●
15.3.1.2 Hydraulic oil (grease) sampling and replacement index

Hydraulic oil shall be regularly tested. For normal product, sample once every 3 months; for
crane working frequently under rough condition, sample once every once month. Please
immediately replace the hydraulic oil that does not meet the requirement in Table 15-09.
Table 15-09 hydraulic oil test items and limit index
Limit index of hydraulic oil physical and
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Test item Unit chemical property change
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L-HS L-HV L-HM
Kinematic viscosity (40℃) mm2/s ±10% ±10% ±10%-±15%
业
Acid value increase mgKOH/g 0.3 0.3 0.3
外
Humidity % 0.1 0.1 0.1

Solid particles -- 20/16 20/16 20/16
海
contamination level
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Please refill lubricating grease by grease gun injection and smearing according to the index
stipulated in Table 15-10.
公
● Wipe oil cup and the surface to be coated before refilling.

销
● The sliding surface not listed in the table shall also be lubricated periodically.
营
● After boom is retraced onto boom bracket, if part of the boom luffing cylinder piston rod
is exposed, it shall be greased once every month.
● Sheave shaft with no cup uses self-lubricating shaft, which does not need maintenance,
and smear lubricating grease after they are disassembled.
● It is recommended to use 2# molybdenum disulfide grease in summer (grey black), and 3#
molybdenum disulfide lithium grease in winter (grey black).
Table 15-10 grease recommendation index
Parameter Dropping Penetration Moisture
Appearance feature
Type Point(℃) degree (1/10mm) value
2# lubrication Light yellow to brown
≥175 265-295 -
grease smooth ointment
3# lubrication Light yellow to dark
≥170 310-340 -
grease brown smooth ointment
15-8
15.3.1.3 Hydraulic oil replacement procedure

● The replacement of hydraulic oil in hydraulic oil tank. Drain the hydraulic oil, remove the
total oil return pipe, strictly clean the oil tank and oil filter. First clean with chemical
cleaning agent with solid particle pollution levels not exceeding 18/15, after it is cleaned and
dried, clean with new hydraulic oil with solid particle pollution levels not exceeding 18/15,
then release the washing oil and refill new hydraulic oil.
● Start the engine, run at low speed, the oil pump is started; respectively operate the gears to
drain the used oil in the oil circuit by new oil, the drained used oil shall not flow into the
hydraulic tank, until the new oil outflows the total oil return pipe, then stop the pump.
During this process, constantly refill new oil to the hydraulic oil to prevent the pump empty
suction.
● Connect the total oil return pipe with the oil tank, set the elements to the initial state, and
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finally refill hydraulic oil until it reaches the required level.
15.3.1.4 Hydraulic oil quantity
务
● When the crane is in travel state, check hydraulic oil level and quantity by observing the
业
liquid temperature gauge calibration position. The liquid temperature and liquid level gauge
外
has double function, which can not only display the hydraulic oil level, but also hydraulic oil
海
temperature. When checking the hydraulic oil level, the level must be between the middle
司
and the top scale line, otherwise timely refill hydraulic oil.
● The highest working temperature of hydraulic oil is 80℃, short time or local max.
公
temperature shall not exceed 85℃.

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营
Filling quantity
Oil temperature
Fig. 15-02 liquid level-temperature meter

15.3.2 Gear oil
When the crane is out of the factory, the main hoist winch reducer, aux. hoist winch reducer,
the main luffing winch reducer, slewing reducer, aux. winch reducer and travel reducer have
been refilled with industrial gear oil. In order to ensure the normal use of the machine, please
15-9
change gear oil regularly according to the requirements.

15.3.2.1 Gear oil inspection and replacement interval
Repla Replace
Delivery After 250h Every 1000h
ce oil oil
date
● If the gear oil is seriously polluted, replace the oil even if it does not reach the replacement
period.
● Check the oil pressure frequently, and refill oil when the oil level is lower than the
prescribed value.
● Gear oil of different brand shall not be mixed.
● Please use the recommended gear oil according to the environmental temperature, using
substandard or gear oil with unsuitable viscosity will damage the reducer.
部
15.3.2.2 Hydraulic oil replacement procedure
务
● Unscrew the oil discharge plug on the lower part of the reducer and the oil filling plug on the
upper part of the reducer, and drain the waste gear oil.
业
● Tighten the oil discharge plug on the lower part of the reducer.
外
● Refill gear oil of the stipulated brand, until the oil level reaches the stipulated position of the
海
detection screw (or oil dipstick).

● Screw the oil refilling plug on the upper part of the reducer.
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15.3.3 Engine oil

公
The crane has been refilled with engine oil according to the requirements in the Engine
销
Operation Manual (approx. 30L).

营
15.3.3.1 Engine oil level inspection

Check the oil level on the engine before operation. The oil dipstick shall be wiped clean and
then insert into the tank. The oil level shall be within the scale line.
The crane must be located on an even ground for oil level inspection, otherwise the reading
may be inaccurate.
15.3.3.1 Engine oil replacement procedure
● Unscrew the oil drain plug under engine oil bottom shell, drain the old engine oil.
● Screw tight the lower oil drain plug.
● Refill the stipulated engine oil into the filling hole until the oil level is within the oil dipstick
scale.
● Screw tight the upper engine oil hole cover.
15-10
Note
When replacing the engine oil, the oil filter shall be replaced as well.
When the oil is hot, do not open the drain plug, to avoid scalding.
There shall be absolutely no diesel on engine cover, otherwise there is a risk of fire. To
ensure the max. cleanliness, especially when replacing a filter and gas exhaust. Spilled fuel
must be cleaned. If the filter is to be replaced, when taking off the fuel filter, it is
recommended to put some cloth to absorb the spilled diesel oil.
The oil level in the crane must be between the min. and the max. of the dipstick
marking. If the oil level is below the min. marking of the dipstick, refill oil according to the
lubrication chart until the oil level is between the max. and the min. mark; otherwise the
engine will be damaged.
Please stop the crane on a solid and even ground before checking the engine oil level,
部
since after the engine is shut down, the oil will accumulate on the oil pan.
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15.4 Lubrication and maintenance for crane in non-normal working conditions
业
15.4.1 Lubrication and maintenance for crane in cold area
Item Precaution measurements Remarks
外
Engine oil Engine oil CH-4, CI-4 andCG-4 etc. in API classification (capacity 35L)
海
suitable for this environment (see engine manual) When refilling or

Ambient temperature -10~-40℃ -35~35℃ adding engine oil,
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when starting the engine do not mix with oil

公
of different brand
Oil brand CF-4 15W-40 CF-4 10W-30
and quality level.
销
Fuel oil Fuel oil suitable for this environment (capacity 650L)
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For 4℃ and above GB252 0# light diesel Drain out water

For -5℃ and above GB252 -10# light diesel before operation,
For -14℃ and above GB252 -20# light diesel and refill fuel full
For -29℃ and above GB252 -35# light diesel into the tank after
For 4℃ and above GB252 0# light diesel operation.
Hydraulic Hydraulic oil suitable for this environment (capacity 400L)
oil Ambient temperature Type
0℃~+40℃ L-HM46 anti-wear hydraulic
oil
-30℃~0℃ L-HV32 low temperature
Lubricating Lubricating grease suitable for this environment
grease Season Type
In summer 2# lubricating grease
15-11
In winter 3# lubricating grease
Industrial Gear oil suitable for this environment Use according to
gear oil Environmental temperature Type engine filling
-20~-40℃ 220LS2 capacity
Coolant Match anti-freeze according ambient temperature(capacity (capacity 40L)
40L)
Environmental Water (L) Concentration Ratio is different
temperature anti-freeze (L) due to different
-4℃ 36.5 3.5 anti-freeze. It is
-7℃ 34.5 5.5 recommended to
use the antifreeze
-13℃ 30 10
that is already
-17℃ 28 12
matched.
-21℃ 26 14
-25℃ 24 16
部
-31℃ 22.5 17.5
-40℃ 20.5
务 19.5
业
Battery Fully charged(under low temperature, the fully charged
battery endures cold better than that is not fully charge)
外
15.4.2 Lubrication and maintenance in dusty environment

海
Item Precaution measurements

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Air filter Clean and replace in time

公
Radiator and oil cooler Clean in time, no blockage

Filter and filter element Change in time
销
Engine oil Change oil in time

营
Slewing bearing Clean and grease in time

Wire rope Clean and grease in time
15.4.3Lubrication and maintenance in seaside operation environment

Item Precaution measurements
Basic machine Carefully check all lubricating points, lubrication positions that are not
installed with oil cup. The exposed surface shall be coated as well.
Exposed oil cylinder rods shall be protected with sleeve, and ensure that
they are timely and effective lubricated.
Lubricate Clean crane body, radiator and oil cooler in time, remove salt
15-12
XGC55 Crawler Crane Maintenance Manual Crane Inspection
16. Crane Inspection
部
务
业
外
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司
公
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16-1
Crane Inspection XGC55 Crawler Crane Maintenance Manual
16 Crane inspection
16.1 Visual inspection
Visual inspection every day on the following components before starting the crane.
16.1.1 Basic machine
A. Check engine for oil leakage, check fuel for leakage or dirt or contamination.
B. Check the tightening system: check guide roller for damage, and tightening degree.
C. Check the cooling system for leakage, damage and contamination.
D. Check the hydraulic system for leakage or damage, and check oil level.
E. Check if the lubricating oil film on slewing bearing outer teeth is intact.
F. Check catwalk, guardrail and cover parts for missing, damage, looseness or missing bolts;
the safety marks shall be clear and intact.
G. Check all meters and displays for proper function, and there shall be no damage.
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H. Check travel gear for oil leakage.
I. Check the lubricating oil film on wire rope for intactness, and check wire rope for
damage.
务
业
J. Check connecting pins for damage.
外
海
司
公
销
I
营
H A C D E F G B
Fig. 16-01 crane inspection parts
16-2
16.1.2 Operating boom and a hook

Visual check must be performed every day before starting the crane. Check hoist boom and its
connecting pins for damage. The crane operator is responsible to check the crane according to
the relevant provisions of the local or international regulations.
Daily inspection is mainly visual inspection and function inspection. Inspection items mainly
include:
● Check crane and the information in inspection manual (crane log) for consistency.
● Check parts and equipment for damage, wear, corrosion and other changes.
● Check the safety devices and brakes for integrity and effectiveness.
Note
The inspection results must be recorded into the inspection manual and proved by
the inspectors.
部
Crane inspection is the responsibility of crane owner and trained operator.
16.2 Regular inspection
务
业
16.2.1 Structure inspection
The crane may not meet the designed safety requirement due to wear, corrosion, external
外
damage, and change of working environment or application changes. For this reason, the crane
海
shall be checked by experienced technical personnel according to the change of working

司
environment or application condition at least once a year starting from crane delivery date.
公
Note
If significant changes had been made on the crane, or after repairs of load carrying
销
part, the crane must be inspected by an experienced technician before operation.

