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7591-000-07 Service and maintenance

Chapter 7

Service and
Maintenance

Different degrees of normal wear of parts of crane (including the engine) will happen during operation; the
user shall use and maintain the crane regularly in strict accordance with the operation manual of crane and
engine, and inspect and maintain the crane regularly to meet the requirement of local environment
department if necessary. After adjustments and repairs have been made the crane shall not be
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7591-000-07 Service and maintenance

operated until all guards have been reinstalled, safety devices reactivated, and maintenance
equipment removed.maintenance of the crane shall conform to ANSI B30.5:2007 section 5-2.3
Notes:
A crane which has been idle for a period of one month or more, but less than 6 months, shall be given an
inspection conforming with requirements of paragraph (d)(3) of 1910.180 and paragraph (g)(2)(ii) of
1910.180 before placing in service.
A crane which has been idle for a period of six months shall be given a complete inspection conforming
with requirements of paragraphs (d) (3) and (4) of 1910.180 and paragraph (g)(2)(ii) of 1910.180 before
placing in service.
Standby cranes shall be inspected at least semiannually in accordance with requirements of paragraph (d)(3)
of 1910.180 and paragraph (g)(2)(ii) of 1910.180. Such cranes which are exposed to adverse environment
should be inspected more frequently.

7.1

Selection of fuel, cooling medium and torque converter oil

7.1.1 Selection of engine fuel


Select light diesel oil which meets the U.S. EPA2007 according to the lowest air temperature of the
operating environment, the sulphur content shall be lower than 15 PPM.
Please refer to the operation manual of the engine for detailed information on engine oil.
Warning: Never use the fuel oil which is mixed with lubricants or other unauthorized additive.
Caution: Be sure to select the fuel of the viscosity suitable for the air temperature; otherwise,
the engine can not start at low temperature due to freezing. In addition, the fuel tank shall be
filled up as far as possible; otherwise, fuel tank freezing and rust will occur due to coagulation
of air moisture in it and thus hard starting of engine will result.

7.1.2

Selection of cooling medium

It is recommended to select long-acting and four season general antifreeze (ethylene glycol) or long-acting
antifreeze with equivalent boiling point, freezing point, PH value and also can adapt the same lowest
temperature. The ratio of antifreeze and water is usually 1:1.

7.1.3

Selection of hydraulic torque converter oil

Caution: Please refer to the operation manual of the hydraulic torque converter for detailed
information on the hydraulic oil for the hydraulic torque converter. Use the hydraulic
oil of the grade recommended in the operation manual and change periodically
according to maintenance period.

7.2

Lubrication

Proper lubrication to the vehicle can reduce the frictional resistance and mechanical wear of the vehicle,
prevent the malfunctions as well as prolong the service life of the vehicle.All moving parts of the crane for
which lubrication is specified shall be regularly lubricated. All control mechanisms for excessive
wear of components and contamination by lubricants or other foreign matter.Lubricating
systems shall be checked for proper delivery of lubricant. Care shall be taken to follow the manufacturers
recommendations as to the points and frequency of lubrication, maintenance of lubricant levels, and types
of lubricant to be used. Machinery shall be stationary while lubricants are being applied and protection
provided Crane shall be stationary while lubricants are being applied and protection provided.and:1Set all
controls in the off position and ensure all operating features are secured from inadvertent motion by brakes,
pawls, or other means2Lower the boom to the ground, if possible, or otherwise secure against dropping
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7591-000-07 Service and maintenance

7.2.1

Grease gauge of chassis

Apply the grease of the grade that recommended by the manual.


Injection methods: Smear or inject with grease gun
Lubrication drawing

Lubrication Table
SN

Name of oil sites

Number of
oil sites

Lubrication
interval
3106mile
(5000km)

Central reduction gear of front axle

GL-5 85W/90
(10000km)

Front steering knuckle

Ball pin of tie rod

Intermediate support of drive shaft

Slide fork of intermediate drive shaft

3106mile
(5000km)
3106mile
(5000km)
932mile
(1500km)
3106mile
(5000km)
6213mile

Transmission

Category of
lubricants (grease)

Add oil

1
6213mile

Method of
lubrication

(10000km)

31065mile

73

Change oil

Inject
with
grease gun

ZL-2 lithium-based
grease

Inject
with
grease gun

ZL-2 lithium-based
grease

Inject
with
grease gun

ZL-2 lithium-based
grease

Inject
with
grease gun

ZL-2 lithium-based
grease

Add oil
GL-5 85W/90
Change oil

7591-000-07 Service and maintenance

SN

Name of oil sites

Number of
oil sites

Lubrication
interval

Method of
lubrication

Category of
lubricants (grease)

Inject
with
grease gun

ZL-2 lithium-based
grease

(50000km)

