PUYUAN ZLJ5370JQZ40V TRUCK

CRANE OPERATION MANUAL

QY40/20-2006.
TRUCK CRANE QY40V
Truck model : ZLJ5370JQZ40V
Industrial mode : QY40V
Engine model : WD615.44

VIN marked position

Indication position of VIN:
Vehicle indication code is located on the nameplate and chassis
frame, the position of the VIN on the frame is shown below:
Marked position of VIN: on right longitudinal beam of chassis
TRUCK CRANE QY40V

Engine No
TRUCK CRANE QY40V
 Operation condition
• All the parts of mechanisms of the crane is in running – in condition in preliminary
period, so within the first 100 working hours, max.lifting load of the new crane must
not exceed 24 t (with 8 falls), and never work with Max.speed
• Supporting surface at working site should be firm and even and not sunk
• Operating crane should be stopped when wind force scale exceed 6 (13,8 m/s)
• The crane should be operated fault – freely.
 Safety operation requirements
• When lifting, do not allow anyone to stand under the boom or on the rotating table
• Do not lift a load when somebody stand below. Do not allow anyone to stand on
lifting load.
• Never overload. Do not drag sideway or raise gradient an article. Prohibit lifting an
article buried in or frozen with the ground
• Never lift on the wheels. Do not travel with a lifting load. Set up the outrigger
before operation and adjust the level by level gauge, the tilt of the whole vehicle
should not be more than 1o
TRUCK CRANE QY40V
 Safety operation requirements
• Prohibit telescope with a lifting load
• Prohibit lifting the same load under the condition that two cranes or more than two
cranes are simultaneously used
• The wire rope on the hoisting winch should be less than 3 rounds when lifting any
load.
• Never adjust the brake of the hoisting mechanism with a load
• When the load has been lifted for a long time the operator should not leave the
operator’s cab.
• If there is overhead electric lines nearby the working site, a certain distance
between the boom or boom + jib and the above lines should be kept as
stipulations issued by relative authorities.
• Operating should be done smoothly and slowly, never pull, push and charge over
abruptly
• Often watch the reading of the oil pressure gauge, and stop the machine
immediately to find out cause and remedy it if abnormality occur
TRUCK CRANE QY40V
 Safety operation requirements
• Pay special attention to buzz sounded from the moment limiter when an actual
load is 90% of a rated load
• Stop operating when one of the following items occur
 Overload or weight of a load is not clear.
 A load will fall down due to unsecured or unbalanced banding and hung
 A lining pad is not located between an edge of a load and the wire rope
 A lifting load or a conducting signal can not be identified due to dark working
site.
 Safety operation will be under the influence of a defective or damaged structure
or part, such as a faulty brake, a safe device or a damaged wire rope
 Operator
• The driver with the certification
• The apprentices that have studied for more than half a year under the
supervision of the driver.
• The service and detection personnel for necessary operation.
TRUCK CRANE QY40V
 Operator
• Labor supervisor assigned by higher level department
• The operator should conform to the following requirement
 Good health, quick response
 Eyesight (include rectify eyesight) should be more than 0,7 , not colour blindness
 Listening can satisfy with working requirements
 The driver and commander should possess the following requirements:
a) The driver of this machine must be familiar with this manual, operation principle,
structure, performance, function and adjusting and maintaining methods of this
machine.
b) Before operating, check the brake, the hookblock , the wire rope and the safety
devices and timely remedy it if abnormality is found
c) When operating focus attention and do not talk with other person. Normally only
respond to a signal from an operator appointed. But, a stop signal should be
responded to whether it is sent anytime by anybody. Refuse to execute if a
command is not conformed to the operation regulation. Stop operating if anyone
climb up this machine.
TRUCK CRANE QY40V

 The driver and commander should possess the following requirements:

d) Do not operate when being ill of having a bad feeling, Prohibit operating after wining
 Preparation before operation
 Superstructure
• Before start the crane, check the following items, when the abnormality occurs,
remedy it timely.
• Inspect every part for lubricating condition. Add oil or grease
• The oil in the hydraulic oil tank should be above the specified level. Do not mix other
oils with different brands. Do use filter screen when add oil, never let any other
foreign matters enter in to the hydraulic oil tank.
• Inspect the pumps, the valves, the cylinders, the motors and the fittings in the
hydraulic oil line for leakage
• Inspect the hose connector in the outriggers, the derricking and the telescoping
mechanisms for looseness
• Inspect the drive coupling of the gear pump for security.
TRUCK CRANE QY40V
 Preparation before operation
a) Superstructure
• Inspect all the connecting bolts of the slewing ring, the slewing and the hoisting
mechanisms for security
• Inspect the hoisting and the telescoping wire rope for wear. Replace them when
the wire ropes fall in to one of the following:
 In one strand, number of broken wire exceeds 10% of the original
 A reduction in diameter exceeds 7% of the nominal diameter
 Kinked
 Obviously loosed
 Seriously rusted
• Lubricate the wire rope twice every month, use the cloth to clear it, and then
lubricate
• Inspect the instruments, the indicators, and the safety device for normality
• Inspect the control levers for manoevrability and reliability and their position for
correctness
TRUCK CRANE QY40V
 Preparation before operation
 Check after duty
• Check every positions for the leakage of oil, air and water
• Check the bolts and nuts for looseness
• Check the tools and the accessories for completeness
• Do necessary cleaning after work
• Record working condition and abnormality
 Check before the traveling of the whole vehicle
• Before start the crane, check the following items, when the abnormality occurs,
remedy it timely
• Check the perfection of the whole vehicle, check the water and oil for sufficiency,
check the joints of the oil pipe, air pipe and water pipe for leakage.
• Check the tire pressure to see if it conforms to the requirements. Check the tire
for damage.
• Check the connection of the battery for tightness
TRUCK CRANE QY40V

 Preparation before operation

 Check before the traveling of the whole vehicle
• Check the instruments, lighters, signals, wipers for normality
• Check the parts of the steering system , brake system, for adaptability safety and
reliability
• Check the tightness of steering shaft universal bolt, left spring bolt, hub bolt,
breakage of the leaf spring
• Check the reservoir to see if there is any water
 Superstructure
• Prohibit anyone in the operator’s cab when the crane is in traveling condition
• Fully retract the boom, place the jib and the hook on the stipulated positions and
the boom on the bracket by the driver’s cab. Connect the hook with the frame
hook with ring and then secure it with the pressing plate
• Apply the brake on the slewing mechanism
TRUCK CRANE QY40V

 Preparation before operation

 Superstructure
• Apply the brake of the hoisting
mechanism
• Fully retract the outriggers
• Disengage the PTO switch. Lock up
the operator’s cab
 Main technical performance and
specification of the crane
TRUCK CRANE QY40V
 Main technical performance and specification of the crane
 Main specification of the whole vehicle
• Working performance specification
1. Max rated lifting capacity ……………………………….40.000 Kg
2. Max lifting moment with basic boom length…………..1430 kN.m
3. Basic boom Max. lifting height ……………………………...11.7 m
4. Max lifting moment with Max. boom length……………..….704 m
5. Boom max lifting height ………..……………………………..40.6m
6. Jib max. lifting height …………………………………...…….55.5m
• Working speed
1. Single line max. speed (main winch) …………….....…145 m/min
2. Single line max. speed (auxiliary winch)………………...88 m/min
3. Lifting boom elevating time …………………………..…….…..59 s
4. Lifting boom extending time………………………..……..…...121 s
5. Slewing speed………………………………………....…….2,2 r/min
TRUCK CRANE QY40V

