MAINTENANCE MANUAL CONTAINER REACH STACKER CONTENTS 1 . Preparing Work before Maintenance 2 . Maintenance Cycle Table of the Whole Machine 3. Maintenance of the Equipment 4 . Lubricating 5 . Functional Oil 6 . Checking of Key Bolts 7 . Safty Regulations during Maintenance Work 8 . Common Faults and Measures 9 . Maintenance of Equipment Tracking Sheet Concerning certain type of reach stacker. some photos. can you operate the reach stacker skillfully and safely. safe operation. we strongly recommend you to read this manual carefully before operation. Please put this manual at an easily reachable position for your reference at any time. work of the equipment are listed. We sincerely appreciate your purchase of our product SANY Container reach stacker. □ Protect you from danger owning to improper operation. The Manual may exclude the modification due to the improvement and updating of products. drawing details or optional components shown in the Manual may differ from your machine. railway transfer station. is showed in this part which indicate the direction of maintenance work of the equipment. □Enhance the reliability of the reach stacker. Reading Guidance 1. Our Company has derived the technology quintessence of the production of the container reach stacker mobile in and out of China. We will provide you with high-quality products and highclass after-sales service. 6. We sincerely wish you realizing your ambitious dreams in the future works and making great achievement. which point out direction for diagnosing common malfunction of the equipment.Maintenance Cycle of the Whole Machine Maintenance cycle of key parts of the machine are showed in this part which provide references to maintain the machine in a regular time. It is recommended for you to read and research the Manual carefully and put it together with your machine.Track Record of Maintenance Taking track record provide convenience to the maintaining staff to keep track of the status of maintenance and is easy to check the working condition of the equipment.Function Oils Technical specification of hydraulic oil etc medium and their standards. . technology.Safety during Maintenance Work Safety matters needing attention while maintenance.Information SANY Group The maintenance manual is a manual for you to use and maintain the machine. 9. 10. The manual shows in details the specifications of performance parameter. which may cause death or serious injury if no preventive measure is taken. 4. there will be more detailed information. 2. 3.Preface Preface This manual mainly introduced specific maintenance method of container reach stacker (here after refer to reach stacker) and other malfunction elimination methods. To make the instructions easy.Lubricating Necessary lubricating materials to enable normal The sign of “Danger” means the direct danger. Only after fully understanding this manual.Guidebook of Identifying Common Malfunction Common mechanical/hydraulic/electric system malfunction are introduced in this part. Brand and type of recommended oil by the manufacturer are also listed in this part.Maintenance of the Equipment Maintenance detailed specification of key parts such as engine. operation. highway terminate station and container freight yard. If it is damaged or lost. It is widely used at the container terminal. you should order another one from Hunan SANY Group. we develop the reach stacker. □Reduce the repair cost and the shutdown time. The Manual covers the information and instructions for safety. transmission. technical characters. transportation. checking and lubrication: safety measure in the working place.Inspection of Key Bolts Inspection requirements of each key fastening bolts and torque are listed in this part. the cover sheet and hood may have been dismounted. lubrication and maintenance. It should be always put in the cab for your reference at any time. please contact us for the latest information. 8. 11. Furthermore.Explanation of Signs Danger 5. It will: □Help you understand the reach stacker. operational principle. Clients must lubricate the equipment according to this cycle table. safety measure of product: introduction of personnel's safeguard measures. driving axle and spreader etc. structural composition. The whole equipment lubricating cycle table which includes lubricating points and lubricating cycle is listed. □Enhance the service life of the reach stacker.Preparing Work before Maintenance Preparing work steps are introduced in the Preparing Work before Maintenance part. lubrication and maintenance of SANY Container reach stacker. 7. and mainly used for the stacking and portage of containers. transportation. For any question on the machine or the Manual. Reading Guidance Thanks for your trust to the SANY products. which is completely new container handling equipment. oil tank and volume are introduced in this part. In order to ensure a better operation of the reach stacker. With the rich experience of designing and manufacturing of engineering machinery. Caution There is no safety indication. Notice It awarks people to take attention to the operation and maintenance. which may cause slight or moderate injury if no preventive measure is taken.Reading Guidance Warning It means the potential danger. Caution It means the potential danger. If you ignore this indication. there will be some potential danger to induce loss of property. . which may cause death or serious injury if no preventive measure is taken. 2 Oil Capacity 5. Maintenance of Equipment Tracking Sheet 9-1 3-6 3-7 3-8 3-10 3-11 3-11 3-13 3-14 Font -Arial Size:10pt 4. Safty Regulations during Maintenance Work 7-1 8.8 Repairing and Maintenance of Tyres 3.9 Repairing and Maintenance of Hydraulic System 3.4 Using Principle of Oil 5-1 5-2 5-2 5-3 6.3 Check and Change of Hydraulic Oil 5.4 Repairing and Maintenance of the Steering Axle 3. Common Faults and Measures 7-1 8.3 Repairing and Maintenance of the Drive Axle 3.10 Repairing and Maintenance of Electric System 3-1 3-5 9.1 Repairing and Maintenance of the Engine 3.1 General 8. Checking of Key Bolts 6-1 7.2 Repairing and Maintenance of Transmission 3.3 Common Faults of Hydraulic System and Measures 8. Preparing Work before Maintenance 1-1 2.4 Common Faults of Electrical Control System and Measures 7-1 8-1 1 8-4 8-6 2 . Functional Oil 5-1 5. Lubricating 4-1 4.1 Oil Specification 5. Maintenance of the Equipment 3-1 3.TABLE OF CONTENTS Container Reach Stacker Maintenance Manual TABLE OF CONTENTS Container Reach Stacker Maintenance Manual 1.2 Common Faults of Mechanical Systems and Measures 8.6 Repairing and Maintenance of the Jib System 3.1 Lubrication 4.2 Lubricating Table 4-1 4-1 5.5 Repairing and Maintenance of the Spreader 3.7 Repairing and Maintenance of the Air Conditioner System 3. Maintenance Cycle Table of the Whole Machine 2-1 3. check if there exists damage and leakage. Maintenance parts 24 shaft Drive axle and brake Leakage Check and add oil of drive axle differential and planet 25 system D A B C D Replace oil of drive axle differential and planet gear case C D 27 Clean venthole adaptor C D 28 Check hand brake sheet and hand brake function 26 A B C D 2-1 .Preparing Work before Maintenance 1-1 Engine C D D 50 D exhaust valve 16 Check and add transmission oil A B C D 17 Check if fixed bolt of the transmission shaft is loose and A B C D Gearbox and Broken ★Hang the warning brand of “stop. Specification: We have already done the maneuverability maintenance of the equipment for you.2000 hrs A B C D 2 Replace air filter core A B C D 3 Replace engine oil and engine oil filter core A B C D 4 Replace diesel filter core A B C D 5 Check cooling water quality and amount A B C D 6 Clean foreign matters on the surface of the radiator A B C D 7 Check belt and belt wheel A B C D Check start. Maintenance Cycle Table of the Whole Machine Plan Of Maintenance Serial No. (One is hung on the steering wheel and one is hung at the end of engine) transmission Check rotary speed inductor A B C D Replace transmission filter core C D 20 Replace transmission oil C D 21 Check if fixed bolt and fixed seat are loose and broken 22 Check fixed bolt of drive axle tightness degree A B C D 23 Check if bolts of pressure plate of tyre are loose or broken A B C D Check if drive axle and brake components have oil A B C D 19 ★Ensure engine will be stopped in the safe working site. and water leakage exists A B C D 10 Check if turbocharger and exhaust gas tube have leakage A B C D 11 Replace oil-water separator filter core B C D 12 Clean oil stain in the oil cleaner B C D 13 Replace cooling water filter core 14 Check if damping pad and fixed bolt are loose and 15 brokenCheck and adjust clearance of intake valve and ★Set the limit stop in the front and back of the tyre. One should take the fist maintenance according to C maintenance including adjustment of engine valve clearance. In the run-in period. MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE Container Reach Stacker Maintenance Manual 2. and take away the key. After working its first 50 to 100 h work. so as to prevent accidental movement of engine. ★The function test should be conducted to. client should have a whole maintenance plan before operating. Applicable plan Check air cleaning status indicator 18 Before repairing and maintenance of the Container reach stacker. reach stacker can only stand the medium or less load work. e n h a n c e t h e r e l i a b i l i t y a n d maneuverability.500 hrs Preventive Maintenance A. use