营
All crane inspections are the sole responsibility of the inspector. The following
drawings are given only as an aid for the inspector. The drawings are only examples,
and we do not claim that they are complete!
Non-observance of the following inspection guidelines or non-adherence of the
inspection intervals can lead to a serious accident!
Repeated inspect by professionals on the working condition of crane and its components.
Prior inspection can discover the hidden danger in time and avoid accidents. If there is any
problem, record and repair, then check again.
The steel construction for load bearing (such as turntable, car-body, track frame, outrigger,
boom, mast, bracket, pendants, etc.) must be checked at least once a year. During inspection
period, the inspection on welding seams when the steel structure is in static or dynamic load
must be done carefully by professional technical personnel, even for welding seam that is not on
16-3
stressed part.
If the crane was subjected to excessive stress, for example an unusual shock or impact during
its time in operation, the inspection of load bearing components must be carried out immediately.
If any damage, such as cracks, can be found at any point of the steel structure, then the extension
of damage must be determined by expert personnel with the aid of material analysis methods,
such as magnetic powder test, ultra sound or X-ray tests. Then it must be determined by expert
personnel if the defective section can be repaired by repair welding or by other means.
Welding inspection usually refers to polyhedral joints, inspection must be done on connections,
or area marked with arrow.
16.2.1.1 Basic machine
Parts name Inspection content
Critical key welding components of the basic machine Crack
Turntable/car-body/track frame/outrigger Deformation
部
Slewing bearing Wear
务
Crawler Loose parts
Crawler shoe Corrosion
业
(A) Turntable
外
海
司
公
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营
16-4
部
务
业
(B) Car-body
外
海
司
公
销
营
16-5
(C) Track frame
部
务
业
外
(D) Slewing bearing

海
司
公
销
营
16.2.1.2 Boom
Part Inspection content
Boom Crack
Fixed jib Parts looseness
Fixed jib strut Flexibility
Rod, connection plate Elongation rate
Wire rope cable Painting
Pin shaft Correct installation
16-6
(A) Boom section
部
务
业
外
海
司
公
(B) Boom single top structure

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营
16-7
(C) Fixed jib section
部
务
业
外
海
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公
(D) Pendant and connection plat

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营
16-8
16.2.1.3 Counterweight
Component Inspection content
Counterweight slab Parts intactness
Counterweight tray Correct connection
Counterweight chain Crack
Deformation
部
务
业
外
海
司
16.2.1.4 Drive gear

公

Travel drive device Parts looseness
销
Slewing gear drive State, function and noise

营
Winch drive Stable start and stop

Normal idle
Lubrication
Sign
16.2.1.5 Wire rope drive
Drum Rope groove, flange wear
Sheave
16.2.1.6 Hydraulic device
Hydraulic pump Connection
Hydraulic motor Operation state
16-9
Oil cylinder Function

Valve Noise
Hydraulic tank Leakage
Hydraulic accumulator State and quantity of hydraulic oil
Hose Inflation pressure
Filter
16.2.1.7 Electrical device
Motor starter Connection
Resistance State
Light device Function
Lead, relay Insulation
部
Switch, button, protection device Direct contact of electrical parts
Fuse Indirect contact of electrical parts
Battery 务 Installation
业
Connection circuit
外
Alarm device
海
16.2.1.8 Crane control device

司
Control valve State

公
Operation handle Function

销
Auxiliary device
Others
营
16.2.1.9 Safety device

LMI Tightness and state
Boom and jib hoist limit device Intactness
Hook rope end limiter Function
Switch device
Alarm device
Locking device
Anemometer
16-10
16.2.1.10 Safety signs

Safety signs on key position such as boom and jib, winch, mast, Intactness
counterweight, slewing, outrigger, oil tank, gear mesh points Legibility
16.2.1.11 Other inspection
Ladder Tightness and state
Cover plate Intactness
Handle Validity
16.3 Winch theoretical service life
The reducers in hoist winch, luffing winch and slewing gear are closed planetary gear reducers.
These gears have been designed for long service life, drive shafts and gear wheels are also long
部
lasting. Even though, an external visual inspection is not sufficient in this case, because the
务
service life can be influenced by insufficient maintenance (lack of grease), defective seals,
业
improper operation or overuse. For this reason, the inspection shall be made by experienced
technicians according to the following guidelines.
外
16.3.1 Inspection
海
16.3.1.1 Inspection interval

司
Every 1000 operating hours, at least once a year (annually).

公
16.3.1.2 Check lubricating oil quantity

On hoist and pull in winches, we recommend to drain the oil and compare the amount with the
销
stipulated oil quantity.

营
16.3.1.3 Check oil color

If the oil is black and/or if the oil smells burnt, one can assume that the oil has been
overheated. In this case, the oil must be replaced.
16.3.1.4 Check for foreign particles in grease
This shall be done in a qualified lab. The used oil is filtered by special filter paper. The oil
sample is visually checked under a microscope for foreign particles. If any are found, then the oil
must be analyzed by a qualified lab to determine the contents of the particles.
16.3.1.5 Evaluate foreign particles in grease
Max. percentage of permissible foreign particles is 0.15% of the total oil quantity, by weight.
Max. permissible foreign particle size is 0.25my.
If the above values have been exceeded, remove the gear and find the cause of increased
contamination and replace the grease.
16-11
Note
These inspections can only be made by expertly trained personnel.
16.3.1.6 Visual inspection

Check transmission gears for leaks, since any pollutant from outside may cause gear failure.
16.3.1.7 Check brakes in gears
Check the brakes at the same time when you check the gears.
If the brakes shall not hold the required test load, users shall open the brake gears to find the
cause.
If the planetary gear is opened due to increased pollutant, check the brakes at the same time.
Note
Only expertly trained personnel may inspect gears and brakes!
部
16.3.1.8 Document after the inspection is completed
务
The result of annual inspections and repair/reconditioning work, including all completed tasks,
must be recorded by the expert or the trained service technician, if necessary, and signed by the
业
inspection station or specialty shop. This documentation must include the crane inspection
外
booklet and repeat inspection column.

海
16.3.2 Theoretical service life

司
The theoretical service life is calculated by winch size and actual working condition.
The winches are classified according to GB3811as follows:
公
Drive gears: M3
销
Load collective: Q1 (L1)

营
Factor of load collective: 0.125

Theoretical service life D: 3200 hrs.
Note
The theoretical service life may not be equated with the actual service life of a winch!
The real service life of a winch is influenced by certain external matters, such as:
● Overload: the crane is not used according to the requirement;
● Lack of maintenance: grease deteriorates after the stipulated interval;
● Erroneous operation: extreme acceleration or deceleration of the load, load free fall;
● Maintenance errors: use of wrong oil, wrong oil quantity, oil deterioration due to
pollutants;
● Installation errors during repair or maintenance;
● Unnoticed oil leakage;
● Improper adjustment of safety devices;
16-12
● Potential hazard;
● Extreme working condition: too low or high temperature, corrosive atmosphere, dust
and dirt.
16.3.3 Used portion of theoretical service life
● The crane operator is obligated to have the crane inspected at least once a year (ISO
9927-1).
● The used portion of the theoretical service life must also be determined. If necessary, the
crane operator must call in an expert.
● When the used portion of the theoretical service life is determined, the actual operating
conditions (load collective) and the operating hours of hoist gears per inspection interval
is determined accordingly. The responsible user shall have it documented in the crane
inspection booklet.
部
16.3.3.1 Determining the operating conditions (load collective)
务
The load collective of the crane is divided into groups (see ISO4301-1).
业
From the determined actual operating conditions, choose one of the following load collective
and find the corresponding inspection interval in crane inspection manual.
外
For mobile cranes in assembly operation, we normally use the load collective L1 (Q1), with
海
the load collective factor km = 0.125

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公
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16-13
Load Factor of load

collective Definition Service life portion collective Graphic view
classification
Load %
10% of running time
Drive gear or parts
with largest load (dead
thereof, which run
load+1/1 load
only at high
Light capacity)
utilization in
Q1 40% of running time km = 0.125
exceptional cases,
L1 with dead load+1/3
but are subjected to
load capacity
constant, but only
50% of running time
light duty Running time%
with only dead load
1/6 of running time Load %

with largest load (dead
load +1/1 load
Drive gear or parts capacity)
thereof, which often 1/6 of running time
Medium
run at high with dead load+2/3
部
Q2 km = 0.25
utilization, but are load capacity
L2
subjected to light 1/6 of running time with
务
duty dead load +1/3 load Running time%
capacity
业
50% of running time
only with dead load
外
Load %
海
Drive gear or parts 50% of running time

thereof, which often with largest load (dead
Heavy
run at high load+1/1 load
司
Q3 km = 0.5
utilization, but are capacity)
L3
subjected to constant 50% of running time
公
medium duty only with dead load

Running time%
销
Load %
营
Drive gear or parts 90% of running time

thereof, which with largest load (deal
Very heavy
regularly run at high load+1/1 load
Q4 km = 1
utilization, and are capacity)
L4
subjected to constant 10% of running time
heavy duty only with dead load Running time%
16-14
16.3.3.2 Determine the actual operating hours Ti

Determine corresponding inspection interval according to the relevant chapters in crane
inspection manual before determining the actual operating hours Ti.
Ti is classified according to the following description:
● Timer on every winch
If your crane is equipped with a timer on every winch, the actual operating hour Ti per
inspection interval can be directly read out.
● Timer for total crane operation time
The percentage of winch operation time in total operating hours of the superstructure can be
calculated.
For mobile cranes, when hoist winches are used, the percentage of winch operation time in
crane total operating hours is 20%.
部
● Combined timer of crane operation and stroke
务
The percentage of winch operation time in total operating hours of the superstructure can be
业
calculated.
For mobile cranes, 60% of crane operating time is superstructure operating time. If 20% of the
外
superstructure operating time is winch operating time, then the percentage of the superstructure
海
operating time in crane total operating hours is 12%.