 Main technical performance and specification of the crane

 Main specification of the whole vehicle

• Traveling specification

1. Max traveling speed……………………………………… > 76 km/h

2. Max gradeability ………………………………..………..………30 %

3. Min turning radius……………..………………………………..<12 m

4. Min clearance…………………….………….……………..…0,281 m

5. Free accelerating emission limit……………………………....40.6m

6. Jib max. lifting height ………………….……………...…. < 2.5 FSN

7. Exhaust displacement ………………..……..confirm with standard

8. Oil consumption/ per 100 kilometers ………………...........40 litres

TRUCK CRANE QY40V - Overall dimension in traveling order
TRUCK CRANE QY40V
 Main technical performance and specification of the crane
 Main specification of the whole vehicle
• Mass specification
1. Self weight in travelling condition (gross)…………… 36900 kg
2. Complete vehicle kerb mass…………..……..…..………36705 kg
3. Front axle load …..………..………………………………. 13600 kg
4. Tandem and rear axle load……..……….……………..…23300 kg
• Dimension specification
1. Overall dimensions ………………..… 12750 x 27500 x 3580 mm
2. Outrigger longitudinal span …………...……..…..…………. 5,6 m
3. Outrigger transversal span…..………………………..….…. 6,6 m
4. Boom length ……..……….……………………….…..…10,6 – 40 m
5. Jib length ……………………..…………………….………… 9- 15 m
6. Boom angle………..………………….………………..…...… 2- 80o
TRUCK CRANE QY40V
TRUCK CRANE QY40V
 Note
1. Above working condition is all with outrigger fully extended, never lift a load on the
wheels
2. Capacities above the thick line in the table are based on the boom strength the
others, on stability of the complete machine
3. The values in the table are the Max permissible values and include weight of the
hook block (the main hook block is 420 kg, the auxiliary :115 kg)
4. A working radius given in the table is a horizontal distance from the centerline of
the hook block to the axis of the slewing ring when the hook block is located.
5. When actual boom length is between two values, determine lifting capacity
according to bigger boom and radius
6. Rated lifting capacity should exclude the weight of clings and self weight of jib
(600kg) when boom is used with jib extended
7. Wire size and length
35*7 IWS-17.0-1960*190.000 mm
35*7 IWS-17.0-1960*120.000 mm
TRUCK CRANE QY40V- Lifting height curve
TRUCK CRANE QY40V- Lifting working area diagram with fully outrigger
TRUCK CRANE QY40V- Lifting working area diagram with a haft outrigger
TRUCK CRANE QY40V

 Note

1. Above working condition is all with outrigger fully extended, never lift a load on the
wheels

2. Capacities above the thick line in the table are based on the boom strength the
others, on stability of the complete machine

3. The values in the table are the Max permissible values and include weight of the
hook block (the main hook block is 420 kg, the auxiliary :115 kg)
4. A working radius given in the table is a horizontal distance from the centerline of
the hook block to the axis of the slewing ring when the hook block is located.

5. When actual boom length is between two values, determine lifting capacity
according to bigger boom and radius

6. Rated lifting capacity should exclude the weight of clings and self weight of jib
(600kg) when boom is used with jib extended
TRUCK CRANE QY40V
TRUCK CRANE QY40V
 The operator’s cab

1. All steel structure. Adopt modern streamline type style, all covered PVC decoration
material. Front window and roof window of the operator’s cab are double layered
integral arc window. Roof window is fitted with roller shutter, right, rear and left
side window adopt toughened glass with 5mm thickness. There is a coat hook at
back of right side moving window, and a tea cup support beside the seat. High
back chair, ergonomics design supply wide vision and comfortable operation for
the operator

2. There are wiper, electric control box, computer, etc. in the operator’s cab. You can
control the engine in the operator’s cab to adjust the accelerator. Heating device or
air conditioner can be fitted according to the requirements of the customers.
Devices in the operator’s cab refer to fig 5.2 . All steel structure. Adopt modern
streamline type style and toughed glass, it is fitted with sun shading board, wiper,
electric control panel and computer, etc. You can control the engine in the
operator’s cab. Electric control box panel refers to fig 5.2
TRUCK CRANE QY40V

Moment Front Derricking Auxiliary Main winch Main Electric Roof

limiter window lever hoisting lever high speed hoisting control window
wiper button lever box wiper

Telescoping lever
Sequence
Adjusting lever
Slewing lever
Horn button
Pressure gauge box
Slewing brake pedal
Main and auxiliary winch lock
Accelerator pedal
TRUCK CRANE QY40V
7 6 5 4 3 2 1
1. Key switch
8 2. Enforcement release button

9 3. Enforcement release II button

4. Moment limiter power
10
5. Oil cooler switch
11
6. Switch
12
7. Wiper switch
8. Wiper water pump switch
13 14 15 16 17 18
TRUCK CRANE QY40V

1. Key switch : Control superstructure power

2. Enforcement extending II switch : In any condition, press this switch to control the
3rd , 4th, 5th, boom section. But this operation is abnormal.
3. Enforcement release switch : Press this switch to release the limitation on all
dangerous directions
4. Oil cooling switch: Open this switch, oil cooling fan and oil cooling fan oil cooling
solenoid valve work.
5. Extinction switch : Press this switch, the engine will be extinct.
6. Moment limiter power switch: Open this switch, the moment limiter will work
7. Wiper switch: Open this switch, the wiper will work.
8. Heater switch: Open this switch, the air conditioner will work
9. Air conditioner switch : Open this switch, the air conditioner will work
10. Sequence telescoping A, B signal indicator: A, B signal output by moment limiter,
when the 1st boom section extends to 17,5 m (the 2nd boom extends to 18 m) the
signal A is input, and signal A indicator will be on.
TRUCK CRANE QY40V
12. Overwinding indicator : this indicator will be on together with alarm when the winch
I is overwinding . Check the overwinding switch
13. Power indicator: When the key switch is turned to on position the indicator will be
on
14. Overwinding indicator: When there are only three turns on the main winch, the
indicator will be on.
15. The 5th outrigger overpressure indicator: When the 5 th outrigger pressure pressure
exceeds 7,7 Mpa, the 5th outrigger pressure switch will close, and the 5 th outrigger
overpressure indicator will on simultaneously.
16. The 5th outrigger / front and rear area detection switch: Press the switch tp let the
5th outrigger work, lifting characteristic in the moment limiter should br changed to
the 5th outrigger working condition. The switch should not be pressed if the 5 th
outrigger is not used, use the lifting characteristic in side rear and front area.
17. Lamp main switch : Turn the switch to the 1 st shift, all lamps on the seasaw
switches will be on, turn the switch to the 2 nd shift, the slewing table lamp and
boom lamp will be besides the above mentioned lamps
TRUCK CRANE QY40V

18. Quick stop switch : Open this switch

to stop all the motion.
19. Slewing brake switch: Open this
switch to release slewing brake
20. Enforcement I switch: when the
cylinder II is not extended homely,
(i.e the 3rd ,4th , 5th boom section are
not retracted completely), but want to
retract cylinder I (i.e want to retract
the 2nd section), only need to turn the
switch to enforcement retraction I.
TRUCK CRANE QY40V
 PTO and oil pump drive unit
• Before engaging PTO, the stop valve by the side of the oil tank must be opened!
• The PTO and oil pump drive unit serve function of transmitting engine power to the
oil pump to get high pressure oil and distribute to working mechanisms of the crane
through control valve to do the motions.
• Engagement and disengagement of the PTO can be done by controlling the PTO
switch of the transmission located above the switches in the driver’s cab. The
pressure should be reach the regulated value required by the chassis before
engagement.
• When engaging, first, depress the clutch pedal and push the PTO switch upward,
and the PTO is engaged together with the indicator being on, then release the clutch
pedal, and the oil pump gets into work.
• When disengaging still depress the clutch pedal first, and push the PTO switch
downward and the PTO is disengaged together with the indicator going out, thus,
power is cut off and oil pump stopped. Depressing and releasing PTO should be
done slowly.
TRUCK CRANE QY40V

 PTO and oil pump drive unit

1. Depressing and releasing PTO should be done slowly

2. After PTO is engaged, at this time the accelerator handle beside

the outrigger control valve block or the accelerator pedal in the
driver’s cab can be use to control the speed of the engine, the
accelerator pedal in the driver’s cab can also control the speed of
the engine.