Slide fork of rear drive shaft

3106mile

(5000km)
3106mile
(5000km)

Wheel reduction gear of rear axle

GL-5 85W/90
6213mile
(10000km)
3106mile
(5000km)

Central reduction gear of rear axle

3106mile
(5000km)

(10000km)

11

Camshaft of front and rear brake

12

Drag link of steering rocker axis and


front/rear pin of steering cylinder

12

13

Slide fork of front drive shaft

1553mile
(2500km)
3106mile
(5000km)
3106mile
(5000km)
3106mile
(5000km)

Wheel reduction gear of front axle

Change oil

Replenish oil
10
W/40
engine oil

1
6213mile

14

Add oil
GL-5 85W/90

(10000km)

Engine oil pan

Change oil

1
6213mile

10

Add oil

CH-4

Change oil

Inject
with
grease gun

ZL-2 lithium-based
grease

Inject
with
grease gun

ZL-2 lithium-based
grease

Inject
with
grease gun

ZL-2 lithium-based
grease

Add oil

GL-5 85W/90
6213mile
(10000km)

Change oil

Caution:
(1) Confirm the work hours of engine by the engine time counter on tachometer, then perform
of Engine Operation
specific maintenance according to Maintenance regulations of engine
engine
Manual.
(2) The lubricant of power takeoff is from the lubricants of transmission box, oil level depends on
the height of oil filling of transmission box.
(3) Clean the grease adhering to the around of screw plug and check for any oil leakage after
replenishing or changing grease.
(4) For the new vehicle that break-in period is completed, drain the old oil and add thin engine oil to
rear axle when changing gear oil of front and rear axle for the first time; put up front and rear
wheels of the crane
crane,, start engine, engage the gear, clean the rear axle after running for about 5
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7591-000-07 Service and maintenance


minutes, then drain the wash oil and add new gear oil.
(5) For the crane that parking work time is long and traveling is less, the oil changing period of
transmission and engine shall be cut down by half.

7.2.2

Chassis need
needss lubrication per month

7.2.2.1 Check transmission gear


Adopt hydraulic transmission oil, which oil volume is about 28 L and shall be determined by oil scale;
change oil for the first time after working 100 hours, then change oil every other 1000 h (working hours);
oil shall be changed once half a year at least.
Warning: lubricants must be changed when the new transmission has been traveled for
1242~3106 mile (2000~5000 km).

7.2.2.2 Check gear oil of front and rear axle

Caution:
(1) Drain the gear oil when it is still hot. For the new vehicle that break-in period is completed,
drain the old oil and add thin engine oil to rear axle when changing oil for the first time; put up
front and rear wheels of the crane
crane,, start engine, engage the gear, drain the wash oil after
running for about 5 minutes, then add new gear oil.
(2) Add grease until it spills from the oil level hole of main reduction gears and wheel.

7.2.2.3 Replenish grease via grease nipple


Caution: clean the dust and soil adhered to the grease nipple by cloth before replenishing grease.
1)

Replenish grease to drive shaft


Intermediate support of drive shaft

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7591-000-07 Service and maintenance

Slide fork of
drive shaft

2)

Universal joint
bearing of drive shaft

Rear suspension

Rear-mounted upper twist site

Rear-mounted lower twist site

3)

Steering system
Steering drag link

Steering
cylinder

4)

Front axle brake

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7591-000-07 Service and maintenance

Tie rod end

7.2.2.4 Electrode mast of storage battery


Keep cleanness and completeness of the connecting line used for electrode mast, ensure battery and
connecting line are well-connected, clean the battery body and the terminal with carbonated water or
purified water, and smear terminal with vaseline.

7.2.3

Chassis need
needss lubrication every 500 hours

7.2.3.1 Change engine oil


Oil filler

Twist the drain plug of oil pan and filter and drain the engine oil when
engine stops and oil is still hot. Then tighten the drain plug, add engine
oil via oil filler to the full scale of oil level dipstick.
Oil volume for changing
Oil pan: about 4.7 Usgal (18L)
Oil filter: 0.264 Usgal (1L)

The engine is running idle for several minutes after replenishing engine oil. About 30 minutes after engine
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7591-000-07 Service and maintenance


stops, engine oil of every part will return to oil pool and then check oil level, replenish oil if the level is
lower than the full scale of oil level dipstick.
At last, check for any oil leakage
Caution:
(1) High speed or full load operation of engine for long-term will accelerate the deterioration of
engine oil. So if engine oil is serious black while checking, change oil in advance without regard
to working time.
(2) For new vehicle, change engine oil after working for 30~50 h.
(3) Change filter element of oil filter while changing engine oil.
(4) Engine oil will become thin with high temperature in summer and become thick in winter, so
select the oil viscosity that meet temperature condition, or it will cause start hard in winter.
Engine oil viscosity table
Ambient temperature

Oil viscosity

Above 40

20W/40

40~-10

10W/40

Below -10

5W/30 or 10W/30

7.2.3.2 Change gear oil of transmission


Twist the drain plug and drain the gear oil when engine stops and engine oil is still hot. Remove the foreign
matters adhered to the plug, then tighten the drain plug. Add gear oil via inspection plug hole. Oil volume:
about 7.3 Usgal (28L).
For new vehicle, change lubricants after traveling for 1242~3106 mile (2000~5000km).