the colored ribbon to separate the safety isolated belt. 1. reach stacker must take a maneuverability maintenance. ★Walk one circle around the engine.1000 hrs Preventive Maintenance A. If necessary. and operation of engine A B C D 9 Check if oil. stop. in repairing” on the engine. preparations should be well done strictly according to the following steps: Maintenance items 1 8 ★Close the main switch. reduce repair cost. Preventive Maintenance A-250hrs Preventive Maintenance A. diesel.PREPARING WORK BEFORE MAINTENANCE Container Reach Stacker Maintenance Manual In order to avoid unnecessary break down of reach s t a c k e r. and worn 44 and pitch Check if fixed seat and lock pin on the pitch oil cylinder A B C D are loose. A B C D 53 Maintenance parts Replace main hydraulic oil tank and brake oil tank clearance and damage 30 31 32 Steering axle A B C D 54 Check if bolts of tyre pressure plate are loose and broken A B C D Check if tyre is deflective A B C D C D or broken 34 Check if spherical pin and fixed nut are loose and broken 35 Applicable plan D ventilation filter core Check anti-tilting inductor Check if steering wheel bearing and fixed nut are loose 33 Maintenance items Check if battery water is sufficient A B C D 55 Check all working lights and indicator lights A B C D 56 Check tyre pressure plate and nut tightness degree A B C D Check tyre status and air pressure A B C D Check horn. broken. and worn system 45 Check if slide block on basic boom is abraded to the limit 46 Check if basic boom has cracks by general vision 47 Check oil amount in main hydraulic oil tank and brake oil B C D D A B C D tank Check accumulator pressure 48 49 Hydraulic Check if hydraulic pressure on the hydraulic nameplate system 2-2 A B C D C D is consistent 50 Replace all high-pressure filter cores C D 51 Replace brake oil and brake cooling oil filter core C D 52 Replace hydraulic oil and hydraulic system filter core C D 2-3 . reversing buzzer. broken.MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE Container Reach Stacker Maintenance Manual Serial No. and alarm light A B C D 57 58 Circuit General items C D 59 Lubricate all slide blocks and lubrication points A B C D Check twist-lock and relevant components A B C D 60 Test anti-tilting protective system A B C D 36 Check twist-lock inductor and indicator A B C D 61 37 Check and adjust 20 /40 chain and limit A B C D 62 B C D 63 38 39 Check crane spreader rotary decelerator gear oil and Crane spreader 40 Function Test twist-lock safety interlocking device system test Test integrated function of hydraulic system Check and treat places with oil or water leakage A B C D A B C D A B C D lubricating oil amount Replace crane spreader rotary decelerator gear oil C D Check if fixed bolt of crane spreader rotary gear case C D is loose and broken Check if slide block on the crane spreader is abraded 41 C D to the limit 42 Check if crane spreader has cracks by general vision C D 43 Check if fixed seat and lock pin on the basic boom are A B C D Contraction loose. Maintenance parts Maintenance items Check if steering axial component has abnormal 29 MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE Container Reach Stacker Maintenance Manual Applicable plan Serial No. and so that it can provide clean fuel to the engine. the acidity of the engine oil will be increased. something. Oil drain plug 1 Phenomenon Engine oil level arising water or coolant 2 Engine oil with metal pellet Surface of the spool with is large area damaged Piston ring damaged. engine oil engine oil leakage from the edge and Diesel filter Diesel oil filter core Filling the oil Cause The lube system is infiltrated with ★Change the diesel filter core The diesel may be blocked into the injection system by jammed and unclean filter. Take care of the filling-up amount of the engine oil as charging. When the filter has been blocked. as the contamination of the carbon. tighten it by hand and then screw it three-fourths coil. then loose the bottom valve. As changing the filter core. Otherwise. at last charging the fresh fuel oil. We have to check the status of engine oil regularly. lube ability may be decreased. which make the diesel deficient atomization. lowering the working efficiency of engine. Because of the reasons above. the engine oil 3 Quick reduction of the come into the combustion chamber. the seal rings of the filter should be infiltrated by the fresh engine oil. which may generate chemical reaction with metals. the cooling and lube ability of the engine oil may be decreased. replace another new one (take care to change all the seal O-rings). prompt treatment should be taken. tighten it by hand till touching and then screw it half coil. If the level is too high. Once abnormal situation is found. the engine oil may be blocked into the system. joints 3-1 3-2 . Besides.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual 。 Filter cover Safety filter core Dust collector Filter indicator Main filter core ★Change the engine oil and engine oil filter oil Function of the engine oil: ― Cleaning: Wash away the wear scraps and carbon in the system. so that the metal goes rusty. Firstly detach the core from the top. if too low of the oil level and there may be not enough engine oil into the lube system. Before oil charging Notice No. clean the inner of the oil cup. the foam may come out. Should be taken out as follows: Fresh engine oil and new filter should be used. Attention while changing the diesel filter core: The seal rings of the filter should be infiltrated by the fresh fuel oil. So that engine oil filter core must be changed. ―Cool down: Take away the heat generated by the engine and its components. The performance and decontamination ability of the engine oil may goes bad as the reason of temperature and carbon. the reason is that the viscosity of the water、diesel and engine oil has been decreased. The filter core of the engine oil plays a part of filtering the engine oil. the engine oil should be changed after the usage of a period to ensure the system normal. Engine oil filter core Engine oil filter Fuel inlet Oil dipstick ★Change the oil-and-water trap filter core The main function of oil-and-water trap is to separate the impurity and water from the oil. If belt abrasion.cooling water is not enough. Do not let the engine work on the state of cold. Cut-off valve Notice Do not wash the radiator with high pressure water. the oil may pressed into the gas handing system of booster and engine. the pressure will higher. ★Check belt and pulley Belt checking mode: Press down each section of the belt. Shell anti-freeze (ice point:-45℃) 50L ★Clean the contamination attached on the surface of the radiator In order to the cool the air thoroughly. you should recharge for fear of overheat of the engine. Ways of clear away the contaminations: ―Take away the radiator cover. Way of adjusting the gap: Turn the crankshaft to the position that the inlet valve just open but the outlet valve incomplete open. lube the o-rings with lubrication. normal working of the air condition and generator if the belt loose. get out the old core. ★Inspect the quality and quantity of the cooling water Observe the cooling water on one's own eyes. replace that. If leaking. periodical clear away of the contamination is necessary. ★Check the damping pad and fixed bolt if they are loose It is essential to check if the damping pad damaged or the loose of the bolts before the startup of engine. Once the vent of crankcase is blocked. ―Inspect the damaged radiator fins and rubber seal components. Notice It is important for the warm-up of the engine. ―Exhaust the air of fuel system. working for 2-3 minutes on the state of 1200-1500rpm till the temperature gets normal is ok. 3-4 . and be earlier if narrow. In the end. and the observe sequence of rotational crankshaft is 6-5-4-3-2-1. refill that in time. ★Check the start-up、halt and operation of the engine Follow steps should be abide by before start-up: ―Check all the oil level(engine、gearbox、 hydraulic oil、drive axle、planet gear、brake coolant). ―Wipe out all the exotics on the radiator fins. Check the valve gap. buff when start-up of the engine. so that it is obvious to know whether the oil cup is clean. it is necessary to clean the bottom oil cup. Notice The check sequence of the air valve is 12-3-4-5-6.