司
● If there is no timer at all

In this case, the operator can guess and calculate the actual operating hours.
公
The given percentage values apply normally for the hoist winch. For auxiliary hoist winches,
销
the actual percentage in total operating hours is not important, therefore it can be calculated by
营
operator.
16.3.4 Determine the used portion of the theoretical service life
For inspection interval i (max. is 1 year, according to ISO9927-1), the used portion of the
theoretical service life is determined according to the following formula:
kmi
Si   Ti
km
Where:
km = factor of load collective, which is calculated by winch, also can be taken from the
operation manual.
kmi = factor of load collective in the inspection interval i, from 16.3.3.1.
Ti = effective operating hours in the inspection interval i, from 16.3.3.2.
After each inspection interval, the used portion is taken off from the remaining theoretical
service life Di (see the figure).
16-15
If the remaining theoretical service life is not enough for the next operating period, then the
winch must be reconditioned or overhauled.
When the theoretical service life has been reached (see 2.2.1), then the winch may only be
operated again after it has been reconditioned or overhauled.
Note
In any case, it must be reconditioned or overhauled at the latest after 10 years after
putting the crane into service.
The general reconditioning or overhaul must be done by the operator and must be done by the
special technical personnel or by a person authorized by the manufacturer and the overhaul must
be verified by the inspection booklet.
After the general reconditioning or overhaul, the manufacturer or the device authorized by the
manufacturer will determine a new theoretical service life D.
部
16.3.5 Example
务
According to the operation manual, mobile crane timer is divided into general meter and crane
working meter, which can be classified by the manufacturer as follows:
业
Drive gear reducer: M3
外
Load collective: light load L1, km = 0.125

海
Theoretical service life: D = 3200 hrs.

The used part theoretical service life S can be calculated into the separate inspection intervals
司
as follows:
公
● The 1st inspection (the 1st year)

销
When km1=0.125, load collective: L1.

If the engine timer read 1000hrs, 20% of which is winch operation time, then T1 = 200 hrs;
营
therefore, the used theoretical service life S1 is as follows:

km1 0.125
S1   T1   200  200
km 0.125
Remaining theoretical service life:
D1 = 3200 - 200 = 3000 hrs.
● The 2nd inspection (the 2nd year)
When km2=0.25, Load collective: L2
The engine timer read 2100hrs, which means during this interval:
2100 – 1000 = 1100 hrs. (1000 hrs is the working time of the first year)
20% of which is winch operation time, which means T2 = 330 hrs. The used part theoretical
service life S2 is calculated into the second separate inspection intervals:
:
16-16
km2 0.25
S2  T 2   330  660
km 0.125
D2＝3000-660＝2340hrs
● The 3rd inspection (the 3rd year)
When km3=0.25, Load collective: L2
The engine timer read 3000hrs, which means during this interval:
3000 – 2100 = 900 hrs. (2100 hrs is the working time of the previous two years)
30% of which is winch operation time, which means T3 = 270 hrs. The used part theoretical
service life S3 is calculated into the third separate inspection intervals:
km3 0.25
S3  T 2   270  540
km 0.125
部
D3＝2340-540＝1800hrs
务
● The remaining theoretical service life can be calculated so on and so forth.
16.4 Inspection in special operating environment
业
16.4.1 Operation in mud, rain and snow
外
Before operation: check all plugs, shafts and pins for looseness.
海
After operation: clean the crane, check bolts and nuts for looseness and drop, and refill oil and
lubricating grease.
司
16.4.2 Operation at seaside

公
Before operation: check all plugs, shafts and pins for looseness, coat grease on rusted areas,
销
especially on connecting rod and control lever.

营
After operation: clean salt on the machine thoroughly, coat grease on rusted areas, maintain
electrical components carefully to prevent corrosion.
16.4.3 Operation in dusty area
Air filter: clean filter element and dust collector beforehand.
Radiator: often clean the central part of radiator to prevent clogging.
Fuel device: clean filter components beforehand.
Electrical subassembly: clean the starter and contact surface of sensor carefully.
16.4.4 Operation in rocky area
Crawler tension is a little looser than normal, check travel gear for damage, crack, abrasion
and scratch, check bolt and nut for looseness and drop.
16.4.5 Operation in sites with falling rocks
The driver’s cab shall be installed with protective screen or cover.
16.4.6 Operation in cold area
16-17
Use lubricant of good stickiness and low viscosity, the battery shall be charged beforehand.
16.4.7 Other working environment
The wearing degree is different due to different installation position of the sheaves on main
luffing mast, sheave block on the rear of the platform and on operating device, check sheave
wearing degree in daily inspection and timely replace them if necessary.
For repair and re-installation of supporting wheels, changing the direction will prolong the
service life of guide rail surface.
16.5 Crane storage
The following work shall be done to ensure that the crane is in good condition for use of the
next time:
● 1. Storage (for less than one month)
Clean the crane; keep it dry and fully lubricated.
部
Cover the crane to prevent dust.
● 2. Storage (for one month to one year)
务
1. After the crane is thoroughly cleaned, check travel gear.
业
2. Keep the crane dry.
外
3. Coat corrosive parts with a thin layer of lubricating oil for fully lubrication.
4. Thoroughly lubricate slewing bearing teeth.
海
5. Replace gear oil and hydraulic oil.

司
6. Replace all filters.

公
7. Remove the storage battery, let it fully charged, remove the earth wire on the end, and
销
store it in room temperature, dry, ventilated place, avoid light.

8. Drain out the cooling water, put a “no water” sign. Store the crane in the warehouse and
营
cover the engine to prevent moisture and dust.

9. Inventory and store tools.
10. Let the crane no load low speed run a while, to prevent excessive wear due to film rupture
or rust when operate the crane next time. In the meantime, special attention shall be paid
to the changes of engine cylinder head temperature.
* * * Lubrication running is repeated and continuous movement of travel, swing and hoist
after the engine is heated.
* * * Pay attention to the quality of lubricants when the crane (basic machine or the whole
machine) operates again, since the lubricant will deteriorate due to lack of running.
16-18
XGC55 Crawler Crane Maintenance Manual Common Trouble and Trouble Shooting
17. Common Trouble and Trouble Shooting
部
务
业
外
海
司
公
销
营
17-1
Common Trouble and Trouble Shooting XGC55 Crawler Crane Maintenance Manual
17. Common trouble and trouble shooting

Trouble inspection and troubleshooting shall be operated by professional personnel; otherwise
the crane may be damaged.
17.1 Common trouble and trouble shooting of hydraulic system
Serial Trouble
Cause Troubleshooting
No. description
1. Insufficient oil. Add oil.
2. Air entering into the suction line. Repair and bleed air.
Noise in
3. Mounting bolt loose. Tighten.
1 hydraulic
pump 4. Hydraulic oil contamination. Replace oil or
5. Hydraulic pump fault. filtrate.
Repair or replace.
Excess heat 1. Internal leakage in main pump. Check and repair.
of hydraulic 2. Constant difference overflow valve fault Check and repair.
部
oil and low in multi-way valve.
2
motion of
务
3. Excess leakage in hoist motor. Check and repair.
executive 4. Low setting pressure of relief valve in Check and repair.
业
system main pump.
1. Too low adjusting pressure of overflow Repair and adjust
外
valve in slewing pump or filter element

clog.
海
2. Serious leakage in slewing pump. Repair or replace.

司
Unable to 3. Serious leakage in swing motor

3 Repair or replace.
swing. 4. Swing system reducer fault. Repair.
公
5. Pilot handle fault. Repair.

销
6. Slewing brake circuit fault. Clean or replace

7. Slewing brake fault. Check and repair
营
1. Too low overflow adjusting pressure in Adjust.

slewing pump.
2. Serious leakage in hydraulic motor. Check or replace.
Sluggish 3. Insufficient control oil circuit pressure or Check and repair.
4
swing. pilot valve fault.
4. Serious leakage of main valve or Check and replace
insufficient direction change. the seal
Big starting 1. Pilot control valve fault. Check and repair.
5
shock 2. Excess charging of accumulator. Check and repair.
Unsteady 1. Swing brake fault. Check and repair.
6
swing brake 2. Buffer valve fault Check and repair.
Unable to 1. Free swing control valve fault or solenoid Check and repair.
change valve circuit fault
7
between free 2. Insufficient inlet pressure of brake. Check and repair
swing
17-2
1. Too low adjusting pressure of Adjust

superstructure multi-way overflow valve
2. Hydraulic motor fault. Check and repair.
3. Serious leakage in control main valve. Check and repair.
4. Insufficient main pump pressure. Check and repair.
5. No pressure in pilot oil circuit. Check and repair.
8 Unable to 6. Pilot fault. Check and repair.
hoist
7. Unloading electromagnetic valve fault, in Check and repair.
constant unloading state.
8. LMI fault, unloading signal cannot be Check and repair.
cleared.
9. Brake cannot be opened. Check and repair.
1. Balance valve fault. Check and repair.
2. Balance valve control circuit block. Check and repair.
3. Brake fault. Check brake.
4. No pressure in brake inlet circuit. Check hydraulic
部
control valve
务
5. No pressure in pilot circuit. Change direction
9 Unable to 6. Pilot valve fault. Check pressure
lower down
业
release valve and
overflow valve.
外
7. Serious leakage in hoist motor. Check and repair.