3. During travelling, if the switch is located wrongly in upper

position, it should be pulled to lower position after depressing the
clutch pedal. Otherwise, danger will occur
TRUCK CRANE QY40V
 Outrigger control mechanism
• Structure of outrigger control mechanisms
• The outrigger mechanism consists of the outrigger control valve block,
outrigger beams, horizontal cylinders, vertical jacks, etc.
Outrigger Horizontal Outrigger Vertical Float
box cylinder beam cylinder plate
TRUCK CRANE QY40V
 Outrigger control mechanism
• The control valve block bracket is
mounted on the left and right
chassis beam behind the front
outrigger housing. The accelerator
control lever the 5th select lever (2),
four horizontal and vertical levers
3rd,4th ,5th 6th are mounted on the
panel so that simultaneous or alone
operation of the 4th outrigger and the 7
65
5th outrigger and can be done 4
32
conveniently and reliably 1
TRUCK CRANE QY40V
 Operation of outrigger
• Before lifting a load, choose even and firm ground and set up outriggers, If the ground
is soft or rugged, put a wooden pad beneath the outrigger float to keep the crane in
stable condition.
1.Extending outriggers should be done according to the procedures below:
Do procedure 3 before the outrigger motions
a)Pull upward the horizontal and vertical select levers 3,4,5,6 to the horizontal position
and push downward the extending and retracting select lever 1 to extend position,
then the 4 outriggers beams are extended by horizontal cylinders
TRUCK CRANE QY40V

 Operation of outrigger

After thee outrigger beams are extended completely, put the extending
and retracting select lever 1 back to neutral position

b)Pull the outrigger control levers 3, 4, 5, 6 backward to vertical position and

push the extending and retracting select lever 1 downward to extend
position, then the 4 vertical jacks are extended and the crane is jacked up.
When vertical jacks are extended fully, check to see if the frame is level by
level gauge. If not, adjust some one of the vertical jacks with the extending
and retracting select lever to level. Then, put the control lever 1 to neutral
position.

c)If use the 5th outrigger, put downward the 5th outrigger select lever 1
homely, extending the front outrigger by operating control select lever.

2.Reverse above procedure when stowing the outriggers

TRUCK CRANE QY40V

 Operation of outrigger

3. Extending and retracting of the float

a) Installation of rear right float : extract the inserting pin of the fixed outrigger float
before the rear right outrigger is extended, then pull the float to the vertical
poison with the vertical cylinder, and fix it by fixed inserting pin. Extract the
inserting pin of the fixed float when the rear right outrigger is extended homely
then rotate the float 45o and pull inside homely, then fixed inserting pin.

b) Installation of other three floats: extract the inserting pin of the fixed float before
the outrigger is extended, then pull the float to the vertical position with the
vertical cylinder, and fix it with fixed inserting pin. Extract the inserting pin of the
fixed float when the outrigger is retracted homely, the push the float inside.
TRUCK CRANE QY40V
 Operation of outrigger

Note :

1. During lifting, never operate any outrigger control levers

2. Extending and retracting speed of the outriggers are adjusted by

operating the accelerator control lever.

3. Once the 5th outrigger touches the ground, the extending should be
stopped. If the 5th outrigger is extended too much, the two front
outriggers will loose and can not burden any force, which is not allowed
to occur.

4. Do the procedures of (3) before the motions of the outrigger.

5. Never control the horizontal telescoping of the outrigger before the

vertical outrigger (vertical cylinder) leaves the ground
TRUCK CRANE QY40V

 Hoisting mechanism
The hoisting mechanism consists of the
hydraulic motors, the winch reducer,
the brake, the roller clamping, the wire
rope over- lowering protection device,
wire rope and the main and auxiliary
hook blocks.
The hoisting mechanism includes main
and auxiliary winch. The structure of
the main and auxiliary winch is the
same (only the length is different), they
can be exchanged. The control levers
of main and auxiliary winch are the
same and in the operator’s cab (refer to
fig 5.1). The operation methods refers
to Fig 8.1
TRUCK CRANE QY40V

 Hoisting mechanism
With the counterbalance valve in the
hoisting mechanism, the boom is not
only operated smoothly but also can be
stopped in any position.
The main winch is used with the boom.
The main winch is designed for duty for
the boom, while hoisting is done, the
length of the wire rope may be
insufficient with the boom length being
increased. Thus, adjust by changing
number of fall of the wire rope, and
when doing so, fit the height limit
weight. Auxiliary winch is used together
with jib or boom nose sheave.
TRUCK CRANE QY40V

 Hoisting mechanism
Note:
a) Select the suitable falls of the wire rope according to the length of the lifting boom.
Do not lift if the hook is rotated due to the twisted wire rope
b) Under any condition, turns of the wire rope on the drum must be at least 3e
c) When a lifting load is away from the ground, give a pause to make sure that
safety is ensured and then raise this load continuously
d) When the load has not left the ground, do not do telescoping or derricking to lifting
a grounded load.
e) Do not abruptly move the control lever from” hoist up” to “hoist down” or from “
hoist down” to “hoist up”. While charging, fist, put the lever in neutral position,
then, operate after make sure that the drum is stopped, otherwise, the machine
parts will be damaged.
f) Lifting capacity includes weight of hook and clings
g) Never use high hoisting speed with load
TRUCK CRANE QY40V
 Derricking mechanism: Push the lever forward to
• The derricking mechanism mainly serves lower the boom derricking
the function of increasing boom angle by
extending or retracting the two derricking
cylinders to charge working radius.
• Boom angles varies from -2o to 80o . With a
boom angle of -2o, Its more convenient to
erect the jib and repair the parts of the
boom nose. The control lever of the
derricking mechanism is located in the
operator’s cab. (see fig 5.1). The operation
method refers to fig 9.1
• With the counterbalance valve in the
hydraulic system, the boom is not only
operated smoothly but also can be stopped Push the lever backward to
in any position. raise the boom derricking
TRUCK CRANE QY40V

 Derricking mechanism:

Note:

1. Operating should be very stable. While lifting a load, abruptly operating will result
in severe shock.

2. During lifting loads, lowering the boom, increases the working radius. And, at this
time, take care of avoiding over- turn caused by overload. The max radius should
be limited according to lifting capacity table.

3. Boom min. elevating angle should not be less than 20 o When boom telescopes
without load. (Elevating angle value can be read by angle indicator)

4. The hook should be lowered sufficiently before lowering the boom.

TRUCK CRANE QY40V
 Boom and telescoping mechanism:
1. The boom and telescoping mechanism
The boom and telescoping mechanism include boom, jib, telescoping
cylinder and telescoping wire rope, etc.
The extending wire rope can not be adjusted. If need to adjust the pulling
back rope of the 5th boom, you can open the housing on the head of the 5 th
boom, adjust according to requirements
If need to adjust the pulling back rope of the 4 th boom, you can extend the
3rd , 4th , 5th boom till the pulling rope on right and left side of the head of the
4th boom is exposed, adjust the bolts according to requirements
The retracting wire rope can not be turned when tightening the bolt
2. Operation of boom telescoping
The boom is hexagon box type welded by low alloy plate steel plate and has
five sections. There is boom nose pulley on the head of the boom, which
can let the auxiliary hook work during the operation of the boom
TRUCK CRANE QY40V

 Boom and telescoping

mechanism:

The telescoping of the boom is

realized by the telescoping cylinder
and wire rope. The 2nd ,3rd ,4th,5th
boom sections can telescope
together by the motion of
telescoping cylinder I, the 3rd ,4th
and 5th boom sections can
telescope simultaneously by the
motion of telescoping cylinder II,
For the diagram of boom
telescoping mechanism, please
refer to fig 10.2
TRUCK CRANE QY40V
 Boom and telescoping mechanism:
Telescoping Telescoping Retracting
cylinder I cylinder II wire rope

Retracting Retracting Retracting

wire rope 2nd wire rope 3rd wire rope 4th
TRUCK CRANE QY40V
 Boom and telescoping mechanism:
When the boom telescoping begins, push the control lever forward, the 2 nd boom
section extends to 17,5m (the 2nd boom section extends homely with 18m), the
moment limiter will output signal A and signal A indicator on. When the 2 nd boom
section extends homely, press S31 telescoping boom sequence adjusting switch
(No.4 in Fig 5.2), the 3rd ,4th and 5th boom sections extend continuously, when they
extends to 18m, the moment limiter will output signal B and signal B indicator on,
release the switch at this time, the boom sections continue. When retracting the
boom, pull the control lever backward, the 3 rd ,4th and 5th boom section retract
simultaneously, the B signal indicator will be out when the 3 rd ,4th ,5th boom section
retract to 18m, at this time, should press telescoping boom sequence adjusting
switch (refer to No 4 an fig 5.1) on the telescoping control lever to retract the 2 nd
boom section, release the switch when the A signal indicator on electric control
box is on, and the 2nd boom section continues to retract.
The control lever of telescoping mechanism is set in the operator’s cab, for the
operation methods, refer to Fig 10.3
TRUCK CRANE QY40V

 Boom and telescoping mechanism:

Push the lever forward to
Note: extend the boom telescoping
With the counterbalance valve in
hydraulic system, boom is not only
operated smooth but also can be
stopped in any position.
1.Before telescoping operation, hook can
be hoist up or down along with boom, so
should operate hoist lever to adjust hook
height simultaneously. Operation should
be done slowly and calmly. Telescoping
with a load is severely prohibited
2.Telescoping motions shouldn’t be done
after retraction, should wait 2 seconds
motions can be done Push the lever backward
to retract the boom
TRUCK CRANE QY40V

 Boom and telescoping mechanism:

Note:
3.Boom is not allowed to drag load sideway in
order to prevent side force of boom
4.Cylinder I retraction enforcement switch (No
20 in fig 5.2) cylinder II extension
enforcement switch (No 2 in fig 5.2) only can
be used for adjustment, prohibit using it in
normal.
5.Before extending the boom, check that of
the block on the nose of telescoping boom is
close up the latter boom, if not, adjust the
retracting wire rope to let them close up.
Prohibit extending the 3rd ,4th and 5th boom
section for operation before the 2nd boom
section extends homely.
TRUCK CRANE QY40V
 Change of the wire rope fall
Change the wire rope fall
according to lifting height curve
(fig 3.1) and max pulling force of
sling wire rope limitation (43500
N) and fall table and rated lifting
capacity table. For the detail,
please refer to fig 10.5
Note :
Lubricate each hook
periodically, lubricate each point
at lest for every 100 hours.
Disassembly dust cover when
lubricate the auxiliary hook
TRUCK CRANE QY40V
 Usage and check the wire rope
When one of the following conditions occur, the
hook should be out of use (the defect of the
boom should not add welding)
1.There are crack and cuts on the surface of the
hook
2.The open degree of the hook should not
exceed the 10% of the original dimension.
3.Worn dangerous cross section is 10% of the
original dimension.
4.Worn cross section of wire hanging point
exceeds 10% of the original height.
5.Twist deformation of the hook exceeds 10 o
6.Dangerous cross section of the tail of the hook
and the thread part have plastically deformation
TRUCK CRANE QY40V
 Hook
Basic structure refers to fig 10.6
 Boom nose sheave
The boom nose sheave includes bracket,
pulley shaft, pulley and inserting pin. It is
placed on the outer side of the boom in
traveling condition or not used.
When use boom nose sheave, should
extract pin 1 to let boom nose sheave
rotate toward inside of the boom around
pin 2 180o ,and fit another pin 2, then let
auxiliary hook, at this time, you can use it
The fall of wire rope is single, can hoist or
lower quickly, but be attention to refer
lifting height curve of the boom when
using boom nose sheave
TRUCK CRANE QY40V
 Boom nose sheave
When use boom nose sheave, should
extract pin 1 to let boom nose sheave
rotate toward inside of the boom around
pin 2 180o ,and fit another pin 2, then let
auxiliary winch wire rope wind through
boom nose sheave fit auxiliary hook, at
this time, you can use it. The fall of wire
rope is single, can hoist or lower quickly,
but be attention to refer lifting height
curve of the boom when using boom
nose sheave, the Max. lifting capacity is 3
ton.
When need not use the boom nose
sheave, disassemble it by the reversed
procedures above mentioned, and fix it
on the outer side of the head of the boom
at last
TRUCK CRANE QY40V
Push the button on the slewing lever first to call the
attention of the staff member in the working radius

 Slewing mechanism Push the lever forward to let the

superstructure rotate rightward
Slewing mechanism includes slewing
motor, slewing reducer, brake , drive
gear and slewing ring etc. Control lever
of slewing mechanism is set in the
operator’s cab (refer to fig 5.1), the
control methods refer to fig 11.1
Let the control lever return to neutral
position and brake by pedal brake, the
slewing will be stopped. The brake of
slewing mechanism adopts normally
closed brake, the hydraulic system can
ensure correct starting of the brake
Push the lever backward to let the
during slewing mechanism operation.
superstructure rotate leftward
TRUCK CRANE QY40V

 Slewing mechanism
Note
1. Smooth operate. Never stop of
changeover abruptly, which is
dangerous and should be avoided
2. When doing slewing, be extremely
careful for persons and obstructions
near the crane and sound the horn to
ensure safe operation.
3. Check slewing ring bolt after the first
100 hours’ working for safety. Make
sure that tightening torque should be
900 N.m .Then check again after 500 Slewing brake pedal
hours’ working.
TRUCK CRANE QY40V- Fig 12.1 Power transmitting diagram