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual Notice As changing the filter core. 3-3 Bolt Notice Shock pad Never start the engine in the case of disengaged of turbocharger and exhaust pipe. Automatic tension pulley. marking and cut off the power instantly. the downward distance should not exceed 10mm. Notice There may be bad influence to the coolant of the engine. Notice The liquid level of the expansion tank should be checked. It is necessary that the cooling water should be changed when it become worse. open the stop valve. The open and close time of gas gate may be relevant to the gas gate cap.which can See User's Guide of “VOLVO Engine”and “Cummins Engine” for more details of use and maintenance. If any part leaking. Function of damping pad: Fasten the engine onto the frame work. change another one. inspect the leakage of oil、diesel or water. Check the tightness of the spring device. please change all the damaged seal rings、 connected pipe. Check the inner shaft of the device. If the belt loose. ―Clean the radiator with abluent. which may ensure the smooth run of the engine oil before the high speed run of the turbine. ★Check the leakage of the turbocharger and exhaust pipe You must check the leakage situation of the pipe of turbocharger as well as the connectors of each gas hose before the start-up of engine. to tighten it. Filter ★Check oil、diesel or water leakage Go around the machine. then tighten the new one by hand. When the . adjust it if necessary. release it as the engine enable. If still loose. It will be late if the cap big. Framework ★Check and adjust the gap of inlet and exhaust valve Rule of thickness ★change the filter core of cooling water Firstly close the stop valve. ―Turn the fire-key to start-up position. neither too the critical low speed. screw it by half coil. ★Check the speed sensor Check the speed sensor and its support to see if the speed signal can be transferred correctly into the control system by the inductor. first plug the outlet. and may even cause injuries and deaths. ★Check the fixed bolts of the drive shaft The loose bolts may be easily sheared in the action of load and vibration. operation or halt of gearbox. Driving axle Parking brake system Fastening bolt of driving axle Driving wheel Fastening bolt of transmission shaft Notice Tightness of bolts of drive axle: moment 1200NM Oil drain plug Prefilter Notice Shell DonaxTD5W-30 shafting oil is adopted for DANA Clark 36000. then fill the oil to the min position level. The fixed bolts should be inspected carefully for fear of any accident.according to the type of the gear-box. Notice Select the right lubricating oil . Then the seal rings of the filter should be infiltrated by the fresh engine oil. let the oil reach the normal temperature. Vent 3-6 . make sure that only when low speed can the gear position be shifted. tighten it by hand and then screw it tow-thirds coil. open the fuel outlet.then draw the dipstick to oil place of the gear-box.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual 3. If it has been polluted. Relighted the loose shaft bolts with 200NM moment. Change the filter core of gearbox: Firstly detach the old core. ★Check the leakage of driving axle and brake components Check items: Oil dipped disk brake and its connecting tube、 parking brake system and its connecting tube、 differential mechanism、drive wheel and drive axle. may bring about leakage of seal components. ★Clean the connector of vent hole The purpose of cleaning the connector of vent hole is to let the steam in the drive axle escape for fear of high pressure in the drive axle. For the protection of driving device. ★Check the tightness of the fixed bolts of driving axle Loose bolts may easily be cracked with load and vibration. then check the oil dipstick.Add the oil as told when the place is lower than the lowest station. Start the engine. Universal joint bearing Check items: fixed seating、damping pad、bolts ★Check if the fixed bolts and fixed seating are loose Action of fixed seating and damp pad: It plays a part of damping the vibration as the start-up. Transmission shaft 3-5 Rotation speed sensor Oil-immersed disc brake Fixed bolt Damp pad Framework Differential 3. if the universal joint shaft damaged. and give it off. ★Change the gearbox filter Block of filter will reduce oil volume of gear shift and lubrication.2 Repairing and Maintenance of Transmission ★Check and add the drive shaft oil Let the engine run slowly. refill the oil to the max level position of oil dipstick. Fracture of bolts may do a serious impact to our device.3 Repairing and Maintenance of the Drive Axle ★Change the gearbox oil Check if there is any prill in the old oil to see the working condition of gearbox components. As it is finished. Fixed bolt Universal joint bearing Check measures: To see if the fixed bolts loose. If not. 3.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual ★Check the hand brake block and hand brake function Start up the engine. ―Tighten the nuts with the moment of 350NM.release the parking brake.When hoisting overload 3-7 ★Check if the steering wheel shaft and fixed bolts loose Check measures: ―Detach the wheel hub cover. so in order to avoid accidents. rotate the wheel hub for 10 loops. deal with it immediately. if one of the cases occurred. Indicator lamp 3-8 . if any component loose or any abnormal cap and damage as well as the leakage of the steering axle. If the indication lights are in the normal operation state. then fixed on. change it if necessary. which make the container retain to current state for fear of accidents. Find out the abrasion and loose components as early as possible and take some measures to give a precaution for fear of accelerate failure of some components. 3. Before the machine lifting. adjust that if necessary. please check the linking structure.5 Repairing and Maintenance of the Spreader ★Check the rotary-lock and its components Check the rotary-lock components if damaged. please carefully inspect the reliability of inductor. ―Detach the lock cushion ring and lock nuts. If there is something serious. Notice It is important to check the rotary-lock and its components because it plays a key role of lifting the containers correctly and safety. With this mode.25mm. ―Mount on the lock nuts. a kind of overload signal mill be formed. change that immediately if damaged. the induction will send no signal. inspect that if the parking brake nipper can shift on the bracket. Knuckle pin ★ Check the status of rotary-lock inductor and indicator Check items: Each inductor and its connection status. adjust it if necessary.4 Repairing and Maintenance of the Steering Axle ★Check if there exists the gap or damage of components of steering axle Check steering cylinder、joint shaft and joint bearing、steering link rod、damping pad、and counterweight. If the gap of inductor block normal. all the wheels should swing to the same direction. Stop the engine. If not. Check the knuckle-pin if it can roll smoothly. check the spacer ring of wheel hub if it lies on the wheel axle. ―Tighten the nuts with the moment of 350NM again. retighten it. make sure that the truck may not move even if the brake is released. ★ Check if the knuckle-pin and fixed nut are loose Clear out and check the shaft bearing. Bearing Notice ★Check the anti-tipper inductor Function of anti-tipper inductor: In normal condition. Danger There may be danger of crush if machine shift freely.Free stroke can be adjusted by the nuts. anti-tipper inductor is in normally closed state. and be parallel of the back wheel. tighten it with the moment of 350NM. do not stop it until the accumulator charging. Each inductor if not firmed or damaged. and the max rotate distance is not allowed to exceed 0. as well as the cap of brake gasket and Brake disk if it satisfied to the requirement. ―Clean out the grease of wheel hub cover and steering wheel shaft. Check the position of rotary-lock link rod if correct and firm. To find out if the sensor damaged as well as the reliability of angle-bar of induce block or bolts and if the space of inductor normal. ★Check the tyre if deviate In normal cases. causes carriage tail to tilt. ―Film the grease on the safety cover of shaft. the clearance between inductor and induce block will be enlarged. turn the fire key to position 1. Fixed nut Steering wheel shaft Notice Take care of the abrasion state of shaft. planetary gear set. The hydraulic motor lies on the upper of disk brake. Inductor Inductor Inductor ★Check if there exists the gap or damage of components of steering axle Regularly inspection on the fixed bolts is necessary for fear of accidents caused by loose of bolts. then 3-9 3-10 . shim and slide block. ★Check abrasion status of the slide blocks in the spreader There are two kinds of slide blocks on the spreader: side-slide blocks and 20'-40' extension blocks. to find out the cracks as early as possible is necessary. Rotary motor is composed of hydraulic motor. please color it for next inspection if necessary. ★General observations of cracks The spreader is the direct container-lifting device of the machine. Please color them if necessary. disk brake.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual 3. then measure the thickness of slide blocks as well as the gap of slide block and slide components. And the stability of structure and welding of fixed seating. bearing of pin hole and fixed bolts should be checked periodically. which do an action of sustention and guiding. at last reinstall the strap. who are connected by fixed bolts. pin roll. shim and slide block. Firstly detach the bottom strap.6 Repairing and Maintenance of the Jib System ★Check the fixed seating and pin roll of the basic boom if loose or abrasion The fixed seating and pin roll of the basic boom is the key components connected with frame and spreader. ★Check the fixed seating and pin roll of the pitch cylinder if loose or abrasion Check if there is any crack around the fixed seating. which provides rotary power. so that the output of motor and disk brake will be enlarged. usually inspection of the important components. adjust and change the shim if necessary. ★Check if the slide block of basic boom wears to extreme Firstly detach the strap. Disk brake is something that avoids accidental rotation and followed by the rotation of hydraulic motor. which makes the brake released and spreader planetary gear rotated. neutral soap lye or special lubricant can be applied to the bead bottom and ring support of the felly. ―Check if the fixation of pipes is in good condition. To facilitate the installation. ―Check if the fixed bolt of compressor is fastening. Forcible prying and smashing should be prohibited to avoid damage to the sealing layer in the tire and bead. Using different type of tyres may cause early damage of tyres or tyre explosion and endanger people and equipment. ―Adjust the transmission strap tightness of compressor. Low tyre pressure may have bad influence on stability and load capacity of the equipment. to find out the cracks as early as possible. any corrosion and overwear. deflate the tire to reduce the air pressure. the pumping pressure should be ensured at around 1Mpa. ―Changing dangers is companied with danger. blow the dust off from backside. When the nut is screwed down. ―Old tyres can be replaced with retread tyres. 