8. LMI fault, unloading signal cannot be Check or replace
海
cleared.
司
1. Too low adjusting pressure of main valve Adjust.

10 overflow valve Check and repair.
公

销
No travel in 4. Insufficient pressure in main pump. Check and repair.

travel gear
5. No pressure in pilot oil circuit. Check and repair.
营
6. Travel balance valve fault. Check and repair.

1. Too low adjusting pressure of Adjust
superstructure multi-way overflow valve
4. Insufficient main pump pressure. Check and repair.
Hoist gear 5. No pressure in pilot oil circuit. Check and repair.
6. Pilot fault. Check and repair.
11 cannot lift up 7. Unloading electromagnetic valve fault, in Check and repair.
hook. constant unloading state.
8. LMI fault, unloading signal cannot be Check and repair.
cleared.
10. Caliper of free fall device is not opened. Check and repair.
11. Clutch of free fall device is not connected. Check and repair.
17-3
1. Hoist balance valve fault. Check and repair.

2. Hoist balance valve control circuit block. Check and repair.
3. Hoist brake fault. Check brake.
Hoist gear 4. No pressure in brake inlet circuit. Check hydraulic
control valve
12 cannot lower 5. No pressure in pilot circuit. Change direction
down hook. Check pressure
6. Pilot valve fault. release valve and
overflow valve.
7. Serious leakage in hoist motor. Check and repair.
17.2 Common trouble and trouble shooting of mechanical drive

No. Trouble Cause Remedy
1. Different Adjust tightening device
部
tightness between
1 Travel deviation left and right
crawler.
务
业
2. Loose crawler. Adjust tightening device
外
1. Excess crawler Adjust tightening device

Too much travel tightness.
2 Pave and flatten the road.
resistance
海
2. Soft road.
1. Loose crawler. Adjust and tighten crawler
司
3 Crawler slip 2. Crawler shoe Replace crawler shoe

公
wear
1. Too loose crawler Adjust crawler
销
Abnormal mesh between 2. Unsmooth mesh Modify the driving teeth top edge,
营
4 drive roller and crawler between drive grind into fillet.

shoe roller and crawler
shoe.
Loose positioning bolt Tighten bolt
5 Slewing reducer shake
of slewing reducer
Abnormal noise when Lack of oil Refill gear oil and grease.
6
swings
Loose luffing motor Loose damping bolt Tighten damping bolt
7 damp, uneven oil supply,
shaking motor
Luffing, slewing and Brake disk in reducer Repair or replace brake disk.
8
travel brake slip wear
Bolt of luffing valve Tighten bolt
9 Luffing braise
element loose
17-4
Insufficient stroke due Tighten bolt

Slow main winch hoist
10 to loose main winch
speed
valve element bolt
Serious shaking of main Main winch balance Install damping on main winch
11 valve has no damping. balance valve.
winch
Main winch lowering Loose bolt of main Tighten bolt
12 speed decreases, main down valve element
winch lower slowly
Main/aux. hoist or main Reducer fault Repair reducer
13
luffing does not move.
Rope climbing when Wrong rope Adjust rope guide sheave
14
main winch hoist installation position
Hoist and lower repeatedly, loosen
15 Wire rope twist rope end to release rope internal
stress, repeat 2 to 3 times.
部
1. Spool out all rope, to let the rope
务 have a certain pulling force,

forcedly arrange the rope on
业
16 Drum rope tangled. drum neatly.
外
2. Repeatedly hoist and lower drum,

arrange rope by hand
海
17.3 Common trouble and trouble shooting of engine

司
公
No.
Trouble Cause Remedy
销
1. Open, burnt fuse. Replace fuse

2. Starter motor fault. Replace starter motor.
营
3. Contactor damage. Replace contactor.

4. Controller damage. Replace controller
5. Communication fault. Check CAN Bus
Starter 6. Low battery voltage. Charge or replace battery
motor has 7. Engine speed sensor fault Replace speed sensor
1 no respond (speed displays value more
for than 900rpm when the
ignition engine is not started).
8. Seat interlocking switch Check seat interlocking switch and circuit.
fault.
9. Control release switch fault. Control release switch fault or operate
release switch handle reaches operating
position.
17-5
1. Low fuel level in tank. Refill fuel.

2. Low battery voltage. Check battery and power circuit.
3. Low engine cranking speed If the engine cranking speed is less than
150rpm, refer to engine no cranking or
slow cranking symptom tree adjustment.
4. Too high vehicle additional Check if the crane is starting with load.
power.
5. Fuel oil leakage. Check fuel pipe, fuel pipe connector and
fuel filter leakage.
6. Resistance force in air inlet Check inlet system resistance, clean or
system exceeds technical replace air filter inlet pipe if necessary.
standard.
Difficulty
7. Fuse class is inconsistent Use qualified fuel.
in engine with application type, or
start or
2 unqualified fuel, with
unable to
部
impurities.
start(emit 8. Fuel filter block. Measure fuel pressure on filter inlet and
务
smoke) outlet port.
9. Insufficient fuel supply. Check fuel flow through filter to find
业
stuck position.
外
10. Fuel oil transfer pump fault. Check fuel transfer pump operation.
Check pump outlet pressure, replace fuel
海
transfer pump if necessary.

11. Incorrect throttle position Check and adjust throttle.
司
adjustment.
公
12. Not operational in cold Check, repair or replace aux. start device
weather. in cold weather.
销
13. Air in fuel system. Fuel system exhaust and check oil inlet
营
pipe for leak.

1. Air in fuel system. Fuel system exhaust and check oil inlet
pipe for leak.
Engine 2. Fuel filter block. Release fuel – separator or replace fuel
can start filter.
3
but cannot 3. Fuel oil wax in cold Replace fuel used in cold weather.
operate weather.
4. Impurities in fuel. Filter or replace fuel.
1. Smoke into air inlet system Check air inlet pipe, find and isolate
Engine while operating. smoke source.
cannot
4 2. Fuel leakage. Check fuel pipe, fuel connector and fuel
stop filter for leakage.
normally 3. Diode short circuit Replace diode.
Impurities Rust in coolant, use unqualified Release and flush cooling system, refill
5 in coolant coolant. qualified coolant.
17-6
Impurities
6 in engine Too much engine oil sediment. Replace engine oil or filter
oil
1. Low oil level or no fuel in Refill fuel.
tank
2. Fuse oil class is inconsistent Use qualified fuel.
with application type, or
unqualified fuel.
3. Engine protection system Isolate engine protection system.
fault.
4. Low battery voltage Check battery and power circuit.
5. Key switch circuit fault. Check key switch circuit.
6. Abnormal power supply to Check for open fuse, replace fuse if there
electrical control module. is open fuse. Check if the emergency
button is pressed down, reset the button if
部
it is. Check if the total power manual
Engine
务
switch is disconnected; close the switch if
can work
it is.
but cannot
业
7 7. Moist lead wire harness Dry the connector by electronic air
start (no
connector. cleaner.
外
smoke)
8. Air in fuel system. Check fuel system for air, tighten or
海
replace fuel pipe, fuel pipe connector and

fuel filter if necessary.
司
9. Electrical control module is Disconnect battery cable for 30s, then

locked. connect battery cable, and start generator.
公
10. Fuel filter block Measure fuel pressure on fuel filter inlet
销
and outlet.
11. Fuel oil transfer pump fault. Check fuel transfer pump operation.
营
Check pump outlet pressure, replace fuel

transfer pump if necessary.
12. Fuel oil return block. Check if fuel return pipe is smooth.
13. Incorrect throttle adjustment Adjust or repair throttle.
or damage.
1. Fuse oil class is inconsistent Use qualified fuel.
with application type, or use
unqualified fuel.
Emit too 2. Air inlet or air exhaust Check for loose or damaged pipe line
much leakage. connector and missing pipe plug. Check
8 black turbocharger and exhaust manifold.
smoke 3. Air inlet system resistance is Check air inlet system resistance
higher than technical Clean or replace air inlet filter and air
standard. inlet pipe.
4. Air cooler block or damage. Check air cooler for block or leakage
17-7
1. Incorrect start procedure. Verify the correct start procedure.