7.2.4

Chassis need
needss lubrication every three months

Check gear oil of front and rear axle


Bleedscrew

Inspection hole

Twist the plug of inspection hole of front and rear axle, check if the oil level is flush with oil filler, and add
gear oil via inspection hole until it spills from the hole.

7.2.5

Chassis need
needss lubrication every six months
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7591-000-07 Service and maintenance


Change gear oil of rear axle
Twist the drain plug and drain the gear oil when engine stops and engine oil is still hot. After gear oil is
drained, tighten the drain plug and add gear oil until it spills from the inspection hole. Deterioration or

leakage in air or hydraulic systems: Daily.

For new vehicle, change gear oil after working for 250 h.

7.2.
7.2.66

Hydraulic oil

The hydraulic oil tank on this product has been filled with hydraulic oil at delivery. Oil grade: L-HV32.
Caution: This product uses full hydraulic drive, so quality, viscosity and cleanliness of hydraulic
oil is crucial to normal operation of the crane. Neglect of hydraulic oil change by users can result
in various malfunctions of the machine easily and greatly reduce its working life. Our company
will not take any consequences caused by users
users failure to change and filter hydraulic oil as
required by this manual.

7.2.
7.2.66.1 Filter or change period chart of hydraulic oil

Date of
delivery

7.2.
7.2.66.2

200 working
hours

Filter or
change oil

Every 6 months

Filter or
change oil

Hydraulic oil change steps

1)

Change the hydraulic oil in the hydraulic oil tank first. Drain the hydraulic oil in the oil tank, and
remove the main oil return pipe. Clean the oil tank and the filter strictly. You can clean them once
with chemical cleaning agent with a level of contamination by solid particles not exceeding 18/15,
and flush with fresh hydraulic oil with a level of contamination by solid particles not exceeding
18/15 after cleaning and air drying, and then drain the flushing oil and fill fresh hydraulic oil.

2)

Start the engine and run it at low speed; let the oil pump start to work; operate mechanisms
respectively to allow fresh hydraulic oil to drive out used oil in circuits of the system in sequence
(the used oil drained must not flow into the oil tank) until fresh oil flows out of the main oil
return pipe. Then, stop oil pump rotation. Remember to refill the hydraulic oil tank with fresh
hydraulic oil continuously while changing oil in circuits so as to prevent oil pump empty suction.
Connect the main oil return pipe with the oil tank. Finally, set all components to initial working
state and refill the oil tank with hydraulic oil up to the specified level.

3)

Standard for hydraulic oil change: Change hydraulic oil immediately when number of
contamination particles per milliliter of hydraulic oil exceeds any of the following values.
10um

3000

20um

300

30um

100

40um

30

50um

10

100um 1
Caution:
A.

Whenever the hydraulic oil is found seriously contaminated, filter or change promptly.

B.

Select appropriate hydraulic oil according to ambient temperature.


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7591-000-07 Service and maintenance


C.

Hybrid use of hydraulic oils of different grades is not allowed.

D.

Service time of hydraulic oil must not exceed 24 months. If the time limit is exceeded,
continued use of the hydraulic oil is not allowed even if it has been filtered.

E.

Check the oil cylinder for any air bubble and improve the sealing performance. Make the
cylinder operate alternately at the maximum speed and please ensure the piston cylinder
extend and retract to both ends to remove the gas in the cylinder completely.

Liquid thermometer

7.2.
7.2.66.3 Hydraulic oil temperature
On the liquid thermometer there are graduations through which you can observe hydraulic oil temperature.
The maximum working temperature of the hydraulic oil is 80.

7.2.
7.2.66.4 Hydraulic oil volume
Check oil level when the crane is on traveling state, observe temperature of the hydraulic oil and check oil
level via the graduated liquid level gauge and liquid thermometer, and replenish hydraulic oil when oil
level is lower than the lowest scale line. Hydraulic system for proper oil level: daily, when used.