3-11 ★Check the tyre condition and pressure Before starting the equipment. and reinstall it. ―Blow the condenser with compressed air. keep the tyre pressure in a normal condition. The hub nut should be screwed down gradually with symmetrical force. at last reinstall the strap. ★General observations of cracks of basic boom Usual inspection of the usage of basic boom. ―While dismantling tire.8 Repairing and Maintenance of Tyres 3. ―Install the pressure plate on the threaded stud of the hub and screw the hub nut. Don't use the high-pressure squirt gun. ―Check the leakage of each pipe connector. adjust and change the shim if necessary. Main checking items within 200 hours: ―Recheck the above checking items. etc. check if there is any cracks on the tyre surface. Before installing felly. make sure 2~3 circles of screw thread of the stud expose. do not pry the tire bead forcibly. The moment of screwing down the hub nut is 350~370Nm. ―Anyone without formally training is strictly forbade to install or dismantle tyres. which affect the quality of the tire. Notice Add proper amount of coolant. Change the over-wear tyre. use the bead detacher or tire detacher. ★Attention when changing the tyres ―If the tire treads at the 1/4 breadth of the tire is worn in 2~3mm. rotary component and control rocker arm. Check tyre pressure. do not use sharp tools. There might be leakage when the refrigerant connector has grease dirt. ―Change the fresh air filter core. ★Check the tyre platen and nut tightness Check the tyre nut tightness.. harness fixation is solid. check the O-shape loop to see whether there are any defects and apply lubricant on it.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual measure the thickness of slide blocks as well as the gap of slide block and slide components. such as grease lubricant. Main checking items within 100 hours: ―Recheck the above checking items. do not hit the tire with a big hammer. some lubricants. ―Must use tyres appointed by Sany Group. should not be adopted. Too much or too less would affect the cooling effect. Any operation doesn't follow the standard schedule may cause explosion which has enough power to hurt even kill someone. pipes is over close to the heating component. add it when it's too low. ―Check if the connector of circuit harness is in good condition. The direction mark on the side of the tire should be in consistency with the forward direction of the front-handling crane. ★Installation of Tyres ―Install the tire in the felly. Air conditioner should be started for several minutes every week in order to lubricate each component even in winder. ★The Dismantlement of Tyre ―Before dismantling tire. The locating cone hole in the felly should match the outer cone of the hub to ensure the superposition of the felly center and the hub center. Trained workers must follow the operation steps with proper tools. ―Test the installed tire by spinning it. 3-12 . Check and clean dirt on the tyres. front axle with 450NM moment. then deal with that immediately for fear of deeper damage. such as glasses. ―While dismantling tire. which is installed in the wheel hub. ―Take off fresh air filter core. replace the O-shape loop. replace the tire. Notice Don't over charge the tyre. ―Check the fixed bolt of air conditioner is fastening. ―Clean out of the dirt on the condenser. ―While dismantling tire. Pay special attention to the compressor clutch plug. Screw the rear axle nut with 350NM moment. 3. Make sure the right-left amplitude of swing at the maximum outside diameter of the tire is less than 3mm.7 Repairing and Maintenance of the Air Conditioner System Main checking items within 50 hours: ―Check transmission strap tightness of compressor and adjust it promptly. ―When the tire is pumped. There can be at least 20 times brake before the warning light on.and then step on the brake pedal iteratively with under square mode and to keep a small period of time at stepping position each time.9 Repairing and Maintenance of Hydraulic System ★Check the oil volume of main hydraulic tank and brake tank Check the oil volume of hydraulic tank and brake tank if it is sufficient by the window (the oil level height should exceed the red line.MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual MAINTENANCE OF THE EQUIPMENT Container Reach Stacker Maintenance Manual 3. there are two main pressure testing points. whose testing pressure should be the same.5Mpa Notice Please step on the brake pedal as testing the pressure of brake system. Diagram of hydraulic rating plate Start the engine. which bring about high pressure of outlet and burst of oil tube. then get another valve as the accumulator being recharged(initial charging pressure). The hydraulic system is sensitive to the impurity. which should be 2325V as the engine halted 27-29V as the max speed. release the pressure. if deficient please fill in. ★ Change the entire high pressure filter Blocked filter may lower the flow of hydraulic oil. Battery Add electrolyte Test voltage Notice ―Steering pressure testing To keep the engine with medium speed. As the engine powered off. you'd better give a further inspection. There are also pressures testing joints.5Mpa individually. 3.5±0. such as dust. liquid and gas. turn over the start-up key to position 1. turn off the main switch. metamorphous oil may accelerate the abrasion and erosion of components such as pump and valve. Accumulator of brake system Accumulator of control system ★Check the if hydraulic pressure is consistent with the hydraulic rating plate ―Test of the main system pressure Main hydraulic oil tank Brake oil tank Notice As checking the oil volume. Check all the connectors if they are tightened. and check the height of electrolyte. The valve is 1. to keep it in idle speed. the tight damage of chromium piston rod may bring about the leakage of seal components. whose rated pressure are 10 0. Smear the grease on the binding post and connectors.5Mpa. 3-14 . Notice Replace all the seal O-rings. the accumulator pressure of control system is satisfied to the requirement of control system. fill with the plasma water when it is not enough. besides.5MPa and 2. tidy the battery. The result will be displayed on the screen. ―Accumulator pressure testing Start the engine. tie line and joints. the pressure of oil tank may be higher if the breather filter blocked. which can be measured directly. ★Change the hydraulic oil and brake oil The oil may be worsened gradually by the effect of pollution and heat. if not there may be some problems in the system. all of the cylinder should retract to the original position. change the hydraulic oil and brake oil. ★Change the breather filter of main hydraulic tank and brake tank The hydraulic system is sensitive to the impurity ★Check all the work light and indication light Turn on all the work lights and indication lights. turn the steering wheel to only one direction. it will bring about to greater oil pump pressure to make the tube easy to burst. which should be 10-15mm higher than the battery. As the engine halted. 3-13 ―Spreader system pressure testing The spreader system pressure is 14 0. the max pressure you have got in this process is steering pressure.75±0. sand. ―Brake pressure testing Brake pressure should be 14. and get Do not forget to fill in the oil for main pump case first before you have finished the whole renewing of the oil. the movement speed of cylinder may be affected. so periodically change the breather filter.5 0. the measured value (the max charging pressure) as the accumulator has been charged completely. change a new filter core with the moment of 140NM. ★ Change the return oil filter The flow may be hampered if the filter blocked. Observation window for oil volume ★Check the pressure of accumulator There are two accumulators of hydraulic system: Brake system accumulator and control system accumulator. let it rotate at idle speed for 5 minutes (the accumulator may not be charged completely until the charging valve of brake system accumulator shift to coolant loop).10 Repairing and Maintenance of Electric System ★Check if there is enough battery water Check the voltage of battery. to see if they are normal. at the position of 3/4 of the window). take periodical examination. The accumulator measured pressure is composed of brake system and control system testing pressure.5MPa. Please adopt for the VG68G hydraulic oil at the tropical zone or long-time use place. Generally. Start the engine. put a rubber gasket under the battery for fear of drain. Lubricating (butter) method: Firstly clean the grease fitting. do not stop to inject the butter with the grease gun until the old grease is forced out. not sufficient lubrication can cause issuing and excessive wear parts. check if all the standby lights (green) is on. give a warning and flash the red light. 