2. Engine is too cold. Preheat engine to working temperature.
3. Engine running under low Take temperature preservation
temperature. measurement to engine.
4. Start aux. device fault. Check cold start aux. device.
5. Coolant temperature lower Refer to coolant temperature symptom
than technical regulation. tree.
Emit too
6. Fuel oil class is inconsistent Use qualified fuel.
much
9 with application type, or
white
qualified fuel.
smoke
7. Air inlet or air exhaust Check pipe line connector for looseness or
leakage. damage and missing pipe plug. Check
turbocharger and exhaust manifold.
8. Air inlet system resistance is Check air inlet system resistance
higher than technical Clean or replace air inlet filter and air
standard.
部
inlet pipe.
9. Air cooler block or damage. Check air cooler for block or leakage.
10 Engine
cannot
1.
2.
Overload.
Tachometer fault 务
Lower load.
Check tachometer.
业
reach rated
外
speed with
load
海
1. Impurities in fuel. Replace with fuel of higher quality

司
2. Air in fuel system. Release fuel system, check oil inlet pipe
Engine for leakage.
11
公
flame out 3. Engine controller power Check if 06F3 and 06F6 is open; check if
fault. wire is open.
销
1. Engine operates a long time Avoid long time operation with light or no
营
turbocharg with light load or no lad. load.

er 2. Engine oil or fuel goes into
12 leakage turbocharger. Dismantle air inlet pipe, check for engine
engine oil 3. Turbocharger oil return pipe oil or fuel.
or fuel block. Dismantle turbocharger oil return pipe,
and check resistance.
1. Too much air intake Check air intake system resistance，clean
pressure. or replace air inlet filter and pipe if
Fuel or
2. turbocharger oil return pipe necessary.
engine oil
block ; Dismantle turbocharger oil return pipe
in exhaust
13 3. Turbocharger cover leakage. and check for block, clean or replace oil
pipe air
return pipe.
inlet
Check if there is engine oil air exhaust
manifold
pipe; replace turbocharger oil seal if
necessary.
17-8
1. Air inlet or air exhaust Check for loose or damage pipe connector
leakage. and missing pipe plug. Check
turbocharger and air exhaust pipe
Air inlet installation.
manifold 2. Air inlet system resistance is Check air inlet system resistance, clean or
pressure is higher than technical replace air inlet filter and air inlet pipe if
14 lower than standard. necessary.
normal 3. Air cooler block or damage. Check air cooler for block or leakage.
value 4. Electronic fault code is
working. Read the current fault code description, if
the fault code works, contact with engine
service center.
1. Too low oil level in tank Refill the oil tank.
2. Electronic fault code works. Read the current fault code description, if
部
3. Wet wire harness connector. service center.
4. Air in fuel oil system. Clean the connector to let it dry.
务
业
5. Fuel oil filter block. Fuel oil system exhaust and check oil inlet
Unstable
15 pipe for leakage.
外
engine idle
6. Insufficient fuel supply. Measure fuel pressure on fuel filter inlet
and outlet.
海
7. Too much load when idle Find out block position by filter fuel flow.
司
8. Fuel oil class is inconsistent Use PTO characteristics under loading

with application standard, or condition when engine speed is low.
公
fuel is unqualified. Use high quality or recommended fuel.

销
1. Too low coolant level. Refill coolant.

营
2. Water tank heat sink damage Check water tank heat sink, clean and
Too high
or block by impurities. repair.
coolant
16 3. Loose fan drive belt.
temperatur
4. Sensor damage. Check fan belt idler.
e
Check temperature sensor and connection
cable.
1. Water tank or heater Check water tank, heater, hose and
Coolant leakage. connector for leakage.
17 wear 2. Engine external leakage. Check engine and parts sealing or washer
for leakage.
Too much 1. Too much engine load. Lower load or lower the gear.
smoke 2. Air in fuel system. Fuel oil system air exhaust.
18 when 3. Air filter block. Clean or replace air filter.
hoisting a
load
17-9
No display Engine speed sensor connector Check and reconnect or replace sensor.
19 of engine clip looseness or damage.
speed
1. Engine overload Lower the gear.
2. Engine is too cold. Preheat engine to working temperature.
3. Air in fuel system. Check fuel system for air, tighten or
replace fuel pipe connector, fuel pipe, oil
tank oil suction pipe and fuel filter if
necessary.
Use high quality or recommended fuel.
4. Fuel oil class is inconsistent
with application standard, or
fuel is unqualified.
Fuel oil 5. Fuel leakage.
20
knocking Check pipe connector, oil pipe, fuel filter
6. Fuel filter block.
部
for leakage.
Measure fuel pressure on fuel filter inlet
务
7. Insufficient fuel supply. and outlet.
Find out block position by filter fuel flow.
业
8. Fuel pump fault. Check fuel pump operation.
外
9. Engine mount wear damage Check pump output pressure.

or error. Check engine mount.
海
10. Wet wire harness connector.

Use cleaner to dry connector.
司
1. Crane overload Decrease load or lower gear.

公
2. Too high engine oil level Drain engine oil to suitable oil level.
Too low 3. Air in fuel system. Exhaust fuel system air and check oil inlet
销
21 output pipe for leakage.

power 4. Low quality of fuel is Use high quality fuel.
营
unqualified.
5. Incorrect valve clearance. Adjust valve clearance.
17-10
1. Incorrect operation method. Check and repair leakage. Gear, lower

2. Electronic fault code works. speed and idle correctly.
Read the current fault code description, if
3. Fuel oil leakage.
service center.
4. Unqualified fuel oil. Check pipe connector for looseness and
5. Air inlet or air exhaust damage and missing pipe plug.
leakage. Use high quality fuel.
6. Air inlet system resistance is Check turbocharger and air exhaust pipe
Excess
higher than technical installation.
fuel oil
22 standard. Check air inlet system resistance, clean or
consumpti
7. Engine oil level is lower replace air inlet filter and air inlet pipe if
on
than technical standard. necessary.
8. Turbocharger oil return pipe Check engine oil level, and refill or drain
block. engine oil if necessary.
部
Dismantle turbocharger oil return pipe
9. Turbocharger oil seal and check for block, clean or replace oil
leakage.
务
return pipe.
业
Check for engine oil in air inlet and air
exhaust pipe. Replace turbocharger oil
外
seal if necessary.
1. Fan drive belt is loose, too Check fan drive belt.
海
tight or not in the middle.

司
2. Diluted engine oil or engine

oil is diluted. Refer to engine oil technical standard.
公
3. Damper damage.
销
4. Air exhaust or air inlet Check damper.

leakage. Check pipe line connector for looseness or
营
damage and missing pipe plug. Check

turbocharger and exhaust manifold.
5. Air inlet system resistance is
Excess Check air inlet resistance.
higher than technical
23 engine
standard.
noise
6. Coolant temperature is
Refer to coolant temperature is higher
higher than technical
than normal value.
standard.
Check engine mount.
7. Engine mount wear, damage
or incorrect.
8. Big noise in fan, hydraulic
Isolate each part and check noise.
pump or compressor.
9. Fan loose, damage or too
large hub axial clearance.
Check fan.
17-11
No.
1. Crankcase ventilation Check and clean crankcase breather and
system block. ventilation pipe.
2. Engine oil does not meet Replace engine oil and filter. Use
the technical standard. recommended engine oil.
3. Too long engine oil Make sure the engine oil replacement
replacement time. time is correct.
4. Engine oil leakage Check for external engine oil leakage.
Excess engine (external). Tighten bolt, pipe plug and pipe
24 oil connector, replace washer if necessary.
consumption 5. Turbocharger oil seal Check air inlet pipe and air exhaust pipe
leakage. for engine oil.
6. Piston ring damage or Check air exhaust for blue smoke
opening direction emission.
coincides.
部
7. Verify engine oil Check ratio between engine oil
务
consumption. consumption volume and operating
time.
业
1. Too much engine oil Replace engine oil and filter.
sludge.
外
2. Engine oil is Check fuel transfer pump operation and

海
contaminated by coolant pump outlet pressure. Replace fuel

Engine oil
25 and fuel. transfer pump if necessary.
司
contamination
3. Fuel oil transfer pump Check bulk engine oil. Empty engine
fault. oil and replace with non-contaminated
公
4. Bulk engine oil is engine oil.

销
contaminated. Replace engine oil filter.

营
17-12
1. Engine oil leakage Check engine for external engine oil

(external). leakage. Tighten bolt, pipe plug and
pipe connector. Replace washer if
necessary.
2. Engine oil level is lower Check engine oil level. Refill or drain
than technical standard. engine oil if necessary.
3. Engine oil does not meet Replace engine oil and filter.
the technical standard.
4. Engine oil pressure Check engine oil pressure switch,
switch, engine oil engine oil pressure gauge, engine oil
26 Engine oil
pressure gauge, engine oil pressure sensor and installation
pressure sensor fault or position.
wrong installation
position.
5. Electronic fault code Refer to current fault code description.
部
works.
6. Engine oil cooler leakage. Check engine oil for leakage or crack.
7. Serious air leakage
务 Check for serious air leakage.
业
8. Turbocharger oil seal Check turbocharger oil seal for leakage.
leakage.
外
海
司
公
销
营
17-13
1. Characteristic curve is Refer to engine technical standard data
beyond standard while table.
the engine is operating.
3. Engine oil is diluted by Check for engine oil dipstick, rain proof
water. cover or oil refilling, replace engine oil.
4. Engine oil filter block. Replace engine oil and engine oil filter.
5. Engine oil is Refer to engine oil contamination
contaminated by coolant symptom tree.
and fuel.
6. Engine oil leakage Check engine for engine oil leakage.
(external). Tighten bolt, pipe plug and pipe
Low engine oil
27 connector. Replace washer if necessary.
pressure
部
7. Engine oil level is higher Check engine oil level. refill or drain
务
or lower than technical engine oil if necessary.
standard.
业
works.
外

海
switch, engine oil engine oil pressure gauge, and engine

pressure gauge, engine oil oil pressure sensor and installation
司

公
wrong installation
position.
销
1. Coolant temperature is Check cooling system.

lower than technical
营
standard;
High engine
28 switch, engine oil engine oil pressure gauge, and engine
oil pressure
pressure gauge, engine oil oil pressure sensor and installation
wrong installation
position.
works.
17-14
No.
1. Bulk engine oil is Check bulk engine oil.
contaminated.
2. Coolant temperature is Refer to coolant temperature is lower
lower than technical than normal value.
standard.
Too much
3. Crankcase ventilation Check and clean crankcase breather and
29 sludge in
system block. ventilation pipe.
crankcase
4. Fuel class is inconsistent Use qualified fuel.
with application type, or
use unqualified fuel.
1. Battery connector loose Clean and tighten battery connector.
部
or corrosion.
2. Alternator belt slip. Check, adjust belt tightening wheel.
务
No or
3. Loose alternator belt Tighten belt wheel fixing bolt.
sufficient
业
30 wheel.
electricity in
4. Bad generator earthing. Check earthing line.
alternator
外
5. Generator damage. Replace generator.