7.2.
7.2.66.5 Table of hydraulic oil characteristics and grades
Characteristics and grades of hydraulic oils required according to ambient temperature (by area and season)
are listed in the table below. Please read it carefully when selecting hydraulic oil.
Ambient
temperature: above
40

Ambient
temperature:
-20~40

Ambient
temperature:
above -30

Ambient
temperature: below
-30

GB11118.1-94

GB11118.1-94

GB11118.1-94

SH 0358-95

L-HM

L-HV

L-HS

Aircraft fluid

Viscosity grade

68

32

22

10

Flash point change (open)


()

180

160

140

92

61.2-74.8

28.8-35.2

19.8-24.2

(5010 (50)

-18

-30

-50

130

130

Item

Reference standard
Variety

Kinematic viscosity (40),


mm/s
Temperature (kinematic
viscosity = 1,500 mm/s) ()
Viscosity index

95

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7591-000-07 Service and maintenance

Item

Ambient
temperature: above
40

Ambient
temperature:
-20~40

Ambient
temperature:
above -30

-9

-33

-45

Pour point ()

Ambient
temperature: below
-30

7.2.
7.2.77 Gear oil
Use the gear oil of the grade recommended in this manual. This product has been filled with SY1172-80
90# industrial gear oil at delivery. Natural parameters of the oil are as follows:
Kinematic viscosity (100), mm/s

Flash point (open) ()

Composition

13.5<24.0

165

Organic acid ester, phosphate ester, silicon acid ester,


fluorocarbon oil, silicone oil, polyphenyl ether +
additives

7.2.
7.2.77.1

Oil change period chart

Date of
delivery

200 working hours

Oil change

Every 12 months

Oil change

Caution:
A.

If the gear oil is found seriously contaminated, change even if oil change period is not
reached.

B.

Check oil level on a regular basis. If the oil level is below the specified position, refill.

C.

Hybrid use of gear oils of different grades is not allowed.

D.

Please use the recommended gear oil according to ambient temperature. Use of
nonconforming gear oil or gear oil of inappropriate viscosity will cause damage to the
reduction unit.

7.2.
7.2.77.2

Oil change site

1) Winch reduction gear

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7591-000-07 Service and maintenance

Fill after this cock is screwed off.

When filling, screw off this cock and


check if the oil level reaches edge of
the cock hole.

Drain oil after the cock on the oil


drain hole is screwed off.

Explanation: Demand quantity of gear oil is approx. 1/2 US gal (1.5 L).

2) Swing reduction gear


Fill after the cock on the oil level inspection hole is screwed off.

Drain oil after


the oil drain
hole plug is
removed.

Check oil level

Explanation: Demand quantity of gear oil is approx. 1US gal (4.5 L).

7.2.
7.2.88 Grease
Use the grease of the grades recommended in this manual. This product uses ZL-2 or ZG-3 grease.
Filling method: Smear or inject with grease gun.

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7591-000-07 Service and maintenance

Parameter
Appearance

Drop point
()

Worked cone penetration


(in)

Moisture (%)

ZL-2 Grease

Pale yellow ~ brown smooth ointment

175

ZG-3
Grease

Faint yellow ~ dark brown uniform


ointment

90

2.5

Category

7.2.
7.2.99

Oil sites of Crane

SN

Lubrication
interval

Name of oil site

Lubrication method

Sort of grease

Upper sheave block (shaft) of boom

Every 10 days

Inject with grease gun

ZL-2 Grease

Sliders on boom

Every 10 days

Smear or inject with grease


gun

ZL-2 Grease

Lower sheave block (shaft) of boom

Every 10 days

Inject with grease gun

ZL-2 Grease

Friction surface on telescopic jib

Every 10 days

Smear

ZL-2 Grease

Upper hinge shaft of luffing cylinder

Every month

Inject with grease gun

ZL-2 Grease

Sheave blocks
auxiliary hooks

Every 10 days

Inject with grease gun

ZG-3 Grease

Oil pump drive shaft

Every day

Inject with grease gun

ZL-2 Grease

Lower hinge shaft of luffing cylinder

Every month

Inject with grease gun

ZL-2 Grease

Outrigger telescoping sliders

Every 10 days

Smear or inject with grease


gun

ZL-2 Grease

10

Main and auxiliary winches

Every 6 months

Pour directly

90# industrial gear


oil

11

Boom spindle

Every day

Smear or inject with grease


gun

ZL-2 Grease

12

Swing reduction gear

Every 6 months

Pour directly

90# industrial gear


oil

13

Wire ropes

Every 10 days

Daub

ZG-3 Grease

14

Sheave block (shaft) of jib

Every 10 days

Inject with grease gun

ZL-2 Grease

(shafts)

of main

and

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7591-000-07 Service and maintenance

Lubrication diagram
14

13

12

11

10
2

10

713

Chapter 7 Service and maintenance

7591-000-07 Service and maintenance

Caution:

7.3

A.

Before filling, wipe up oil cups and the surfaces to be oiled.

B.

Sliding surfaces not listed in the table shall also be greased periodically.

C.

Hybrid use of greases of different grades is not allowed.

D.