Engine Triple gear pump

Hydraulic Outrigger control Upper control

oil tank valve block valve block

Hydraulic Hydraulic
motor motor
Slewing Hoisting
gear winch

Horizontal Vertical Boom Boom

outrigger outrigger telescoping derricking
cylinder cylinder cylinder cylinder
TRUCK CRANE QY40V
 Hydraulic system
Working principle
Hydraulic system is divided in to superstructure hydraulic system and
chassis hydraulic system. All the hydraulic system adopts manual control, the
main valve in superstructure hydraulic system adopts multichannel proportional
valve with load sensitivity which can make the crane with better jogging. Main
valve supply constant pressure to control the oil to make more stable slewing
motion. Valve block in chassis hydraulic system is fitted with low pressure
relieve valve, which can avoid improper operation, which can result in the bend
of outrigger horizontal cylinder piston rod. Hydraulic system diagram refer to Fig
12.2
The working mechanism consists of the hoisting, the telescoping, the derricking,
the slewing and the outrigger mechanisms. They are all hydraulically driven.
Power is given by the engine and taken off by the PTO, drives triple gear pump
to get high pressure oil is directed to the hydraulic motors or the hydraulic
cylinders via the control valve to accomplish all the functions. The power
transmitting refers to Fig 12.1
TRUCK CRANE QY40V- Fig 12.2 Hydraulic system diagram
TRUCK CRANE QY40V
 Hydraulic system
Working principle
The hydraulic pump is triple gear pump driven by same shaft. The “63” pump enters
into main and auxiliary winch control valve thru center slewing center, which is
specially supplied for hoisting winch motor, The pressure oil of “80” pump enters into
telescoping and derricking mechanism control valve, which is supplied for derricking
and telescoping. If there is no telescoping and derricking motion, the pressure oil of
“80” pump can also combine with the supply oil of “63” pump thru compound valve for
hoisting winch hydraulic motor. The “32” pump is used for the outriggers and the
slewing hydraulic motor.
Because of the compound oil circuit in the hydraulic system, any combination of
motion of the crane can be carried out.
Technical data:
Main winch working speed : 145 m/min Boom full elevating time : 58 s
Boom full extending time : 121 s Slewing speed : 2,4
r/min
Fuel tank effective capacity : 700 lit Oil return filter accuracy : 10 µm
TO TANK 63 80
FROM PUMP 32
 TRUCK CRANE QY40V
 Hydraulic system
Main working circuit introduction :
1. Main hoisting circuit :
Single pump working displacement : 63 ml/r. Double pump combination working
displacement : 143 ml/r
Variable motor displacement : 107 ml/r, adopts hydraulic controlled variable, cut off by
pressure, which is safe and with high efficiency.
The balance valve is fitted on the oil circuit on the hoisting direction, which can
prevent the load from falling because of stalling, and can keep the load in any position
in the air.
Hoisting oil circuit winch brake is normally closed type, and control the lever of main
winch, pressure oil is taken out from main valve feedback pot, then decrease the
pressure thru pressure relief valve to open the winch brake cylinder directly, thus
ensure normal hoisting or lowering motions. When the lever returns to neutral
position, the pressure oil of winch brake cylinder returns back to oil tank thru main
valve, and the brake serves its function by the action of spring force
TO TANK 63 80
FROM PUMP 32
 TRUCK CRANE QY40V
 Hydraulic system
Main working circuit introduction :
2. Auxiliary hoisting circuit :
Single pump working displacement : 63 ml/r. Double pump combination working
displacement : 143 ml/r
Variable motor displacement : 107 ml/r.
The balance valve is fitted on the oil circuit on the hoisting direction, which can
prevent the load from falling because of stalling, and can keep the load in any position
in the air.
Hoisting oil circuit winch brake is normally closed type, and control the lever of main
and auxiliary winch, pressure oil is taken out from main valve feedback pot, then
decrease the pressure thru pressure relief valve to open the winch brake cylinder
directly, thus ensure normal hoisting or lowering motions. When the lever returns to
neutral position, the pressure oil of winch brake cylinder returns back to oil tank thru
main valve, and the brake serves its function by the action of spring force
TO TANK 63 80
FROM PUMP 32
TRUCK CRANE QY40V

 Hydraulic system
Main working circuit
introduction:
3. Derricking circuit :
Single pump working
displacement : 80 ml/r.
When derricking up, the Max.
system working pressure is
adjusted to 21 Mpa. The
balance valve is fitted on the
oil circuit on the derricking up
direction, which can prevent
the load from falling because
of stalling, can keep the load
in any position in the air
TO TANK 63 80
FROM PUMP 32
 TRUCK CRANE QY40V
 Hydraulic system
Main working circuit introduction :
4. Telescoping circuit :
Pump working displacement : 80 ml/r.
The boom has 5 section, the 2nd ,3rd ,4th
and 5th boom are telescoped by
telescoping cylinder and telescoping wire
rope. First let cylinder I extend to drive
the extending of the 2nd ,3rd ,4th and 5th
boom section. When the cylinder I
extends homely, let the cylinder II extend
to drive the extending of the 3rd ,4th and
5th boom sections. For the retraction,
cylinder II first, then cylinder II. The
balance valve and low pressure relief
valve are fitted in the circuit to ensure
stable and reliable stop during boom
retraction
TO TANK 63 80
FROM PUMP 32
 TRUCK CRANE QY40V
 Hydraulic system
Main working circuit introduction :
5. Slewing circuit :
Pump working displacement : 32 ml/r.
Fixed motor displacement : 28 ml/r.
All the slewing system can work stably.
Opening of slewing brake solenoid valve, to
let solenoid disengage, the brake close,
engage the solenoid valve, the brake is
started by the action of constant pressure
Thecontrol
slewingoil.brake solenoid valve control button is set on the panel, close the solenoid
valve can let the slewing of the superstructure par in lock condition.
When open the control button of the slewing solenoid valve, the superstructure part is in
float condition, which can realize the free centralization of the slewing to prevent the
boom from bending because of side force
The check oil add valve is fitted on the A, B pot of motor to prevent the damage of
slewing motor because that the oil in the circuit is absorbed emptily
 TRUCK CRANE QY40V
 Hydraulic system
Adjusting of hydraulic system
The relief valves are built in the hydraulic system for the outrigger, the telescoping,
the derricking, the slewing and the hoisting mechanisms to prevent the system from
overloading and to ensure safety operation. The relieve valve pressure of boom
derricking, derricking system are adjusted to 21 Mpa, the relieve valve pressure of
winch mechanism is adjusted to 20 Mpa. Pressure of the relief valves is set before
delivery and should not be arbitrarily adjusted under normal condition. If necessary
or when the relief valves are replaced, adjusting should be done by experienced
technician who is familiar with the structure of the hydraulic system and by the
sequence below.
Adjusting according to the following method:
1. Adjusting according the relief valves for the telescoping and the derricking
mechanisms. Loose the adjusting screw of the relief valve, move the telescoping
control lever to Max. derricking angle position and progressively tighten the adjusting
nut of the relief valve while watching the pressure gauge 1. Lock up the adjusting
screw as soon as the pressure is up to 21 Mpa.
 TRUCK CRANE QY40V
 Hydraulic system
Adjusting according to the following
method:
2. Adjusting the relief valves of the
hoisting mechanism. First, set up the
outriggers to make the crane in working
order. Then, loose the adjusting screw of
the relief valve for the hoisting mechanism,
Turn off the controlled oil pipe of the
hoisting reducer brake and plug the oil
pipe, move the hoisting control lever to
“raise” position and progressively tighten
the adjusting screw while watching the
pressure gauge 2. Lock up the adjusting
screw as soon as pressure is up to 20
Mpa, then assemble the control oil pot of
the winch reducer brake.
 TRUCK CRANE QY40V
 Hydraulic system
Adjusting of hydraulic system
Note:
1. Check cartridge of filter after 250 h working, clean or change if necessary.
2. Clean water or foreign matter from the bottom outlet oil pot of hydraulic oil tank once
every half month. Every year (or after 2000h working) change all hydraulic oil (prolong
change period if the oil doesn’t go bad). Shorten oil change period, when crane is
used in severely bad environment
3. All the valves in hydraulic system have been set before leaving the factory. Adjusted
pressure volume should not touch arbitrarily
4. Don’t weld on cylinders without authorization. Prohibit using cylinder as welding
ground conductor.
5. All pars, especially devices of hydraulic system should not adhere with oil and dirt, so
cleaning should be done after working.
6. Adjusting hydraulic system according to above mentioned requirements, other
methods should not be used
TRUCK CRANE QY40V
 Electric system
General
This system, a single wire system with 24V DC and earth negative, consists of
chassis’ electric and superstructure’ electric.
Instruction of chassis electric refers to ZLJ5413 special purpose’chassis
operational manual.
Superstructure electric includes operator’cab electric, slewing table electric,
boom electric and moment limiter installation.
Superstructure electric and chassis electric are connected by the slip ring of the
center revolving joint
1) Superstructure power (AX1.1, AX1.2, AX1.3, AX1)
2) Superstructure start (AX3)
3) Rear outline lamp, boom nose lamp (AX2)
4) Superstructure extinction (AX4)
5) Loop outline lamp (AX5)
6) The 5th outrigger overpressure ring (AX6)
 TRUCK CRANE QY40V