6. Manual total power Close manual total power switch.
海
switch is open.
司
Incorrect fuel
31 Sensor damage Replace sensor
quantity
公
Engine idle
32 Fuel inlet pipe aging damage. Reinstall diesel inlet pipe.
and flameout
销
Water leakage
营
33 of water tank Water tank pipe aging. Replace water tank pipe
pipe
Impurities in Rust in coolant, us Drain and flush cooling system, refill
34
coolant unqualified coolant. qualified coolant.
Engine oil
pressure only Engine oil pressure sensor
35 Replace sensor
displays two damage
or full lattice
Water leakage 1. Water pipe aging. Replace engine water pipe.
36
in engine 2. Loose fixing pipe clamp. Tighten pipe clamp.
Engine speed
37 decrease with Fuel filter block. Replace fuel filter.
load
17-15
Engine water Coolant temperature is too
38 temperature high, sensor cannot detect it Replace sensor.
alarm due to sensor fault.
Generator
Generator relay sticking of
39 unable to Wipe the contacts.
contacts.
generate
Engine Engine throttle mechanism
40 Replace throttle mechanism.
throttle block fault.
Battery charge
is not
41 functional, but Loose generator connector. Tighten connector.
the charge
light is on
Engine cannot Engine ignition witch
42 Replace engine ignition switch.
light damage.
部
Engine
43 sometimes Loose battery earth line. Tighten battery earth line.
cannot start
Engine 务
业
Wrong adjustment of power Adjust power limiter or start the engine
44 flameout with
limiter. after the load is unloaded.
外
load
17.4 Common trouble and trouble shooting of electrical system
海

司
1. Battery switch is not open. Start battery switch.

公
2. Insufficient battery power or damage.

Measure by multi-meter,
charge or replace battery.
销
Open the key

3. Circuit between relay and contactor Check circuit.
1 switch, no
营
fault.
electricity
4. Open fuse. Replace.
5. Power connector damage. Replace.
6. Key switch damage. Replace.
17-16
1.
Loose or open circuit between Check circuit.
contactor and control module.
2. Charge signal fault: check circuit or Check circuit or replace
replace generator. engine.
3. Contactor damage. Replace.
4. Ignition switch damage. Replace.
Motor has no Repair or replace.
5. Starter generator fault.
2 response after Replace fuse.
6. Fuse open or burnt.
ignition Replace or charge battery.
7. Low battery voltage.
8. Engine speed display more than Check engine speed sensor
900rpmunder not starting state. and circuit.
Electronic control engine
1. Communication fault. Check CAN connection.
2. Incorrect display configuration. Reconfigure display
Motor has 1. Battery lack of electricity. Timely charge or series
部
movement connect battery.
after ignition, 2. Engine fuel solenoid valve fault Replace solenoid valve.
3 but
务
not 3. Oil supply pipe line is not smooth. Clean and keep oil line
业
powerful smooth.
enough to start 4. Starter generator fault. Adjust, replace or repair
外
successfully by professionals.
海
Engine speed 1. Hand throttle circuit or foot throttle Check circuit.

4 cannot be circuit loose or open.
司
controlled 2. Throttle wire damage. Replace.

公
1. Pressure sensor fault. Clean or replace sensor.

Engine oil 2. Engine oil needs to be replaced. Replace engine oil
销
5 pressure alarm periodically.

all the time 3. Circuit fault between sensor and Check circuit.
营
controller.
Main/aux. 1. Crane is in limit release mode. Release limit.
hook upper 2. Circuit between controller and Check circuit.
6
limit main/aux. winch fault.
inoperative 3. Rope switch damage or open circuit. Replace.
1. Crane is in limit release mode. Release limit.
Main/aux. 2. Circuit between controller and Check circuit.
hook lower main/aux. winch rope end limit switch
7
limit fault.
inoperative 3. Switch circuit fault. Check circuit.
4. Rope end limiter damage. Replace.
17-17
1. Pilot pressure valve, unloading close Check circuit.

valve and control circuit fault.
2. Main/aux. winch over release. Do not use lowering down
operation or replace with
luffing down.
3. Circuit between main/aux. winch Check circuit.
Main/aux.
locking switch and control module
8 winch unable
loose.
to lower down
4. Main/aux. winch locking switch Replace.
damage.
5. Circuit between main/aux. lowering Check circuit.
valve connector and controller fault.
6. Controller fault. Replace controller and
update the program.
1. Overload. Decrease load.
部
3.
务
Main/aux. winch locking switch Replace.
damage.
业
4. Main/aux. winch over luffing. Do not use hoisting up
外
Main/aux. operation or replace with

9 winch unable luffing up.
海
to hoist up 5. Circuit between main/aux. winch Check circuit.

司
locking switch and control module

loose.
公
6. Main/aux. winch locking switch Replace

damage.
销

营
update the program.

1. Crane is in assembly mode. Switch to working mode.
2. LMI is not correctly calibrated. Recalibrated LMI
parameter.
3. Circuit between boom upper limit Check circuit.
Main/aux.
proximity switch and controller fault.
luffing upper
10 4. Boom and jib upper limit proximity Replace.
limit
switch damage.
inoperative
5. Boom angle sensor damage or LMI Check and replace circuit.
console circuit fault.
6. Controller fault. Check controller and
update program.
17-18

2. To main luffing upper limit. It is permitted to use
hoisting up or winch up.
3. Circuit between main luffing locking Check circuit.
switch and control module loose.
4. Circuit between controller and main Check circuit.
luffing up valve.
5. Main luffing up valve joint damage. Replace.
Main/aux. 6. Circuit between main luffing locking Check circuit.
11 luffing unable switch and control block loose.
to hoist up 7. Main luffing locking switch damage. Replace.
8. Circuit between boom upper limit Check circuit.
proximity switch and controller fault.
9. Boom upper limit proximity switch Replace.
部
damage.
10. Boom angle sensor damage or LMI Check circuit.
务
业
11. Boom angle sensor damage. Replace.
12. Controller fault. Check and replace circuit.
外
1. Overload. Decrease load.

海

司
3. Controller error. Replace controller and

update program.
公
4. To main luffing lower limit. It is permitted to use

销
lowering down or winch

down.
营

switch and control module loose.
Main/aux. 6. Circuit between controller and main Check circuit.
12 luffing unable luffing up valve.
to lower down 7. Main/aux. winch overluffing. Lower down load.
8. Circuit between controller and main Check circuit.
luffing down valve.
9. Main luffing lowering down safety Replace.
valve joint damage.
switch and controller loose.
11. Main luffing locking switch damage. Replace.
12. Boom angle sensor damage or LMI Check circuit.
13. Boom angle sensor damage. Replace.
17-19
1. No or too low anemometer voltage Detect anemometer power

signal. signal.
Anemometer 2. Circuit between anemometer and Check circuit.
13
fault controller fault.
4. Anemometer damage. Replace.
1. Circuit between beacon light and Check circuit.
rocker witch fault.
Beacon light is 2. Loose beacon light circuit. Check circuit.
14
not on 3. Open fuse. Replace.
4. Rocker switch damage. Replace.
5. Beacon light damage. Replace.
17.5 Common trouble and trouble shooting of LMI and display
No.
部
1. Open fuse circuit. Replace.
务
LMI display
1 2. Power circuit loose or open. Check circuit.
black screen
业
3. Display damage. Replace.
No LMI 1. Too lower voltage signal. Check power and
外
Display after connection line.

2
the engine is 2. No data is loaded. Reload date.
海
started 3. Display or LMI console damage. Replace.

司
No weight 1. Loose or open connection line between Detect relevant circuit.

display, but console force sensor. Replace.
公
3
has angle 2. force sensor damage.
display
销
1. Too lower voltage signal. Detect voltage value to see

营
if there is problem in
LMI displays
4 circuit.
data on and off
2. Loose CAN bus connection. Detect connection line.
3. Display screen damage. Replace.
Too difference 1. Incorrect calibration. Recalibrate.
between 2. Loose force sensor circuit. Check circuit.
weight 3. Force sensor damage. Replace.
5
displayed on 4. LMI console fault. Repair or contact
LMI and manufacturer.
actual weight
17-20
LMI empty 1. Incorrect calibration. Recalibrate.

hook 2. Loose force sensor circuit. Check circuit.
calibrates, 3. Force sensor damage. Replace.
reopen the key 4. LMI console chip damage. Repair or contact
6
switch, no manufacturer.
change on
empty hook
display
Much error 1. Incorrect calibration. Empty hook recalibrate
7 LMI empty 2. Force sensor damage. Replace.
hook display
LMI displays 1. Incorrect calibration. Recalibrate.
empty hook 2. Loose force sensor circuit. Check circuit.
8 weight under 3. Force sensor damage. Replace.
heavy or light 4. Console fault. Repair or contact
部
load manufacturer.
1. CAN bus circuit fault or there is no Reconnect, connect
9
LMI
communicatio
end resistance.
务 resistance.
业
2. No correct original configuration on Recalibrate.
n fault
display.
外
Incorrect 1. CAN bus circuit fault. Check display connection.

海
display value 2. Corresponding sensor damage. Replace.

10
or alarm for no 3. Display damage. Replace.
司
cause
1. Circuit between monitoring display Check circuit.
公
and power module fault.

Monitoring
销
2. Circuit between monitoring display Check circuit.

display black
11 and camera fault.
营
screen or no
3. Camera damage. Replace.
display
17.6 Common trouble and trouble shooting of electrical aux. function
No.
1. Circuit between rocker switch and light Check circuit.

Winch light fault.
1 and working 2. Open fuse. Replace.
light is not on 3. Light damage. Replace.
Cab indoor
2 2. Loose light circuit. Check circuit.
light is not on
3. Light damage. Replace.
17-21
1. Radio circuit fault. Check circuit.

Radio is not
3 2. Open fuse. Replace.
working
3. Radio damage. Replace.
1. Circuit between wiper motor and Check corresponding
switch fault. circuit.
Wiper is not 2. Open fuse. Replace.
4
working 3. Switch damage. Replace.
4. Electro motor fault. Check and replace.
5. Transmission gear stuck or damage. Check and replace.
1. Circuit between switch and control Check circuit.
module fault.
Installation
5 mode switch
3. Switch damage. Replace.
inoperative
update program.
部
1. Poor earthing. Repair.
Buzzer alarm 2. Open wire. Repair.
6
does not work 3.
4.
Buzzer fault.
LMI fault. 务 Repair or replace.
Contact us.
业
1. Burnt fuse. Replace.
外
2. Open wire. Repair.