When adding grease to bushings, shafts, and bearings, fill until used grease can be
forced off.

E.

If a part of piston rod of the boom luffing cylinder is exposed with the boom kept
on its support, grease the exposed part monthly.

F.

Identification shall be labels or diagrams as described in SAE J983 OCT80, SAE


J298, or reference V.

Initial inspection and maintenance

Inspection procedure for cranes in initial inspection shall be pay attention to the following:
a. Checked main

random repair parts and documents.

b. Leaked and worn hydraulic conponents


c. Checked electric conponents and electric curcuit.
d. Checked hydraulic oil,lubricating oil,grease oil and cooling fluid.
e. Checked critial

conponents .

f. Checked unsteadily for slewing

g. Checked surface paint.


h. Closed encloser ,controltank and toolbox.

7.3.1 Regular inspection and maintenance


Inspection procedure for cranes in regular service is divided into two general
classifications based upon the intervals at which inspection shall be performed. The
intervals in turn are dependent upon the nature of the critical components of the crane and
the degree of their exposure to wear, deterioration, or malfunction.

7.3.2 Inspection and maintenance of transmission


Examine for oil level of transmission everyday.
Start the engine until the transmission reaches normal working temperature (82.2~93.3)
with the rotation speed of 1000-1500 rmp. Then operate the engine with idle rotation and
exchange all the gears slowly to fill up all components of the system with oil. Adjust the
gears to neutral position in order to set the engine at neutral speed.

7.3.3 Inspection and maintenance of tire


Examine whether the tire and wheel rim are damaged once a week. Repair notch, scratch,
fracture, puncture and wear to avoid tire malfunction. Repair or exchange the wheel rim
that is bent, broken down or loose.

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7591-000-07 Service and maintenance


Examine the tire valve once a week. Ensure every tire valve with tire valve cover.
Examine fixed nut of wheel for loose condition once a week. The fixed nut of wheel shall
have a twist for 400-500 ft. lbs.
Tire pressure

Examine the charging pressure of every tire from time to time.

The tire pressure has a possibility to be enlarged because of friction heating during
traveling hours. The tire pressure also has a possibility to be enlarged by overspeed
traveling. In this condition, it is prohibited to outlet the air inside of the tire while slowing
down or switching off is allowed until the tire is cooling down.
The charging pressure shall be measured by precise tire gauge after the tire is cooling
down (once for a certain time).
It is very dangerous to outlet air from the tire that has not been cooled down, which shall
be prohibited. The tire pressure will be decreased and temperature will be increased while
traveling is still going on, at this condition, tire will break down.
Insufficient air pressure over low air pressure will increase the tire bending which could
cause the friction between tire surface and road. This will over enlarge the tire tension,
which increases the danger of friction and damage.
Appropriate air pressure there will be a largest contact surface between tire surface and
road at appropriate pressure, which will increase tire life.
Over large air pressure
over large air pressure will decrease the tire bending which
could cause the squeezing between tire and tire thread to accelerate the wearing of tire
surface.

7.3.4 Inspection and maintenance of air storage tank


Open the outlet valve of air storage tank to release the moisture and sediment at
least once a day.

7.3.5 Inspection and maintenance of cooling liquid level


Examine the cooling liquid level in radiator of engine at lease once a day. Add some
cooling liquid as necessary. The cooling liquid level shall reach the top of radiator tank
with visual measurement. The solution with 50% concentration of the ethylene glycol is
the cooling liquid used for the whole year. Refill up the corrosion inhibitor as necessary.
Please refer to Operation Manual attached with engine or consult the nearest service
center of engine manufacturers for method to select appropriate regulator of cooling
system.
Corrosion inhibitor and clean solution of water shall be adopted to cooling down
efficiently when weather temperature has not reached the freezing point.

1.3.6 Inspection and maintenance of rope


Wire rope inspections
the employer of the crane must conform with the requirements of wire rope
inspections as per the requirements of 1926.1413 & ANSI B30.5:2007 section 5-2.4.
All running ropes in service shall be visually inspected once each working day. A visual inspection
shall consist of observation of all rope that can reasonably be expected to be in use during the
days operations. These visual observations shall be concerned with discovering gross damage that
may be an immediate hazard, including the following: distortion of the rope such as kinking,
16

7591-000-07 Service and maintenance


crushing, unstranding, birdcaging, main strand displacement, or core protrusion. Loss of rope
diameter in a short rope length or unevenness of outer strands shall provide evidence that the rope
or ropes must be replaced. general corrosion broken or cut strands. Care shall be taken when
inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive
pickup points on drums.
Visual examination for hoisting wire rope shall be provided at least once a day. Visual
examination must include the observation to all wire ropes in the whole working day. Visual
observation shall be used for concentration discovering for obvious break that maybe cause direct
harm. The examination includes: wire rope transformation, such as twisting, flattening, loose
strand, cripling, main strand displacement or rope core lengthening; decrease of small wire rope or
severely uneven outside rope strand. The rope shall be exchanged when the above condition
occurs.
The wire rope shall be well lubricated. And maintenance must be provided in accordance with the
grease painting specified in the manual. Socketing shall be done in the manner specified

by the manufacturer of the wire rope or fitting.