Power Starting Cab Waiting Fan Cab Wiper Rear Nose Warning Engine Solenoid of
supply switch lamp lamp wiper lamp lamp light stop brake slewing

Fig.13.1 Electric
diagram
TRUCK CRANE QY40V

 Electric system
General
Superstructure electric
diagram refers to the following
diagram I to III
Superstructure electric
mainly includes : all kinds of
control switches, indicators,
wiper, horn, main and auxiliary
winch over winding device, three
turns over lowering device
moment limiter, heater and air
conditioner
 TRUCK CRANE QY40V

Moment Temp
limiter limiter

Encoder Winding
rope rope box

Check after and connect Slow Mid High Fan Temp Indicator Fan
Fan Pressure
to switch 5 outrigger speed speed speed heater sensor lamp Indicator cooling
TRUCK CRANE QY40V

Switch to Switch for Telescoping High Nose

speed The 5 over Clutch Cooling
th
connect lowering in order boom
solenoid pressure lamp oil pump
lamp
TRUCK CRANE QY40V

 The function and operation of safety device

Moment limiter

Moment limiter is measuring device with electronic computer as main part, it can
reflect basic specifications of the crane in various conditions. When the actual load
reaches 90% of rated load, the pre-warning signal will sound, when reaches or exceed
the rated load, the warning signal will sound and all the operations in dangerous
directions will be cut (i.e telescoping, hook up, boom lowering), only the operations in
safety directions are permitted, thus to prevent turnover, boom folded and personnel
injury because of overload of the crane during operation and ensure normal and safe
operation of the crane. But the operator should not reply on the moment limiter
completely, should operate the crane according to the values in the lifting capacity
table. For details of it, see “Instruction manual of moment limiter”
 TRUCK CRANE QY40V
 The function and operation of safety device
Lifting height limiter
As the hookblock is raised up to a certain height, the height limiting weight is
connected by it, the limit switch turned on and the buzzer in the switch box sounded
to warn, indicator (No.1 in fig5.2) on. Simultaneously, raising the hookblock, extending
and lowering the boom are cut off and safety, ensured. At this time, only allow
lowering the hookblock or retracting or raising the boom (operating toward safe
direction) to disengage the limiting weight and to bring lifting back to normal. In
particular case, if slightly over-hoisting is needed, press enforcement button on the
side of instrument box and all the motions are restored to normal. Do so very carefully
so as to avoid an accident.
Safety device for derricking
In case of high- pressure hoses or oil pipes in the circuit for derricking cylinder being
broken or cut off, the counterbalance valve functions to block the working oil from the
lower chamber of cylinder so that no falling of the boom will occur, and safety , is
ensured.
TRUCK CRANE QY40V

 The function and operation of safety device

Safety device for telescoping
In case of high-pressure hoses or oil pipes in the circuit for the telescoping cylinder
being broken or cut off, the counterbalance valve in the circuit functions to block the
working oil from the upper chamber of the cylinder so that the boom can not retract by
itself and safety is ensured.
Over- lowering cut off device for wire rope.
In order to prevent the wire rope from lowering after lowering completely, when the
last three turns of the wire rope remain on it, the switch of the overlowering device on
the main winch is closed to cut off lowering motion of main winch, and acousto-optic
warning sounds, at this time, only hoisting motion of main winch is permitted. In
special condition, press enforcement switch (No 10 in fig 5.2) to continue lowering
motion of main winch, but should be very careful to avoid accident.
Overpressure protection device of the 5th outrigger
When the bearing pressure of 5th outrigger exceeds set value (7.7Mpa) during front
area lifting operation, the acousto-optic warning in operator’s cab will sound
TRUCK CRANE QY40V

 The function and operation of safety device

Lock device for the outriggers
In case of high-pressure hoses or oil pipes in the circuit for the vertical jacks being
broken or cut, the two way hydraulic lock valve in the hydraulic system functions to
block the pressure oil from the two chambers of the jacks so that the outriggers can
not retract or extend by themselves and safety is ensured.
Boom angle indicator
The boom angle indicator is located at the bottom of the rear end of the basic boom
(at the right side of the operator’s cab) and within operator’s clear view, when he is in
the cab, indicating the boom angles correctly.
Lifting performance table
It is located on the right glass wall of the operator’s cab . It provides with the lifting
capacities with different boom lengths and the working radius and the lifting height.
During lifting, the values shown by the table must not be exceeded.
TRUCK CRANE QY40V

 Others

Hydraulic oil cooling system

The hydraulic system of this truck

crane adopts hydraulic oil cooling
system which includes wind cool and
radiator. When the oil temperature
reaches 70oC, should open the cooler
to cool the hydraulic oil, then let it
return back to the oil tank. Control
switch of the cooler is set in the
operator’s cab.
TRUCK CRANE QY40V
Maintenance
Lubrication
a) Lubricating chart
The working oil and lubricating oils and greases used in the crane can not only ensure
smooth and normal working of the machine parts but also prolong service life and
allow full play to every functions. Therefore, lubricate points with specified oils
periodically. For the lubricating points
b)Cautions in lubricating
Before injecting oil, clean the oil inlets and the grease cups
Inject grease into the bushes, shafts and bearings until original grease is up to outside
Selection of the oil
Hydraulic oil and Filter or exchange period table of hydraulic oil.
The product is full hydraulic drive, so the quality, adhesion and cleanness of the
hydraulic oil is very important for the normal working of the crane. If the customers
ignore the exchange of the hydraulic oil, it is very easy to result in the faulty of the
crane, and greatly shorten the lifetime.
TRUCK CRANE QY40V
 Maintenance
Selection of the oil
Filter or exchange period table of hydraulic oil.
Our corporation will not accept the responsibility of all consequences, if the
customers don’t exchange or filer the hydraulic oil according to the operational
manual.
Filter or exchange hydraulic oil timely at any time the heavy dirtied hydraulic oil is
found.
The customers should select relative brand hydraulic oil according to working
environment temperature, which is helpful to normal working of hydraulic system and
prolong the lifetime of hydraulic parts.
When the temperature is -10oC ~ 40oC, use L-HV32 hydraulic oil
When the temperature is -40oC ~ 30oC, use L-HS32 hydraulic oil
When the crane leaves factory, the brand of hydraulic in the hydraulic system is L-
HV32
When usage time of hydraulic oil is more than 24 months, it should not be used,
though it is filtered.
TRUCK CRANE QY40V
 Maintenance
Selection of the oil
Temperature of hydraulic oil
Max working temperature of hydraulic oil is 80 oC
Effective capacity of hydraulic fuel tank is 273L
Volume of hydraulic oil
Check the oil volume: should check the oil volume when the crane in
preparation condition for traveling, the oil volume should be kept between center of
lower sticker and center of upper sticker
Gear oil
Add or exchange lubrication oil /grease periodically to ensure necessary
requirements for normal working and prolong life time. The lubrication oil /grease of
different brand should not be used together.
TRUCK CRANE QY40V

 Maintenance
Gear oil
Note:
Exchange the oil if the gear oil is heavy polluted, though it doesn’t reach
exchange period
Often check oil lever, if it is below regulated volume, add oil.
Use recommended lubrication oil according to environment temperature,
unqualified or unsuitable adhesive lubrication oil will damage reducing
mechanism.