3. Limit switch inoperative. Replace.
海
Hoist limiter 4. Heavy drum rope brake. Replace.

7
inoperative 5. Solenoid valve inoperative. Repair or replace.
司
6. Solenoid valve poor earthing. Repair.

公
7. Limit switch poor earthing. Repair.

8. Controller fault. Contact us.
销
1. CAN resistant in electrical control box Connect or replace

营
is not connected or damage. resistant.

2. Incorrect circuit in electrical control Check corresponding
Communicatio
8 box. circuit in the box.
n fault
3. Loose or open corresponding incorrect Check corresponding
communication module CAN circuit. circuit.
4. Controller damage. Replace controller.
Fault 1. Indication light circuit damage. Check circuit.
9 indication light 2. Light damage. Replace.
is not on
1. Circuit between light and control Check circuit.
Tricolor light module fault.
10 is not on or 2. Light damage Replace.
incorrect 3. Controller program fault. Replace controller and
update program.
17-22
1. Circuit between gradienter and CAN Check circuit.

bus fault.
Gradienter 2. CAN bus does not connect resistance. Connect resistance.
11
fault 3. Loose gradienter circuit. Check circuit.
5. Gradienter damage. Replace.
1. Circuit between horn and button fault. Check circuit.
Horn dose not 2. Open fuse.
12
sound 3. Horn damage or handle horn button Replace.
switch damage. Replace.
1. Circuit between free swing switch and Check circuit.
solenoid valve fault.
Free swing 2. Open fuse. Replace
13
inoperative 3. Free swing solenoid valve joint Replace.
damage.
部
4. Free swing switch damage. Replace.
1. Circuit between blink light and control Check circuit.
module fault.
务
业
2. Circuit between swing/travel pressure Check circuit.
Travel and
switch and control module fault.
外
14 swing light
3. Pressure switch damage. Replace.
fault
海
4. Blink light damage. Replace.

5. Relay damage. Replace
司
6. Open fuse. Replace

1. Circuit between reverse travel control Check circuit.
公
valve and control module fault.

Unable to
销
15 2. Open fuse. Replace.

reverse travel
3. Reverse travel control valve head Replace.
营
damage.
1. Circuit between oil temperature sensor Check circuit.
and controller fault.
2. Oil temperature sensor damage or not Replace.
reaching set temperature.
No movement
3. Circuit between oil fan motor control Check circuit.
16 of oil fan
valve and control module fault.
motor
4. Oil fan motor control valve head Replace.
damage.
5. Circuit error between oil cooling switch Check circuit.
and valve.
17-23
17.7 Common trouble and trouble shooting of air conditioning system

1. Poor contact of electrical or Check corresponding
connector. circuit.
2. Fan switch, relay or thermostat Replace.
1 Fan does not work
switch damage.
3. Open use or too low batter voltage. Replace.
4. Fan damage. Replace.
1. Obstacle on the air inlet side. Rinse.
Fan is working, but 2. Evaporator or condenser fin block. Rinse.
2
with small volume 3. Unsmooth heat transfer. Check.
4. Wind impeller stuck or damage. Check or replace.
1. Clutch does not close due to broken Check circuit.
Compressor wire and poor contact.
部
inoperative or 2. Loose compressor belt. Tighten.
3
difficulty in 3. Broken or damaged wire of
operation compressor clutch.
务 Replace clutch coil.
业
4. Too much or too little refrigerant. Check.
Clear leakage point.
外
Insufficient coolant 1. Refrigerant leakage.

4 Refill a suitable amount
(refrigerant) 2. Insufficient refrigerant.
海
of refrigerant.
Condenser is blocked by dust condenser
5 Poor condensing Rinse or replace
司
fan damage.
Hot water valve Replace hot water
公
6 Poor cooling effect due to warm air

damage solenoid valve
销
Low high pressure

gauge pressure, 1. Insufficient refrigerant.
营
Refill.
sometimes low 2. Low pressure pipe line is blocked.
7 Rinse.
pressure gauge is 3. Hot compressor and high pressure
Check and replace.
negative, pipe, internal fault.
compressor fault
High high pressure Empty, vacuum, refill
gauge pressure, high 1. Air in the cycling system. refrigerant.
8
low pressure gauge 2. Refrigerant overcharging. Release a certain
amount.
17-24
1. Too big
expansion
valve. Replace.
Frost on low
2. Poor contact Install correctly.
pressure pipe
of sensing Release refrigerant to
surface
bulb. the required quantity.
3. Too much
refrigerant.
High and low
pressure gauge is Insufficient
Refill refrigerant.
lower than normal refrigerant.
value.
Block in low
Value of low
High or low pressure hose, Repair system, replace
9 pressure gauge is
pressure expansion valve liquid reservoir if there
部
sometimes
block by ice or is ice.
negative.
dust.
Evaporator freezes. 务
Thermostat
Replace.
业
inoperative.
Cold expansion
外
Expansion valve
valve inlet side due Rinse or replace.
block.
海
to frost.
Not cold expansion
司
valve outlet side, Expansion valve

value of low temperature
公
Replace.
pressure gauge is sensing pipe or
销
sometimes bulb leakage.

negative.
营
17.8 Screw connection and hydraulic piping tightening recommended moment

During daily and monthly inspection, check the connection bolts and nuts for looseness and
falling, and the condition of hydraulic piping looseness. Tighten the loose parts and fill the
falling ones.
Screw connection tightening moment (JG/T5011.11-1992) Unit: N·m
Class 4.6 4.8 5.8 6.8 8.8 10.9 12.9
Stress
230 310 380 440 600 830 970
(MPa)
M6 4-5 5-6 7-8 8-9 10-12 14-17 17-20
specification
M8 10-11 13-15 16-18 18-22 25-30 34-41 41-48

Screw
M8×1 10-12 14-17 17-20 20-23 27-32 37-43 43-52
M10 19-23 26-31 31-36 36-43 49-59 68-81 81-96
M10×1 21-25 28-34 35-41 41-48 55-66 76-90 90-106
17-25
M12 33-39 45-53 55-64 64-76 86-103 119-141 141-167
M12×1.5 35-41 47-56 57-67 67-79 90-108 124-147 147-174
M14 53-63 71-85 87-103 103-120 137-164 189-224 224-265
M14×1.5 57-68 77-92 94-110 110-131 149-179 206-243 243-289
M16 82-98 111-132 136-160 160-188 214-256 295-350 350-414
M16×1.5 87-104 118-141 144-170 170-200 228-273 314-372 372-441
M18 113-135 152-182 186-219 219-259 294-353 406-481 481-570
M18×1.5 127-152 171-205 210-247 247-291 331-397 457-541 541-641
M20 160-192 216-258 264-312 312-366 417-500 576-683 683-808
M20×1.5 178-213 239-287 294-345 345-407 463-555 640-758 758-897
M22 218-261 293-351 360-431 416-499 568-680 786-941 918-1099
M22×1.5 239-286 322-386 395-473 458-548 624-747 863-1034 1009-1208
M24 277-331 373-446 457-547 529-634 722-864 998-1195 1167-1397
部
M24×2 301-360 406-486 497-595 576-589 785-940 1086-1300 1269-1520
务
M27 405-485 546-653 669-801 774-801 1056-1264 1461-1749 1707-2044
M27×2 437-524 589-706 723-865 837-1002 1141-1366 1578-1890 1845-2208

业
M30 550-658 741-887 908-1087 1052-1259 1434-1717 1984-2375 2318-2775
外
M30×2 608-728 820-982 1005-1203 1164-1393 1587-1900 2196-2629 2566-3072

海
M36 961-1150 1295-1550 1587-1900 1838-2200 2500-3000 3466-4150 4051-4850
M36×3 1017-1218 1371-1641 1680-2011 1946-2529 2653-3176 3670-4394 4289-5135

司
M42 1536-1839 2071-2479 2538-3039 2939-3519 4008-4798 5544-6637 6479-7757

公
M42×3 1653-1979 2228-2667 2731-3269 3162-3786 4312-5162 5965-7141 6921-8345
M48 2308-2763 3110-3723 3813-4364 4415-5285 6020-7207 8327-9969 9732-11651