rotation-resistant ropes, because of their higher susceptibility to damage and increased
deterioration when working on equipment with limited design parameters. The internal
deterioration of rotation-resistant ropes may not be readily observable. The frequency of
inspection of the wire rope shall be increased when using rotation-resistant rope in boom hoist or
luffing attachment service. Rotation-resistant rope shall be given special care during installation as
it is easily damaged.
boom hoist ropes, because of the difficulties of inspection and the important nature of these ropes.
Rope shall be stored to prevent damage or deterioration. Unreeling or uncoiling of rope shall be
done as recommended by the rope manufacturer and with care to avoid kinking or inducing a
twist.
Prior to cutting a rope, seizings shall be placed on each side of the point to be cut. The minimum
length of each seizing shall be equal to or exceed the nominal diameter of the wire rope to which it
is being applied. Seizing may consist of wire, strand, tape, or other material as ling as the seizing
holds the wires and strands firmly in place during the ropes cutting and handling. The required
number of seizings is as follows:
(1) on preformed wire rope, one seizing on each side of the point to be cut
(2)on nonpreformed wire rope, at least three seizings on each side of the wire rope to be cut.

7.
7.44

Periodic inspection and maintenance

Periodic inspection of the crane shall be pay attaintion to the following :


1) Deformed, cracked, or corroded members in the crane structure and boom.
2) Loose bolts or rivets.
3) Cracked or worn sheaves and drums.
4) Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking
devices.
5) Excessive wear on brake and clutch system parts, linings, pawls, and ratchets.

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7591-000-07 Service and maintenance


6) Gasoline, diesel, electric, or other power plants for improper performance or noncompliance
with safety requirements.
7) Excessive wear of chain-drive sprockets and excessive chain stretch.
8) Excessively worn or damaged tires

7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
pneumatic relief pressure valves. Records shall be kept where they are available to appointed
personne by the manufacturer.

Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.

7.3

Initial inspection and maintenance

Inspection procedure for cranes in initial inspection shall be pay attention to the following:
g. Checked main

random repair parts and documents.

h. Leaked and worn hydraulic conponents


i. Checked electric conponents and electric curcuit.
j. Checked hydraulic oil,lubricating oil,grease oil and cooling fluid.
k. Checked critial

conponents .
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7591-000-07 Service and maintenance


l. Checked unsteadily for slewing

g. Checked surface paint.


h. Closed encloser ,controltank and toolbox.

7.3.1 Regular inspection and maintenance


Inspection procedure for cranes in regular service is divided into two general
classifications based upon the intervals at which inspection shall be performed. The
intervals in turn are dependent upon the nature of the critical components of the crane and
the degree of their exposure to wear, deterioration, or malfunction.

7.3.2 Inspection and maintenance of transmission


Examine for oil level of transmission everyday.
Start the engine until the transmission reaches normal working temperature (82.2~93.3)
with the rotation speed of 1000-1500 rmp. Then operate the engine with idle rotation and
exchange all the gears slowly to fill up all components of the system with oil. Adjust the
gears to neutral position in order to set the engine at neutral speed.

7.3.3 Inspection and maintenance of tire


Examine whether the tire and wheel rim are damaged once a week. Repair notch, scratch,
fracture, puncture and wear to avoid tire malfunction. Repair or exchange the wheel rim
that is bent, broken down or loose.
Examine the tire valve once a week. Ensure every tire valve with tire valve cover.
Examine fixed nut of wheel for loose condition once a week. The fixed nut of wheel shall
have a twist for 400-500 ft. lbs.
Tire pressure

Examine the charging pressure of every tire from time to time.

The tire pressure has a possibility to be enlarged because of friction heating during
traveling hours. The tire pressure also has a possibility to be enlarged by overspeed
traveling. In this condition, it is prohibited to outlet the air inside of the tire while slowing
down or switching off is allowed until the tire is cooling down.
The charging pressure shall be measured by precise tire gauge after the tire is cooling
down (once for a certain time).
It is very dangerous to outlet air from the tire that has not been cooled down, which shall
be prohibited. The tire pressure will be decreased and temperature will be increased while
traveling is still going on, at this condition, tire will break down.
Insufficient air pressure over low air pressure will increase the tire bending which could
cause the friction between tire surface and road. This will over enlarge the tire tension,
which increases the danger of friction and damage.
Appropriate air pressure there will be a largest contact surface between tire surface and
road at appropriate pressure, which will increase tire life.
Over large air pressure
over large air pressure will decrease the tire bending which
could cause the squeezing between tire and tire thread to accelerate the wearing of tire
surface.