4. Reach stacker use Mobil EP2 hanging type automobile universal lithium grease.1 Lubrication ★ROPS system test Test if the ROPS system is working. 6 spreader 4. it would lock the motion immediately (except contraction). if there is any sign of abnormal. Find out parts that need adjustment. Once the controller get the front tilting signal. that red light would turned on. Amounts Shell antifreeze (freezing point-45°C) 1 250 h 1000 h or one year 1000 h or one year 1000 h or one year 2000 h or one year 2000 h or one year one year 4-2 . test all the hydraulic functions such as pitch and contraction of jib. check if clearance between sensor and sensing block is normal. Lubricant is to guarantee the normal operation of machine of lubricating necessary materials. reverse buzzer and rotary warning light Turn on the horn. expansion.2 Lubricating Table 4-1 Mobil lubricating grease EP2 Sideshift surface of spreader 4 60 h or every 4 week 4 Extension-contraction cylinder lug of 4 spreader Rotary lock of spreader 8 Turntable slewing bearing of spreader 4 Transmission axle 3 Parking brake 1 Diesel engine Brake oil tank Reducer of driving axle Differential of driving axle Hydraulic oil tank ★Test the Rotary-lock safe interlocking device system Before turning on the rotary lock. reverse buzzer and rotary warning light to check they are working. treatment should be taken promptly. check if all the sensor light (yellow) is on. Boom lamp Lubricating Table of the Machine Lubricating points Brand Steer axle 15 Pitching cylinder fulcrum 2 Lubricating pump 4 Jib extension and contraction Extension and contraction surface of Pivot of jib and spreader Add lubricant coating in order to ensure the smooth rotation and sliding parts. The signal would get through relay to control the front red acoustooptical alarm prompt. while the rotary isworking . display screen will also have the malfunction warning signal. banning the use nonspecified lubricant by Sany Group.Lubricating Shell Diesel engine CG-415W40 Shell transmission oil DonaxTD5W-30 Shell gear oil VG150 （>0? ） Shell gear oil VG150 （>0? ） Shell anti-wear hydraulic oil VG46T 1 1 2 1 1 Shell multi-function Torque converter transmission oil Donax 1 TD 5W-30 Engine radiator Cycle 14 lubricating block ★Check horn. 2 Damping cylinder lug of spreader Sideshift cylinder lug of spreader 4. Once the controller gets the signal.LUBRICATING Container Reach Stacker Maintenance Manual LUBRICATING Container Reach Stacker Maintenance Manual Front headlamp Rear headlamp ★Test the overall function of hydraulic system Operate the electro-hydraulic control handler. contraction and sideshift of spreader. and check the quality and quantity of all the liquid often. water content. so client should use recommended oil.000.025 360 64 Level 9 128.400.3 Check and Change of Hydraulic Oil The Shell brand antiwar hydraulic liquid is adopted for this machine. additives and cleanliness.000 17/14 125.400 2.000 18/15 250. They will be compared with the normal value to determine whether the hydraulic liquid needs to be replaced. 5. The hydraulic liquid in the tank should be checked every 6 months in the forms of the appearance appraisal and quality analysis. the number of those with the size of 15~25m will not exceed 11.000 8.000. of Oil and Water 5-1 5-2 . SAEJ1165) Level of The Size of the Solid Particles（ μm） Cleanliness >5 >15 16/13 16.000.000 5.000 11. The appearance appraisal refers to estimating whether the performance of the hydraulic liquid deteriorates.800 4. Only all the liquid has good quality and enough quantity. the number of the particles with the size of 5~15m will not exceed 64.2 Oil Capacity You must use the right Fuel、Hydraulic Liquid、 Cooling Liquid as SANY test says. the number of the particles with the size above 5m should not exceed 130. oxidization.000 Notice The cleanliness level 17/14 in ISO standard indicates that.012 180 32 The Brake Oil 150 Level 8 64.000 64. in the 100ml oil sample. the engine is able to work. Please see the following table: Shell antifreeze Antifreeze The Size of Solid Particles (μm) 35 Shell anti-wear hydraulic oil The Level Of The Engine Oi converter oil Hydraulic oil NAS1638 Standard 2 11 The capacities in the above table are for reference. Capacity Table Type Fuel Brand Specification Diesel oil CG-415W/40 0 10 20 30 Capacity (L) The Fuel Tank 470 The Hydraulic Liquid 900 The Engine Cooling Liquid 50 The Gear-box and Torque Converter 60 The Driving Axle 49 -20# Shell diesel engine API Classification Engine oil -30 -20 -10 Item CC or above The Wheel Reductor SAE30 SAE10 SAE20W SAE10W/30 Shell gear oil Driving axle oil VG150(>0℃). This system's requirement on the cleanliness of the hydraulic liquid equals to level 8 or level 9 in NAS1638 which is comparable to 17/14 level of ISO standard. Please see the two tables: Appearance Appraisal of Hydraulic Liquid Phenomenon Contaminant Darkening Color Oxygen Milky White Water or Bubbles Bubbles Air Floating Impurities or Sediments Solid Particles Separation of Oil and WaterSeparation Water The ISO Standard (DIS4406.050 720 128 Notice Notice The level 8 in the NAS1638 indicates that.700 1. Cleanliness 5～15 15～25 25～50 50～100 >150 Level 7 32. VG100(≤0℃) The quality analysis refers to regular laboratory tests made on various items.000 19/16 500.000 32. The oil level indicator is placed on the side of the oil tank in order to check the oil level in the tank. Among the items.00 22. in the 100ml oil sample. the number of those above 15m should not exceed 16. including the viscosity. GL5 SAE90 SAE80W Transmission Shell transmission oil torque DonaxTD5W-30 SAE10W/30 SAE10～20W SAE30～40 VG46T（>0℃）Shell Transmission cooling oil Lubricatiing oil transmission oil DonaxTD5W-30 G eneral lithiumed oil SAE20W/40 SAE10W Maypoles oil EP2 -45℃ (freezing point-45 Oil features are different from different manufacturer. so on and so forth. the cleanliness is the major one which indicates the quantity and size of the solid particles in the hydraulic liquid.FUNCTIONAL OIL Container Reach Stacker Maintenance Manual FUNCTIONAL OIL Container Reach Stacker Maintenance Manual 5. ―Use the cleaning liquid (diesel. the checking results of which are not up to the requirement.46 Guangdong province (China). carefully check fastening status of key bolts. Fastening Torque Standard Standard Nut and Bolt Screw Standard Screw Standard Thread Fastening Thread Fastening dimension Torque（N.8%～6. America. New Zealand etc. please connect your nearest and Sany service engineer. areas Brake oil—Hydraulic oil No.1% Mechanical Impurities: 5% Variations of density (15C/4C): 0.68（Suitable environment temperature≥35℃） Shell hydraulic oil No. ―Open the hydraulic oil tank to clean the hole cap. periodic check will avoid accidents. Sweden. The change of oil should follow the following steps: ―Remove the plug on the bottom of the hydraulic oil tank to drain the hydraulic oil in the tank and pipe. Loose bolts will possibly cause acute shaking.second time: 500h ，following changing period: 1000h Hydraulic oil—Running-in of new equipment: Change it after 50h. Brazil. screw up immediately. Add the hydraulic oil filtered by 5m filter (filtering car) to the oil tank through the filter element until reaching the full scale of the oil indicator. ―Lubricate the bolts and nuts to stablize their friction coefficient. weak function.25m*y=120Nm Needed force: y=120Nm\0. ―Standard measurement of torque is Nm: For example: Screw bolt or nut with a spanner(1m) with 120N force twisting the spanner end. Australia etc.5% Hydraulic oil—Shell hydraulic oil NO.8%～6. and.46（Suitable environment temperature 35℃～-5℃） Shell hydraulic oil No.32T +Additive LZ9990A.m） M6 12 3 M14 12 3 M8 28 7 M16 28 7 M10 55 10 M20 55 M12 100 M30 100 20 10 ― Make sure thread on the bolts and nuts are clean before install them.25m spanner: 0. Canada etc.m） dimension Torque（N.46+Additive LZ9990A，Proportion: 5.Russian. and other dangerous phenomena. the particle contamination level in the hydraulic liquid in the tank should not exceed 18/15 (which is comparable to NAS10 level) The hydraulic system of this machine has the following items for oil change: Variations of viscosity: 10 The increase of acid number: 0. ―Add oil to the tank: Open the air filter lip on the top of the oil tank.5% Hydraulic oil—Shell hydraulic oil NO.46 + Additive LZ9990A， Proportion: + 5.8%～6.1~0.selecting principles are： Brake oil: Hydraulic oil No.32T Changing period: Hydraulic oil—Running-in of new equipment: change it after 50 h . areas Brake oil—Hydraulic oil No.68 Northern area of China. which would generate following torque: 1m*120N =120Nm Same torque by using a 0.10 Variation of color (Union grade): above +2 The hydraulic liquid. damaged parts.8%～6.Checking of Key Bolts Hydraulic oil type: Shell hydraulic oil No. they should be replaced with equal or higher standard bolts or nuts. Southeast Asia. the cleaned hole lip should be installed back.5%（Suitable environment temperature ＞-5℃） Hydraulic oil No.32T + Additive LZ9990A，Proportion: 5. 