3 months Exchange 12 months Exchange

Delivery
oil and oil and
date
filters filters
TRUCK CRANE QY40V
 Maintenance
Change the hydraulic oil
Examine the hydraulic oil periodically. For normally used product, examine every 3
months, for the product used frequently and in bad environment, examine every
month. The examined item and limitation value see tab 6.1
The different brands, the different kinds of hydraulic oil can not used be together
Change procedure
a) First change hydraulic oil in oil tank, drain out hydraulic oil in oil tank and
disassemble master return oil pipe, seriously clean oil tank and filter. Use the
chemical preparation for cleaning that its solid grain pollution grade is not more than
18/15, then drain out clean oil, and add new hydraulic oil.
b) Start the engine, and run in slow speed to let the oil pump work, control each
mechanism separately. Use new hydraulic oil to drain out original oil in system’s
each return line, and the original oil should not run into the hydraulic oil tank. Stop
the oil pump until the new oil flows out from the master return oil pipe. While change
the oil in each return line, refill new oil into hydraulic oil tank continuously to prevent
the oil pump from empty suction.
TRUCK CRANE QY40V
 Maintenance
Change procedure
c) Connect the master return oil pipe with oil tank, and finally let each element in
working primary state, refill hydraulic oil in to the oil tank to the stipulated level.
Lubrication grease
• Please use good quality lubrication oil lubrication points refer to fig 31.2 and tab 21.2
• Wipe off the oil cup and the surface that be coated before adding oil
• Lubricate the sliding surfaces that
have listed in the table periodically
• If one part of piston rod of boom
derricking cylinder is exposed,
lubricate exposed part once every
year, when the boom is stored on the
boom bracket.
Oil for engine
Refer to engine operation
manual
Inspect and maintain periodically
 TRUCK CRANE QY40V

8 10
1 2 4 5 6
3 7
9

1 week
10 week
1 week
30 week 16
10 weeks
180 week 15 11
30 weeks 17 14 12
180 weeks 13
TRUCK CRANE QY40V

6. Derricking cylinder lower pivots

1 ZG-3 calcium base grease
7. Accelerator pedal shaft seat
15 ZL-2 lithium base grease
8. Slewing reducer
7
HJ-20 machine oil
9. Boom support shaft
10 No.90 industrial gear oil
10. Winch reducer
13 L-HV32 hydraulic oil
11. Slewing ring oil mouth and gear surface
8 HP57-28 hyperbola gear oil 12. Control level turning shaft and connection point

13. Hydraulic oil tank

1. Boom upper pulley shaft
2. Boom lower pulley shaft 14. Hook pulley shaft

3. Jib rolling shaft 15. Power Propeller shaft

4. Derricking cylinder upper pivots 16. Oil pump propeller shaft
5. Jib pulley shaft 17. Telescoping boom friction pad
TRUCK CRANE QY40V
 Maintenance
Check and maintenance in running period
When the crane has finished 200h lifting works, do the following check and
maintenance:
a) Check the gear meshing in the tank of the hoisting, slewing mechanism, change
the lubricating oil, clean the tank.
b) Drain out hydraulic oil, clean hydraulic tank, change filter cartridge, filter or change
the hydraulic oil.
c) Clean the dust and oil of the tank, check all the assy’ oil, air, water and electric
lines for leakage, and adjust or repair it.
d) Adjust, tighten the connecting bolts for each parts
e) Adjust, align the sensitivity and reliability of each safety devices.
According to the variation of the season and temperature, change the
lubricating oil engine, transmission transfer box, steering box, hoisting mechanism
reducer, slewing mechanism reducer. Disassemble, inspect and clean the cooling
system. Adjust the carburetor and ratio of the battery electrolyte.
TRUCK CRANE QY40V
 Maintenance
Wire rope
Installation method of wire rope refers to
fig 21.3
Wind the wire rope (of main winch/
auxiliary winch) on the roller of the
crane, pay attention to avoid twist.
Let new wire rope through boom top end
exchange auxiliary winch wire rope first
when the wire rope of main and auxiliary
winches all need to be exchanged
Let the wire rope through wire rope fixed
hole of the roller, then insert the rope in
to the hole from other side, to fit the wire
rope on the roller
Pay attention to the inserting way of the
wedge, winch should not be fitted
reserved
TRUCK CRANE QY40V
 Maintenance
Wire rope
Keep the length to hook, and wind the
rest of wirer rope in the roller slowly
Wind thee rope while pulling in order to wind
the wire rope on the roller orderly
Refer to tab 3.2 and hang thee wire on the hook
Fit the winch wire rope on the rope end cone sleeve
Disassembling of the wire rope
Let the wedge out by the hammer and round bar, and disassemble cone sleeve at
wire end from the wire rope.
Extract wire rope from the roller while winding the wire rope on the revolution roller
Use the same way of disassembling cone sleeve, to let the wedge out by the
hammer and round bar, and disassemble wire rope from the roller.
Precautions of operation of the wire rope
Often clean the dirt on the wire rope and lubricate it periodically in order to prolong
the lifetime of the wire rope.
TRUCK CRANE QY40V
 Maintenance
Disassembling of the wire rope
When need to extend the boom and use new wire rope, pay attention to avoid
twisting of the wire rope and the swinging of the goods. When the wire rope is
twisted, turn the wire rope toward the opposite direction of twisting for the same the
opposite direction of twisting for the same rounds to straight it
when fit the new wire rope, if it is difficult to fit all the wire rope evenly, turning the
roller for several turns continuously, it is better to turn 3/ 4 round for once time
First hoist up/down the hook during test running, then lift light load several time, next
add the load gradually, thus it can disperse twisting force and decrease twisting
phenomena.
Often exchange the winch and the wire rope end to let it be worn evenly in order to
use all the wire rope effectively.
Replace standard of wire rope
The longer the wire rope is used, the heavier the aging and damage degree are. It is
difficult to judge when we should replace the wire rope. According to the safety
regulation of the truck crane. The stipulations are as followings.
TRUCK CRANE QY40V

 Maintenance
Replace standard of wire rope
1. When the broken wire rope of every strand is 10% (exclude the wire core)
2. When the diameter is more than 7% less than nominal diameter
3. When the wire rope is twisted
4. When the shape of wire rope is changed obviously, the wire core is
exposed, and is in birdcage shape and it corroded
Replace the wire rope when the above mentioned (1) to (4) phenomena occur.
5. When the wire rope is disengaged from pulley and is pulled tightly.
6. When the wire rope is damaged by the sparks
7. When the wire rope is damaged by the sparks of electric welding or air
welding.
8. When short circuit occurs
9. When the wire rope is effected by high temperature
When the above mention (5)to (9) phenomena occur, replace, replace the wire
rope or not according to damage degree.
TRUCK CRANE QY40V

 Maintenance
Coat the lubrication grease
on the surface of the wire
rope
1. First clean the dust or used
grease on the surface of the
brush or cloth before coat
the lubrication grease on
the wire rope
2. Coat the lubrication grease on the surface of the wire rope evenly by the
brush or cloth. Don’t use the abandoned oil of machine oil because it has
acidity
3. Note: Never touch the wire rope at the front of the pulley by hand in
order to avoid the hand being cut by the wire rope when move the wire rope
by the hand
TRUCK CRANE QY40V
 Troubleshooting during crane operation

Emergency method

No fault will occur if only correctly operate and serve this crane. In order to avoid an
accident in case of a trouble being developed in the hydraulic system, it is better to
take following measure to unload and then remedy it. Be careful when doing so.

When the derricking fails to lower: first, lower the lifting load on the ground, then
remove the fitting of oil pipe to the upper chamber of derricking cylinder and loose
the counterbalance valve and the lower chamber of derricking cylinder, and the
boom lowers while oil flows out slowly.