7.3.4 Inspection and maintenance of air storage tank


19

7591-000-07 Service and maintenance


Open the outlet valve of air storage tank to release the moisture and sediment at
least once a day.

7.3.5 Inspection and maintenance of cooling liquid level


Examine the cooling liquid level in radiator of engine at lease once a day. Add some
cooling liquid as necessary. The cooling liquid level shall reach the top of radiator tank
with visual measurement. The solution with 50% concentration of the ethylene glycol is
the cooling liquid used for the whole year. Refill up the corrosion inhibitor as necessary.
Please refer to Operation Manual attached with engine or consult the nearest service
center of engine manufacturers for method to select appropriate regulator of cooling
system.
Corrosion inhibitor and clean solution of water shall be adopted to cooling down
efficiently when weather temperature has not reached the freezing point.

1.3.7 Inspection and maintenance of rope


Wire rope inspections
the employer of the crane must conform with the requirements of wire rope
inspections as per the requirements of 1926.1413 & ANSI B30.5:2007 section 5-2.4.
All running ropes in service shall be visually inspected once each working day. A visual inspection
shall consist of observation of all rope that can reasonably be expected to be in use during the
days operations. These visual observations shall be concerned with discovering gross damage that
may be an immediate hazard, including the following: distortion of the rope such as kinking,
crushing, unstranding, birdcaging, main strand displacement, or core protrusion. Loss of rope
diameter in a short rope length or unevenness of outer strands shall provide evidence that the rope
or ropes must be replaced. general corrosion broken or cut strands. Care shall be taken when
inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive
pickup points on drums.
Visual examination for hoisting wire rope shall be provided at least once a day. Visual
examination must include the observation to all wire ropes in the whole working day. Visual
observation shall be used for concentration discovering for obvious break that maybe cause direct
harm. The examination includes: wire rope transformation, such as twisting, flattening, loose
strand, cripling, main strand displacement or rope core lengthening; decrease of small wire rope or
severely uneven outside rope strand. The rope shall be exchanged when the above condition
occurs.
The wire rope shall be well lubricated. And maintenance must be provided in accordance with the
grease painting specified in the manual. Socketing shall be done in the manner specified

by the manufacturer of the wire rope or fitting.


rotation-resistant ropes, because of their higher susceptibility to damage and increased
deterioration when working on equipment with limited design parameters. The internal
deterioration of rotation-resistant ropes may not be readily observable. The frequency of
inspection of the wire rope shall be increased when using rotation-resistant rope in boom hoist or
luffing attachment service. Rotation-resistant rope shall be given special care during installation as
it is easily damaged.
boom hoist ropes, because of the difficulties of inspection and the important nature of these ropes.
20

7591-000-07 Service and maintenance


Rope shall be stored to prevent damage or deterioration. Unreeling or uncoiling of rope shall be
done as recommended by the rope manufacturer and with care to avoid kinking or inducing a
twist.
Prior to cutting a rope, seizings shall be placed on each side of the point to be cut. The minimum
length of each seizing shall be equal to or exceed the nominal diameter of the wire rope to which it
is being applied. Seizing may consist of wire, strand, tape, or other material as ling as the seizing
holds the wires and strands firmly in place during the ropes cutting and handling. The required
number of seizings is as follows:
(1) on preformed wire rope, one seizing on each side of the point to be cut
(2)on nonpreformed wire rope, at least three seizings on each side of the wire rope to be cut.

7.
7.44

Periodic inspection and maintenance

Periodic inspection of the crane shall be pay attaintion to the following :


1) Deformed, cracked, or corroded members in the crane structure and boom.
2) Loose bolts or rivets.
3) Cracked or worn sheaves and drums.
4) Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking
devices.
5) Excessive wear on brake and clutch system parts, linings, pawls, and ratchets.
6) Gasoline, diesel, electric, or other power plants for improper performance or noncompliance
with safety requirements.
7) Excessive wear of chain-drive sprockets and excessive chain stretch.
8) Excessively worn or damaged tires

7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
pneumatic relief pressure valves. Records shall be kept where they are available to appointed
personne by the manufacturer.

Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.

7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
21

7591-000-07 Service and maintenance


pneumatic relief pressure valves. Records shall be kept where they are available to appointed
personne by the manufacturer.

Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.
Inspection interval
New

Periodic inspection items

Every
Month

Every 3
months

Every 6
months

Every
year

60
hours

250
hours

Air, water and oil leakage


of each part of engine

Engine start condition and


abnormal sound

Engine revolutions
exhaust condition

and

Tighten cylinder head and


divided manifold

Valve clearance

Every
250
hours

Every
500
hours

Every
1000
hours

Engine

Tighten the engine fixing


bolts
Wash fuel
strainer

filter

and

Discharge the sediment in


fuel tank

Replace cooling water


Tightening condition
radiator cap
Belt relaxation and injury

of

Caution:
(1) Refer to the Engine operation manual for the service and maintenance of parts and components of
engine assembly.

22

7591-000-07 Service and maintenance

Inspection interval
New

Periodic inspection items

60
hours

250
hours

Every
Month

Every 3
months

Every 6
months

Every
year

Every
250
hours

Every
500
hours

Every
1000
hours

(2) The additives such as antifreeze, rust inhibitor, preservatives, etc. In coolant liquid and engine oil have
a certain degree of toxicity, so it is necessary to avoid the long-term skin contact. Dispose the additives
according to the local rule of environmental protection if it is not used.
Discharge
cylinder

water

air

Check air pressure and


rising condition.

Filter
element

in

Clean
wash

or

Replace

Replace filter element


Exhaust
sediment
Fuel filter

Engine oil

Replace
filter
element

Exhaust
sediment
Oil-water
separator

Replace
filter
element

Oil
quantity
and black
color

Replace

Motor system
Air and oil leakage of each
part of motor system

Shaking of transmission
control system

Looseness
of
transmission
connection end

the
shaft

23

7591-000-07 Service and maintenance

Inspection interval
New

Periodic inspection items

60
hours

250
hours

Every
Month

Every 3
months

Swing of transmission
shaft and shaking of spline

Replace
Liquid
level

Replace

Drive system
Looseness,
cracking,
damage and deformation of
every part of front axle and
rear axle
Looseness of wheel nuts

Shaking of front wheel hub


bearing

Shaking of rear wheel hub


bearing

Abnormal tire pressure


(tread depth, abnormal
wear, sheetmetal, stones
and other objects)

Exchange tire location


Steel ring damage

Every
500
hours

Looseness of rear axle


flange and drive flange

Gear oil of
rear axle

Every
250
hours

Looseness of transmission
shafts neck bearing

Liquid
level

Every
year

Shaking of transmission
shafts bearing

Gear oil of
transmission

Every 6
months

Replace the grease and


grease seal of wheel hub
24

Every
1000
hours

7591-000-07 Service and maintenance

Inspection interval
New

Periodic inspection items

Every
Month

60
hours

250
hours

Oil leakage of steering


system

Play and operating state of


steering wheel

Every 3
months

Every 6
months

Every
year

bearings
Steering system

Performance
steering gear

of

power

Front wheel alignment

Left & right rotation angle

Brake system
Air leakage
system

of

brake

Looseness, shaking and


damage of each part of
brake system

Play of brake pedal or


stroke of push rod in brake
chamber

Brake performance

Interval of brake facings

Abrasion of brake facings

Abrasion of brake drums

Hand braking performance


and reliability of hand
braking operating rod

Abrasion between brake


drums (hand brake) and
brake facings

25

Every
250
hours

Every
500
hours

Every
1000
hours

7591-000-07 Service and maintenance

Inspection interval
New

Periodic inspection items

60
hours

250
hours

Every
Month

Every 3
months

Every 6
months

Every
year

Brake
chamber
performance
and
the
abrasion of slippers

Crack at slack adjuster

Every
250
hours

Every
500
hours

Every
1000
hours

Suspension system
Looseness, sharking and
damage of every part of
suspension system

Oil leakage and damage of


shock absorber

Electrical system
Liquid level of storage
battery

Specific gravity of liquid


of storage battery
Electric
brush
commutator of starter

and

Generator

Caution: the inspection of starter and generator shall be conducted after disassembly; replace the
damaged parts.
Pay much attention to installation, demounting, disassembly and reinstallation operate
softly and steadily by applicable tools to avoid damage.
Looseness and damage of
joints of electrical wirings

Chassis accessories
Function and damage of
illuminating system

Functions of speaker, air


conditioning, heater and
defroster

Functions and liquid level


of Wiper and windshield
sprinkler

26

7591-000-07 Service and maintenance

Inspection interval
New

Periodic inspection items

60
hours
Performance of
each
instrument and indicator
light
Functions
switches

of

250
hours

various

Functions of switch and


indicator light of power
takeoff

Every
Month

Every 3
months

Every 6
months

Every
year

Every
250
hours

Replace the lubricating oil


of power takeoff

Caution: replace the lubricating oil of new power takeoff after 20 hours in use.
Looseness, damage of
exhaust pipe and muffler
Performance
muffler

of

Every
500
hours

exhaust

Performance of cab door


lock catch

Looseness and damage of


cab, splash guard etc.

Add grease on each part of


chassis

27

Every
1000
hours