5. area Brake oil—Hydraulic oil No. please check it with torque spanner and screw the bolts and nuts to torques according to figures in the following table.25mgKOH/g Moisture: <0. following changing period: 2000h Bolts' Fastening Torque of Main Components (Undetermined) ―Checking of fixed bolt of engine ―Checking of fixed bolt of torque-converter ―Checking of fixed bolt of transmission shaft ―Checking of fixed bolt of drive axle ―Checking of fixed bolt of crane spreader rotary Recommended Bolt dimension M12 1 20Fixed bolt of engine M16 70 200 M12 130 65 Fixed bolt of transmission axle M24 360Fixed bolt of driving axle 1150 2 Fixed bolt of tyre platen 980 M24 M30 2 475 1 0 Fixed bolt of steering cylinder M30 1 40 Notice 75 5 Fixed bolt of torque converter gear case ―Checking of fixed bolt of tyre pressure plate fastening torque(Nm) 1600 1 0 Fixed bolt of up/down counter weight Notice If the bolts are loose. Germany.05% Variations of surface tension: 15 dyne/cm Residue carbon: 0.46+AdditiveLZ9990A， Proportion: 5.8%～6.CHECKING OF KEY BOLTS Container Reach Stacker Maintenance Manual FUNCTIONAL OIL Container Reach Stacker Maintenance Manual During utilization.5% Hydraulic oil—Shell hydraulic oil No.) and paste to clean the oil tank. ―If it is qualified after being checked and cleaned. should be changed in time.4 Using Principle of Oil Working temperature of brake oil and hydraulic oil don't exceed 80℃.5%（Suitable environment temperature ＞-5℃） 6.05~0. 6-1 .8%～6.32T（Suitable environment temperature≤-5℃） Before start.05 Copper sheet erosion: disqualification Rust preventing ability: disqualification Ash content: 0. ―If the bolts of counter-weight are loose.5% Hydraulic oil—Shell hydraulic oil No. If bolts or nuts are broke. etc.25m=480N 20 Notice when the environment temperature is under 0℃，equipment has to be warming-up for one hour. The following items of the bolt should be carefully checked: Southern area of China（All year long） Brake oil—Hydraulic oil No. 5-3 Proportion: + 5.32T Severe cold region (temperature lower than-25 ℃）. broken bolts.32T + Additive LZ9990A，Proportion: 5. ★Safety regulations in working place： ―Make sure equipment parked in a safe place； ―Segregate a safe area with a ribbon if necessary. oil filter jammed. Air filters or air intake jammed. Add or replace lubricating oil. water pump is damaged Check whether the fan belt is loose. water) cracked. helmet and safe shoes while working. ―Cut off or lock the electric power switch to prevent unauthorized reenergize. the customers can restore the economic losses and keep our corporate image. preheating Difficult to start up time is short. Cylinder head Cracks Self-faults / coolant is not enough Check whether the coolant is enough Check whether cylinder head or Fuel level of oil sump tank (with Cylinder head or cylinder body cylinder body crack. ―Safty belt must be weared while working in high position. in repairing” on the equipement. Thermostat is failure. Cause of faults Engine Oil Cooler is damaged water Check whether the oil cooler is damaged Replace. economic and social benefits. Use the appointed fuel 7-1 8-1 . failure. fetch containers and operating with containers. The fan belt is loose. ★Safety regulations of product: ―Use warning sign. The Check thermostat.Common Faults and Measures 8. meet the quality requirements. ―Regarding to information of certain situations and working conditions which haven't included in this manual. ―Hang the warning brand of “stop. ―Arrange a signaler to assist the work if necessary. gas power or electric power. air Check whether the fuel is out. checking and lubricating. It must bring some certain impacts to users on the progress of work. With a timely diagnosis and elimination. The machine can finish the operations such as pile.1 General Safety regulation while maintenance.COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual SAFTY REGULATIONS DURING MAINTENANCE WORK Container Reach Stacker Maintenance Manual 7. please ask manufacturer for help. This section will state the common faults of machine and give elaboration corresponding to the measures in three major aspects of mechanical system. when the faults occur. Diesel does not flows smoothly. hydraulic system. Category Faults Measures Temperature is too low .2 Common Faults of Mechanical Systems and Measures Table 8-1 Common Faults of Mechanical Systems and Measures 8. and electrical control system. Check water pump The water with oil but oil without ★Safe protection of persionnel： ―Must wear working clouth. Low lubricating oil is too thin Replace filter Water leakage Water tank is damaged Replace Oil radiator leakage(gearbox) Oil radiator is damaged Replace Check whether the fuel oil circuit Engine power is not enough Insufficient fuel. ―Release the electric power or discharge the storage energy liquid power. enters into oil-pipe Check whether oil line plugs or enters with air Check whether coolant water is Engine is Engine temperature is too high abnormal Lack of water coolant. oil-pipe plugs . etc. The Check whether the air intake is air intake jammed smooth. Thermostat enough.Safty Regulations during Maintenance Work 8. Starting voltage is insufficient Engine high-speed EDC fuel control unit has problem Bellows cracks with air-leakage Self-faults Engine speed up with difficulty Engine parking by itself Engine high-speed Replace EDC fuel control unit with problem Check the EDC fuel control unit No oil in tank. cylinder liner water Check whether cylinder circle damage Lubricating oil pressure is too Low-oil level. s e c o n d f i l t e r o f e n g i n e j a m m e d diesel box is not enough Clean the oil tank Engine exhaust pipe leakage Exhaust pipe is damaged. the cleanliness of Use the clean diesel. oil Category Faults Cause of faults Check whether the fuel circuit flows smoothly engine The diesel rough filter and COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Replace oil scraper. the belt is too tight Replace the belt. Engine fan belt broken Adjust the belt tension Engine is Wear intensity between air valve and Replace air valve or guide tube. exhaust Check the leakage position and pipe joint is not sealed enough repair Self-faults. abnormal E n g i n e w i t h b l u e . cannot break away in the condition Step on the clutch switch as brake.s m o g guide tube becomes larger. big noise damper cylinder Tighten the loose bolt Tighten loose bolt Check the charging pump； Low oil level、charging pump is damaged、high oil level、too much To avoid to make the torque Gearbox working hours on fallback condition converter work on the condition of is abnormal Check the oil level of luboil； High oil temperature of torque converter、the clutch fall-back mode.COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Category Faults Automatic deceleration of the Cause of faults Oil supply is not smooth Measures Diesel is too dirty. Gearbox is control unit if it is normal、check Gearbox cannot shift Gearbox control unit with problem abnormal the valve core if it is blocked Low brake oil pressure、oil brake circuit with air、brake block Drive axle Foot brake force not enough abrasion and invalidation is Check the fans of cooler system abnormal Check the EDC fuel control unit Supercharger sealing component is Replace the sealing components leakage damaged Fuel meter shows wrongly Fuel meter or liquid level sensor is Check fuel meter and liquid level damaged sensor Self-faults Replace High temperature of brake oil Big noise gear change Manual shift is incapable change the flabellum if they were Gear damaged、shaft bearing wear Replace the wear and damaged or damaged components Contact Failure Inspect the contact Contact Failure Inspect the contact Retaining mechanism Failure Check the retaining mechanism Brake cylinder cannot release Check the oil circuit of brake handle Work Handle Joystick failure Traversing Angle adjustment failure machine crankshaft with leakage Cab mobile Clutch slipping Check weather brake oil leakage damaged Engine supercharger with oil Oil seal of engine front the magnetic coil of gearbox magnetic valve if it is burn-out、 scraper ring is damaged E n g i n e s p e e d u p w i t h d i f f i c u l t y EDC fuel control unit with problem Measures Check the signal of gearbox Low oil pressure、low oil level、 Check the oil level； charging pump is damaged、 Check the charging pump； Clutch abrasion and invalidation Change the clutch Cab cannot move mechanism Cab shock Cab vibration. of long period brake check the clutch switch if it is available Big noise Gear mesh with problem、shaft Check the gear mesh condition； bearing abrasion or damaged Change the damaged or abrasion shaft bearing Deficiency pressure of oil pressure gauge Low oil level、charging pump is damaged、pressure control valve of Check the pressure control valve； clutch is damaged，oil seal components of clutch is damaged 8-2 Check the charging pump； Change the damaged seal components 8-3 . ⑦Filter plug ①seal components damaged or ①change the seal components distorted ②tighten the loose parts Leakage of hydraulic oil ②joints、pipelines are free 8-4 8-5 . without filter or change Periodic filteration ④The constant input of dust. as a result of cavitation erosion etc. sand Change the filter core periodically and other debris Change the hydraulic oil ②Magnetic valve is damaged or the ②Clean or change the magnetic spool is locked valve Hydraulic Oil Hydraulic oil pollutes and goes bad ①Adjust the distance of brake System ①check the system pressure ①Check and adjust the pressure ③Check the electrify state of Brake ①Insufficient fuel supply ①Low oil pressure Boom System Measures ①Brake valve failure valve ②Brake Failure ②Check the clearance of brake Without foot brake valve the ③Pressure Relay Fault block brake function failure ④Accumulator Failure ③Clean or Replace ⑤Gear pump Fault ④Replace ⑥Brake valve block fault ⑤Replace the gear