Troubleshooting

If fault occurs during lifting work, should investigate and analyze first to find out
real cause and adopt adequate methods. The normal troubleshooting refer to below
TRUCK CRANE QY40V
Trouble no
1. PTO is out of control

Cause

1. Pressure is insufficient
2. Air line blocked or leaked
3. PTO switch is out of control
4. Solenoid valve is blocked

Remedy

1. Raise pressure
2. Check and repair air line
3. Repair or replace
TRUCK CRANE QY40V
Trouble no
2. Oil line leaks

Cause

1. Fitting loosened
2. Seal part damaged
3. Pipe broken

Remedy

1. Tighten
2. Replace
3. Weld or replace
TRUCK CRANE QY40V
Trouble no
Oil pressure fails to raise
3.
Cause

1. Oil level too low in tank or suction line blocked

2. Opening pressure of relief valve is too low
3. Insufficient displacement of oil pump
4. Pressure line and returning line communicated each other or
leakage too much in component
5. Oil pump damaged or leakage too much in it

Remedy
1. Add oil or check suction line
2. Adjust relief valve
3. Speed up engine
4. Repair oil line, especially valves, center revolving joint and
motor
5. repair
TRUCK CRANE QY40V
Trouble no Noise in oil line
4.
Cause

1. Air entering into line

2. Oil temperature too low or oil too dirty
3. Pipe line and component not tightened
4. Oil filter blocked
5. Oil level in tank is insufficient

Remedy

1.Repeat operating to clear off air in system or repair

pump to make sure no leakage in suction line
2.Run oil pump at low speed to warm up oil or renew oil
3.Tighten
4.Replace filter element
5.Add oil
TRUCK CRANE QY40V
Trouble no
5. Overheating oil pump

Cause

1. Line or valve inside is blocked

2. Pressure too high
3. Environment temperature too high

Remedy

1.Repair and remedy

2.Adjust relief valve
3.Stop running to cool down
 TRUCK CRANE QY40V
Trouble no
6.

Outrigger can not retract or extend

Cause

1. Two way hydraulic lock faulty

Remedy

1.Repair
TRUCK CRANE QY40V
Trouble no
7.
Outrigger will retract by itself while lifting is being done

Cause

1. Ineffective seal of check valve in two way hydraulic lock

2. Internal leakage in cylinder

Remedy

1.Repair
2.Repair the seal part of piston
TRUCK CRANE QY40V
Trouble no
8.
Pressure gauge inoperative

Cause

1. Damping hole blocked

2. Pressure gauge damaged or inlet line blocked

Remedy

1.Repair
TRUCK CRANE QY40V
Trouble no
9.
Pressure is too high or shocking occurs
when telescoping is being done

Cause

1. Damping hole blocked of counterbalance valve

2. Friction too large between sliding surface and
fixed surface, or block between them

Remedy

1.Clean
2.Repair and lubricate
TRUCK CRANE QY40V
Trouble no
10.
Shocking occurs when boom
lowers

Cause

1. Air entering into cylinder

2. Damping hole blocked of counterbalance valve

Remedy

1.Repeat raising and lowering boom without a

load to clear off air and add oil
2.Clean
TRUCK CRANE QY40V
Trouble no 11.

When brake has been applied

load lowers slowly

Cause

1. Brake friction lining

2. is worn out seriously

Remedy

1.Replace friction lining

TRUCK CRANE QY40V
Trouble no
12.

Accelerator is out of control

Cause

Air entering in to master and slave

cylinder

Remedy

Drain out air from

exhaust screw of slave
cylinder
TRUCK CRANE QY40V
Trouble no
13. Oil pressure is too high with
unloaded hook block

Cause

1. Pipe line blocked

2. Filter blocked

Remedy

1. Turn off fitting to clean out dirt

2. Replace or clean filter element
TRUCK CRANE QY40V
Trouble no
14.

Load will not hoist up

Cause

Oil pressure too low

Remedy

Check and adjust pump and relief

valve
TRUCK CRANE QY40V
Trouble no
15.
Boom will not slew

Cause

1. Oil pressure too low

2. Opening pressure too low in two way damping
valve

Remedy

1. Check and adjust pump and relief

valve
2. Adjust pressure and check spring
for ineffectiveness
TRUCK CRANE QY40V

 Lifting conduct signal

Preparation
Extend the arm straightly to
let be above the head,
part the five fingers
naturally and keep the
palm forward
TRUCK CRANE QY40V

 Lifting conduct signal

Need main hook
Make a first naturally
with single hand to let
it be above the head
and touch the top of
the head slightly
TRUCK CRANE QY40V

 Lifting conduct signal

Need auxiliary hook
Make a first with one
hand and keep the
forearm upward,
extend the other hand
to let the palm touch
another elbow jointly
TRUCK CRANE QY40V

 Lifting conduct signal

Hook - up
Extend the forearm
upward straightly, part
the five fingers
naturally and let the
above the shoulder,
and turn around the
wrist.
TRUCK CRANE QY40V

 Lifting conduct signal

Left hook down
Extend arm downward to
let it be 30O between the
body, part the five
fingers naturally and
turn around the wrist.
TRUCK CRANE QY40V

 Lifting conduct signal

Turn the hook leftward
Extend the right forearm
side upward straightly,
five fingers together
with palm toward the
moving direction of the
load, and let the forearm
be level with the
shoulder
TRUCK CRANE QY40V

 Lifting conduct signal

Turn the hook rightward
Extend the left forearm
side upward straightly,
five fingers together
with palm toward the
moving direction of the
load, and let the forearm
be level with the
shoulder
TRUCK CRANE QY40V

 Lifting conduct signal

Hook a little up
Extend the forearm side
upward with the palm
little higher than the
shoulder, and turn
around the wrist, swing
the palm upward
repeatedly
TRUCK CRANE QY40V

 Lifting conduct signal

Hook a little down
Extend the forearm side
downward, and the
angle between the arm
and the body should be
30o, turn around the
wrist with the palm
downward repeatedly
TRUCK CRANE QY40V

 Lifting conduct signal

The hook slewing leftward
Extend the right forearm side
upward naturally, five
fingers together with palm
toward the moving
direction of the load, move
horizontally repeatedly
TRUCK CRANE QY40V

 Lifting conduct signal

The hook slewing
rightward
Extend the left forearm
side upward naturally,
five fingers together
with palm toward the
moving direction of the
load, move horizontally
repeatedly
TRUCK CRANE QY40V

 Lifting conduct signal

Indicating the landing
position
Extend five fingers to
indicate the landing
position of the load
TRUCK CRANE QY40V

 Lifting conduct signal

Hoist the boom
Extend the arm horizontally to
one side with the thumb
upward others fingers
together, and swing the
forearm upward
TRUCK CRANE QY40V

 Lifting conduct signal

Hoist the boom
Extend the arm horizontally to
one side with the thumb
upward, others fingers
together, and swing the
forearm downward
TRUCK CRANE QY40V

 Lifting conduct signal

Hoist the boom a little
Let one of the forearm at one
side of the chest with five
fingers extending, palm
downward, and keep no
moving. The thumb of
another hand should toward
the palm of the former hand
with other fingers together
and move upward and
downward
TRUCK CRANE QY40V

 Lifting conduct signal

Lift the boom a little
Let one of the forearm at one
side of the chest with five
fingers extending, palm
upward, and keep no moving.
The thumb of another hand
should toward the palm of the
former hand with other
fingers together and move
upward and downward
TRUCK CRANE QY40V

 Lifting conduct signal

Extend the boom
Make a first with two hands
separately, and let the palm
upward, the two thumbs
move toward two sides
separately
TRUCK CRANE QY40V

 Lifting conduct signal

Retract the boom
Make a first with two hands
separately with the palms
downward, two thumbs move
toward each other
TRUCK CRANE QY40V

 Lifting conduct signal

Stop
Let the forearm be horizontal in
front of the chest, extend the
five fingers and let the palm
downward and wave the hand
horizontally to one side
TRUCK CRANE QY40V

 Lifting conduct
signal
Emergency stop
Place two forearms
horizontal in front of
the chest, extend the
five fingers, and let
the palm downward
and wave two
forearms to two
sides separately
TRUCK CRANE QY40V

 Lifting conduct signal

End
Extend all the fingers and
two hands cross in front
of the forehead
TRUCK CRANE QY40V