销
M48×3 2513-3008 3387-4055 4152-4970 5207-5777 6556-7848 9069-10857 10598-12688

营
Hydraulic piping tightening moment (JG/T5011.11-1992)Unit: N·m

Nominal diameter 1/8″ 1/4″ 3/8″ 1/2″ 3/4″ 1″ 11/4″ 11/2″
Tightening Pipe connector and
— 50 70 95 180 210 350 550
moment screw(high pressure)
(N·m) Pipe screw(low
15 20 30 50 70 110 160 200
pressure)
17-26
Note
1. Due to the large tightening moment, using spanner to increase the moment by 4 times.
2. Check and tighten strictly according to the time schedule of daily, monthly and
annually inspection.
3. The tightening of hydraulic piping tightening moment table. When the moment is
beyond the limit, the sealing connector is subject to deformation, special attention
shall be paid when tightening under the casting, since there is danger of forming
crack.
4. There shall be no scar on hydraulic coupling surface, and clean the hydraulic
coupling carefully to prevent dirt into it.
部
务
业
外
海
司
公
销
营
17-27
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Hydraulic System Diagrams
18. Hydraulic System Diagram
部
务
业
外
海
司
公
销
营
18-1
Hydraulic System Diagrams XGC55 Crawler Crane Maintenance Manual
18. Hydraulic system diagram- domestic configuration
部
务
业
外
海
司
公
销
营
18-2
XGC55 Crawler Crane Maintenance Manual Hydraulic System Diagrams
Hydraulic system diagram- Linde configuration
部
务
业
外
海
司
公
销
营
18-3
Hydraulic System Diagrams XGC55 Crawler Crane Maintenance Manual
Hydraulic system diagram-mixing configuration
部
务
业
外
海
司
公
销
营
18-4
XGC55 Crawler Crane Maintenance Manual Electrical System Diagrams
19. Electrical System Diagrams
部
务
业
外
海
司
公
销
营
19-1
Electrical System Diagrams XGC55 Crawler Crane Maintenance Manual
19. Electrical system diagrams
部
务
业
外
海
司
公
销
营
Fig. 19-1
19-2
部
务
业
外
海
司
公
销
营
Fig.19-2
19-3
部
务
业
外
海
司
公
销
营
Fig.19-3
19-4
部
务
业
外
海
司
公
销
营
Fig.19-3a
19-5
部
务
业
外
海
司
公
销
营
Fig.19-4
19-6
部
务
业
外
海
司
公
销
营
Fig.19-5
19-7
部
务
业
外
海
司
公
销
营
Fig.19-6
19-8
部
务
业
外
海
司
公
销
营
Fig.19-7
19-9
部
务
业
外
海
司
公
销
营
Fig.19-8
19-10
部
务
业
外
海
司
公
销
营
Fig.19-9
19-11
部
务
业
外
海
司
公
销
营
Fig.19-10
19-12
部
务
业
外
海
司
公
销
营
Fig.19-11
19-13
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Appendix
20. Addendum
部
务
业
外
海
司
公
销
营
20-1
Appendix XGC55Crawler Crane Maintenance Manual
20. Addendum
To aid the crane inspector, a check list is attached for repeat inspections of XGC55crawler crane from
XCMG, Construction Machinery Co., Ltd. Building Machinery Co.
Company: ……………….. Inspector: …………………..
Data: …………………….
Manufacturer: XCMG, Building Machinery Co., Ltd. Model: ……….…….……….
S/N: ……………………..
Year: …………………….. Inventory No.: ……………...
Signature of inspector for No.1 to No.20: …………………..
1. Inspection group: crane documentation

Item to be checked A B C D E Remarks
Crane operation manual
Maintenance manual
Lifting capacity manual
部
LMI operation manual
务
Engine operation manual
Air conditioner operation manual
业
Plan operator
外
2. Inspection group: charts/signs

海
Data tag
司
Load capacity data

Decal for operating instructions
公
Warning and safety signs

销
Other safety signs

3. Inspection group: travel gear
营
Item to be checked ABCDE Remarks

Track frame
Drive gear (drive sprocket, travel reducer)
Tensioning roller
Upper roller
Lower roller
Crawler shoe
Crawler shoe connection pin
Steps
Lifting parts
Connection parts (pin shaft, bolts)
A: Existing/Complete B: Condition/Maintenance C: Function
D: Repair/Replacement E: Re-inspection required
done = X not done = — not required = 0
20-2

Data: …………………….
S/N: ……………………..
4. Inspection group: car-body

Car body structural parts
Outrigger structural parts
Outrigger pad
Connection pin shaft
部
Central rotary
Chassis catwalk
务
业
Hydraulic cylinder
Connection tightening bolts
外
4. Inspection group: slewing gear

海
Slewing bearing
Slewing reducer
司
Connection tightening bolts

公
4. Inspection group: turntable

销

Slide door
营
Windshield
Windshield wiper
Mirror
Seat
Heat
Ventilation
Radio
First aid kit
Light
Warning sign
20-3

Data: …………………….
S/N: ……………………..
6. Inspection group: power unit
Engine
Coupler
Air inlet system
Exhaust system
Lubrication system
部
Cooling system
Fuel system
Turbocharger
务
业
Filter
Fuel tank
外
Muffler
海
Oil level gauge

司
Fuel lines and connector

Engine strut, cushion
公
Connection tightening bolt

销
7. Inspection group: hydraulic system

营

Oil tank
Filter
Hydraulic pump
Hydraulic motor
Main valve
Line
Hose
Pressure relief valve
Hydraulic cylinder
D: Repair/Replacement E: require recheck
done = X not done = —not required = 0
20-4

Data: …………………….
S/N: ……………………..
8. Inspection group: electric system
Motor
Generator/alternator
Battery group
Cable, wire, harness
Fuse
部
Resistance
务
Lighting
Lighting/signal/indication/tricolor
业
light, camera
外
Signal device
Control handle
海
Pedal valve
司
Battery switch
Limit switch: gear, steering, drive
公
Support force indicator y

销
9. Inspection group: safety control system

营
Hoist limit switch I and II

Lowering down limit switch I and
II
Boom limit switch I and II
Jib: boom limit switch I
Jib: boom limit switch II
Load instance limit
Controller
Angle sensor: boom/tower jib /jib
LMI/ tension sensor/speed sensor
Anemometer, level gauge
20-5
Data: …………………….
S/N: ……………………..
10. Inspection group: cable drive system

Main hoist winch
Aux. hoist winch (tower jib
luffing winch)
Main luffing winch
部
Aux. rope reeving winch
Main hoist rope
Aux. hoist rope
务
业
Main luffing rope
外
Aux. reeving rope

Wire rope sheave block
海
Rope end installation

司
11. Inspection group: counterweight system

公
Counterweight slab
销
Counterweight tray
营
Locking device
Self-assembly/disassembly
12. Inspection group: hook
Sheave block
Rope bar on sheave block
Axle retainer
Load hook
Load hook installation
Hook block
20-6

Data: …………………….
S/N: ……………………..
13. Inspection group: boom system
Boom/tower jib/fixed jib monitor
Supporting force monitor
Angle sensor
Length indicator: boom/tower jib/fixed jib length
Emergency off
部
Engine shutdown
Boom/tower jib/fixed jib welding structure
务
业
Wire rope sheave
Boom/tower jib/fixed jib backstop device
外
Hydraulic cylinder
海
Reservoir
Spooling out rope
司
Spooling in rope
公
Boom assembly and raising/lowering

销
Rated load
Dynamic load
营
Static load
boom/tower jib/fixed jib connection pendant
Boom center hitch
Boom connection pin shaft
Pendant connection pin shaft
Catwalk
Boom ladder
Note: 1) The crane inspection must be done by experts according to safety regulations.
2) Inspection of winches for used part of theoretical service time.
20-7
营
销
公
司
海
外
业
务
部
XGC55 Crawler Crane Maintenance Manual Memorandum
21. Memorandum
部
务
业
外
海
司
公
销
营
21-1
Memorandum XGC55 Crawler Crane Maintenance Manual
Memorandum
部
务
业
外
海
司
公
销
营
21-2
部
务
业
外
海
司
公
销
营
XCMG, CONSTRUCTION MACHINERY CO., LTD. BUILDING MACHINERY CO.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD.CHINA
Add: No.19 Taoshan Road, Xuzhou Economic Development Zone, Jiangsu, China
Post code：221004
Tel: +86-(0)516-87892525
Fax: +86-(0)516-87892074
Service Tel: +86-(0)516-87892088
Service Fax: +86-(0)516-87892080
Spare Parts Tel: +86-(0)87892086
Spare Parts Fax: +86-(0)87892083
Website: http://www.xcmg.com

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XGC55 CRAWLER CRANE

XCMG, CONSTRUCTION MACHINERY CO., LTD. BUILDING MACHINERY CO.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA

injury or crane damage.

machine according to instructions in them.

4.1 Maintenance of slewing bearing………………………….……..……..…….…………4-2

4.3 Check slewing bearing bolt ………………………..……………..……..…….…………4-3

4.4 Check bolt moment ……………………………………………..……..…….…………4-3

5.1 Check oil level…………………………………………………..……..…….…………5-2

7.2 Check oil level…………………………………………………..……..…….…………7-2

9.5 Check reducer connection bolts…………………………………..……..…….…………9-5

10. Hydraulic System………………………………………………..……..…….…………10-1

10.1 System inspection……………………………………………..……..…….…………10-2

10.2 Hydraulic oil tank……………………………………………..……..…….…………10-2

10.4 Check hydraulic system for leakage…………………………..……..…….…………10-7

10.5 Check pressure hose…………………………………………..……..…….…………10-7

12. Air Conditioner……………………..……………………………..……..…….…………12-1

14.3 Wire rope……………………………………………………..……..…….…………14-5

14.4 Lifting device………………………………………………..……..…….…………14-16

15. Use and Replacement of Oil and Grease………………………..……..…….…………15-1

15.2 Recommended list of common oil grease…………………………….…….…………15-5

15.3 Lubrication and oil replacement………………………………..……..…….…………15-7

17.5 Common trouble and trouble shooting of LMI and display…………………………17-21

1. Service and Maintenance

1. Service and Maintenance

entering into the container.

Make sure that the lubricating grease is free of water.

assistant equipment, and make sure it is free of any risk or damage.

● Prevent over-lubricating, which is not only a waste but also harmful:

The lubricant drops on catwalk may cause injury due to slip;

will cause oil overflow from the tank;

or too much pressure.

● Oil waste and used filter element

immediately if there is power failure.

Disconnect battery power line (-).

Do not continuously apply voltage above 200V.

Place earth connect within 1m around welding point.

1. Inspection on crane condition

according to the “lubricating and maintenance plan”, such as:

● Check oil level and lubricating oil quality

● Check display and monitor device

● Check airbag and filter system for cleanness and function

● Check shafts for sufficient lubrication and abnormal clearance

● Check the nitrogen loading pressure of accumulator.

● Check shafts for damage and wear.

● Check crane equipment for damage and wear.

Item Content Consu Interval (working hour)

4.5 Visually check slewing reducer

Item Content Consu Interval (working hour)

Item Content Consu Interval (working hour)

10.1 Check lighting system ■

Item Content Consu Interval (working hour)

Fig. 3-01 engine outline

after it is stopped before maintenance work.

broken bolts must be replaced.

Fig. 3-02 flow chart of fuel system

Notes on fuel system:

6. Oil return nozzle

8. Oil return circuit to oil tank