pump ⑥Clean or Replace the valves ⑤High temperature.3 Common Faults of Hydraulic System and Measures Category Table 8-2 Common Faults of Hydraulic System and Measures Brake Category Faults Cause of faults Measures Magnetic valve blocked Clean the magnetic valve ①Internal drain of telescoping ①Strip inspection and change the Automatic retraction of the pitching cylinder seal components boom ②Self-lock function of logic valve ②Check the logic valve Libration phenomena as the System Faults Cause of faults ①Parking brake failure ①Clean the parking brake Without the handbrake or ②Magnetic valve failure ②clean the magnetic valve or handbrake failure ③Feed pump Failure change ④Shuttle Valve Failure ③check the return line boom retraction ④Clean or Replace Steering System Poor or not to shift invalidation ②Hydraulic steering gear failure ②clean and replace ③Serious leakage of steering ③change the seal components cylinder ④clean ④Prefill valve Failure ②Logic valve with problem valve of between pump and main ①cooler failed ①replace No pitch、telescoping of the ③Only one movement of differential valve ②Air-cooled hydraulic motor of ②change the hydraulic motor boom magnetic valve ②Check the logic valve cooling circuit is damaged. oxidation metamorphism ⑥Enter with water and air.COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual 8. made ③change the back pressure spring inadequate wind ④change the reversing valve ③Oil supply of loop feed pump is ⑤clean the cooler not enough ⑥swash the out radiator The boom can not reach its position No pressure in the system Spreader System Without movement High oil temperature differential magnetic valve Cooling ①Low oil tank level ①Add the hydraulic oil to the tank System ②Cushion protection distance of ②Minish the cushion protective ④Inter drain of change valve is telescoping cylinder is too large distance serious ③Deficiency pressure of the system ③Increase the working pressure of ⑤low flow of cooler the system ⑥out radiator is too dirty ①Overfall valve、relief pressure ①Change and clean the overfall ①Use the substandard quality valve damaged or valve core valve、relief pressure valve hydraulic oil blocked ②Check the oil pump feedback ②Use the substandard viscosity ②No output of oil pump oilcircuit hydraulic oil ①Electrical Fault ①Change the circuit ③Long-term use of hydraulic oil Check the mass of hydraulic oil. there is contact component Category Faults Cause of faults Measures Big Error of pressure sensor ①Broken circuit or short circuit ①Check and recovery power line ②Change ②Invalidation of sensor ②Rust-eaten of magnet ①Change loop Non-operation of Magnetic ③Spool abrasion or invalidation of ②Scrubbing magnet Wrong signal of accelerator valve seal-ring aging ③Change spool or seal ring pedal. careful observation and research and rich experience are needed to determine the real cause of malfunctions. start-up the engine. eliminate them from the easy ones to hard ones. ground wire Check and recovery valve ⑤Change the spring when step on the pedal. After determine the cause of malfunctions.4 Common Faults of Electrical Control System and Measures Category Due to the complexity of malfunction of electric-control system. the ①Wane switch failed ①Change speed reduces ⑤Invalidation of deflection spring Air Ejection from Magnetic valve Water level alarm as full water tank Electricity component No indication of fuel level Invalidation of magnetic valve Change the magnetic valve ①Short circuit ①Check and recovery ②Fault of structure of water level ②Change ②Lead wire is off ②Check and recovery switch ③Full install，make sure that the ①Bulb broken ①Change the bulb ③Reverse of water level switch switch close if there is water in the ②Something wrong with electricity ②Find out the reason then deal with water tank wire it ①Broken circuit ①Check and recovery ①Too soft of contact spring ②Reverse of power line and signal ②Check and correct ②Ragged and protrude bottom ①Adjust the elastic force board ②Remove of the protrude part ③Tightly seized of armature and ③Refit that to make it more flexible mechanical parts ④Change the contacts Non-operation of wane switch Indicator light failed Contactor armature cannot fall line when electricity failure ①Line abrasion，there is contact Inaccuracy of fuel oil level resistance between signal line and ①Check and recovery power line ②Change Electricity Non-operation of Temperature ①Fault of circuit switch ②Switch damaged ①Inaccuracy of temperature switch Big error of temperature switch adjusting valve Contactor cannot fully close ①Check and recovery ①Fault of circuit switch ②Switch damaged ②Large range of contacts Contact of relay generates heat ③Severe burning loss of contact ④deficient pressure of contacts ①Change Adjust the elastic force of the spring ①Load exceeds the rated capacity ①Readjust ②Change Too soft of contact spring when power on ②Change ②Invalidation of temperature switch Non-operation of pressure ④Contacts are fusion welded component together ②Invalidation of sensor 8-6 resistance between signal line and ①Find out the reasons then deal with it ②Change the contacts ③Change the contacts ④Change the contacts ②Check and recovery 8-7 .COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual 8. Reverse of pedal power wire and ④Severe oil carbon pollution in the ④Scrubbing magnet which reaches the max speed. Faults Cause of faults Measures Big error of movements of ①Adjusting valve of pressure switch ①Reset pressure switch inaccuracy ②Change ②Invalidation of pressure switch No signal of pressure sensor ①Broken circuit ①Check and recovery ②Reverse of power line and signal ②Check and correct line Table 8-3 Common faults of electrical control system and measures Electricity ①Line abrasion. 8V ①Short circuit of horn power wire The horn chirping ceaselessly and control power line ①Check and recovery when being electrified ②Fusion welding of contact of horn ②Change the relay controller Acousto-optic alarm failure ①Lead wire break off or circuit ①Inspection and recovery broken ②Change or start-up contractors ③Connectors loose or drop ③Check connector and wire After starting the engine.change that the wire ring it as being conformed to be damaged ①Footplate locked，enable to step ①Make the footplate elastic Engine speed cannot reach to to the end ②Ensure the output signal of the rated speed ②Output signal of gun with mistake gun1. ③The fuse of enter point power is ③Change the fuse Change that if necessary of relay when it is closed Measures ①Find out the reason then deal with Pool contact of relay There is sparkle on the contact Cause of faults Electricity component No response of screen when the burn-out system is electrified ④Check and recovery ④Input-output circuit failure ⑤Check and recovery，refresh the ②Change the spring ⑤Endless loop of program program ③Change ⑥The controller is damaged ⑥Change the controller ①Contact is not qualified ①Change the contacts ②Too soft of contact spring ③Burning loss of contact. that component no movement of start-up relay ③Pool contact of lead wire or Inspection Press down the set-up button， which cannot constitute control ③Re-connect the zero line contactors ③Find out the reason then deal with the wiper has no response circuit ④Inspection on relay，change that ④Loose of the lugs of relay or it of that ④Relay damaged as being conformed to be damaged contactors or something wrong with ④Find out the reason then deal with ⑤Priming button failure ⑤Inspection on button .6V~3. circuit fuse ②Change the fuse body after ③No zero line in the control circuit. poor ①Retighten the contactors contact ①Pool connection of armature and ①Clean out the joint surface ①Loose of the lead wire contact ②Find out the reason then deal with iron core ②Change the contact spring and ②Burn-out of fuse of control circuit it ②Large pressure of contact contactors if necessary ③Position handle not at neutral ③Put the position handle to neutral position position Exception noise of direct current contactor The engine cannot setup when pressure Cannot break away the accumulator switch rotate the key switch ①Contacts are welded together ①Change the contacts or switch ④Setup relay damaged ④Inspect on the relay，change ②Tightly seized of mechanical ②Repair it to make it flexible ⑤Failure of setup key switch that after confirmation ⑤Check on the key switch and structure Electricity component change that as confirmed Non-operation of preheating ①Circuit broken ①Inspection and maintenance heater ②Heater damaged ②Change ①Pool contact of startup key switch ①Find out the reason then deal with ①Loose of conductor connector ①Retighten the connector ②Burn-out of the body of control it of that ②Burn-out of control circuit fuse ②Find out the reason then clear of Electricity Rotate the start-up key switch. the crane can function. ②Still with signal as parking ②Warner damaged No indication of the whole car speed，and can only run at gear one 8-8 ①Earth connection of power line ①Check and repair with problem ②Change ②Velocity sensor is damaged ③Change the gate，and change ③Breadboard is damaged the frequency divider is necessary 8-9 .COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Category Faults COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Cause of faults Measures Category Faults ①Circuit broken ①Check and recovery ①There is dust、dirt or burnout it ②Burn-out of power fuse ②Change the fuse ②Too soft of contact spring ②Inspection on spring force. and ①Braking system has some mal ①Inspection and exclusion engaging a gear. with a braking signal ②Open the parking button not move with the lights lighting. ③General oil supplying valve necessary magnet coil is short. wire is wrongly maybe has some malfunction ④Change jointed. condenser maybe has some Electricity ①Adjust the distance of the four blinking or bright all the time as the cut-out switch after you confirm has some malfunction ①Induction distance of location The yellow indication light The spreader has unlocked. but ①The induction distance of lock in ①Adjust the two induction distance ④Confirmed and recovery no red indication light or sensor with problem of tighten sensor ⑤Confirmed and change twinkling ②Tighten sensor is damaged ②Change the sensor White indication light damaged Change the white indication light cannot refrigerate automatically contact is sweated ④Cooler electromagnetic valve no red indication light or maybe has some malfunction The spreader has locked in. change proportion valve output signal. change the valve have some malfunction general oil supplying valve if Duct pilot is short. no handle signal ②Change and recovery ④Change input of the screen or with ③Check according to the safety ⑤Check and maintain it. protective table ③Change the ring No operation of the boom circuit failure the button or handle if necessary ⑤The button of operating handle ③With or without safeguards has some malfunction has some ①Big interfer signal ①Make the handle earth-touching ②Handle signal wire scored reliable ③Handle damaged ②Repair the handle ④Electric proportional valve ③Change the handle damaged ④Change the proportional valve malfunction The operation of the boom Lose of control 8-10 8-11 . for example. etc ④Spreader controller damaged them ①The cut-out switch of its power supply trip ②The on-off of freezing pressure Something wrong with Air conditioner ①Inspect the fault. but ①Change the fused body Electricity ②Temperature switch is damaged ②Change component twinkling ③Movement controlling relay ③Change contacts The spreader has locked in.COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Category Faults COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Cause of faults Measures Category Faults Cause of faults Measures Some of the one-to-four gears ①Gear handle is not flexible ①Check and repair gear handle ①The power supply fuse of hanger ①Change the fuse cannot be put up ②Connectors loose or drop ②Check connector and wire control device is burned out ②Inspection and recovery ②The lines of general oil supplying ③Check and resume it. the main cut-out switch of duct pilot trip No movement of the spreader conducting wire insulation is short to Find the causations and exclude ground. electric coil is burnout. but ⑤Radiator motor failure no white indication light or ①Malfunction of lines. and then close it ③Loose or off connection of the ②Check and Change lines on air conditioning control ③Inspection and recovery malfunction ①The fuse of power supply is burned out component Hydraulic cooling system sensor with problem location sensor ②Location sensor is damaged ②Change the sensor ③The yellow indication light is ③Change the yellow indication damaged light The spreader has released but ①Wrong induction distance of ①Adjust the two induction distance no red indication light or unlock sensor of unlock sensor twinkling ②Location sensor is damaged ②Change the sensor Red indication light is damaged Change the red indication light the spreader has not location panel. Power supply being on. conducting twinkling wire is abraded ②Corresponding electromagnetic valve is locked Only part movements of ③The ring of magnetic valve spreader damaged ④Spreader controller damaged ①Inspection and recovery ①Burn-out of power fuse of boom ②Tidy the magnetic valve control ①Change the fusing body ②Circuit failure. the the page data of the screen is abnormal ①Bus failure ①Check the wire and recovery ②Bus terminal resistance damaged ②Change the resistance and or lead fell off check the wire and recovery ①Power fuse burn out No operation of controller ②Power fuse burn-out on the enter ①Change the fuse point ②Change the fuse ③Power fuse burn-out on the enter ③Check and recovery point ④Check、recovery and refresh the ④To judge the state of the program program according to the instruction book ⑤Change the controller ⑤Controller damaged No operation of extended block ①Power fuse burn-out ①Change the fuse ②No blinking of communication ②Check and recovery indication light communication wire ③There is light on the input、output ③Change the extended block points but no operation Cab can not move 8-12 ①No key switch ①Check the switch ②Magnetic valve damaged ②Check and repair magnetic valve ③Connector lug loose or drop ③Check connector and wire 8-13 . The terminal resistance locates on its plugs. ①Check whether the wire is broken or water intake. and the red light of the with water I/O extended block always on ①Check whether the wire is broken or water intake. Communi ③Connector lug loose of drop ①Rough road surface ①Smooth the road surface ②Distance of Proximity switch ②Adjust the distance of Proximity improper switch ③Proximity switch damaged ③Change the Proximity switch ④Connector lug loose of drop ④Check connector and wire ①Too much redundancy data ①Refresh the page ②The screen is disturbed by ②Eliminate the interference source Electricity magnetism ③Change the screen component ③The screen damaged figures distorted Measures ①Turn on the key switch ①Reverse plug of rod and rodless Abnormal show of the screen， Cause of faults ①Without key switch ③Connectors loose or drop ROPS give an alarm Faults cation wire Controller and screen The screen is ok but no content on it ②Check whether terminal resistance burn out or bad connects.COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Category Faults Nutation emergency is failed COMMON FAULTS AND MEASURES Container Reach Stacker Maintenance Manual Cause of faults Measures Category Communication fault of the The engine works but no speed Check whether the wire broken or ②Magnetic valve of Nutation ②Overhaul the magnetic valve engine and the controller information on the screen with water emergency failure ③Check connector and wire ①Joint the wire correctly Inaccuracy of weight- pressure sensor ②Change the pressure sensor measuring ②Pressure sensor damaged ③Check connector and wire There is length and angle indication Controller and I/O extended on the screen but without gear Check whether the wire broken or block information. Controller and length and angle The indication of the length and sensor angle of the boom is abnormal the others are ok ②Check whether terminal resistance burn out or bad connect .As the terminal resistance locates in the length angle sensor . MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual 9.Maintenance of Equipment Tracking Sheet Maintenance of equipment tracking sheet 2 Maintenance of equipment tracking sheet 1 Equipment Manufacture Using Start Name No. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time 9-2 . 9-1 Maintenance Part Materials Working Place Equipment Manufacture Using Start Name No. Date Maintenance No. Date Maintenance Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time No. Date Maintenance No. 9-3 Maintenance Part Materials Maintenance of equipment tracking sheet 4 Equipment Manufacture Using Start Name No. time 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time 9-4 .MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual Maintenance of equipment tracking sheet 3 Equipment Manufacture Using Start Name No. Date Working Place Maintenance Contents Materials Materials Materials Maintenance type quantity Source date Operator Using No. Date Working Place Maintenance Contents Materials Materials Materials Maintenance type quantity Source date Operator Using No. 9-5 Maintenance Part Materials Maintenance of equipment tracking sheet 6 Equipment Manufacture Using Start Name No. Date Maintenance No.MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual Maintenance of equipment tracking sheet 5 Equipment Manufacture Using Start Name No. time 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time 3-4 . Date Working Place Maintenance Contents Materials Materials Materials Maintenance type quantity Source date Operator Using No. Date Maintenance No. time 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time 9-8 .MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual Maintenance of equipment tracking sheet 7 Equipment Manufacture Using Start Name No. 9-7 Maintenance Part Materials Maintenance of equipment tracking sheet 8 Equipment Manufacture Using Start Name No. 9-9 Maintenance Part Materials Maintenance of equipment tracking sheet 10 Equipment Manufacture Using Start Name No. Date Working Place Maintenance Contents Materials Materials Materials Maintenance type quantity Source date Operator Using No. Date Maintenance No.MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual Maintenance of equipment tracking sheet 9 Equipment Manufacture Using Start Name No. time 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time 9-10 . MAINTENANCE OF EQUIPMENT TRACKING SHEET Container Reach Stacker Maintenance Manual Maintenance of equipment tracking sheet 11 Equipment Manufacture Using Start Name No. Date Maintenance No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 9-11 Maintenance Part Materials Working Place Contents Materials Materials Materials Maintenance type quantity Source date Operator Using time .