SANY RSC45 Container Reach Stacker. Maintenance Manual

Preface

Reading Guidance

Thanks for your trust to the SANY products. We

Preface

Reading Guidance

work of the equipment are listed. The whole

sincerely wish you realizing your ambitious dreams

equipment lubricating cycle table which includes

in the future works and making great achievement.

lubricating points and lubricating cycle is listed.

This manual mainly introduced specific

1.Information

Clients must lubricate the equipment according to

maintenance method of container reach stacker

The maintenance manual is a manual for you to

this cycle table.

(here after refer to reach stacker) and other

use and maintain the machine. It should be always

malfunction elimination methods. Concerning

SANY Group

put in the cab for your reference at any time. If it is

certain type of reach stacker, there will be more

6.Function Oils

damaged or lost, you should order another one

detailed information.

Technical specification of hydraulic oil etc medium

from Hunan SANY Group. The Manual covers the

We sincerely appreciate your purchase of our

and their standards, oil tank and volume are

information and instructions for safety, technology,

product SANY Container reach stacker. We will

introduced in this part. Brand and type of

operation, transportation, lubrication and

provide you with high-quality products and high-

recommended oil by the manufacturer are also

maintenance. Furthermore, some photos, drawing

class after-sales service.

listed in this part.

details or optional components shown in the

Our Company has derived the technology

Manual may differ from your machine. To make the

quintessence of the production of the container

7.Inspection of Key Bolts

instructions easy, the cover sheet and hood may

reach stacker mobile in and out of China. With the

Inspection requirements of each key fastening

have been dismounted.

rich experience of designing and manufacturing of

bolts and torque are listed in this part.

The Manual may exclude the modification due to

engineering machinery, we develop the reach

the improvement and updating of products. It is

stacker, which is completely new container

recommended for you to read and research the

8.Safety during Maintenance Work

handling equipment. It is widely used at the

Manual carefully and put it together with your

Safety matters needing attention while

container terminal, railway transfer station,

machine.

maintenance, checking and lubrication: safety

highway terminate station and container freight

For any question on the machine or the Manual,

measure in the working place, safety measure of

yard, and mainly used for the stacking and portage

please contact us for the latest information.

product: introduction of personnel's safeguard

of containers.

measures.

The manual shows in details the specifications of

2.Preparing Work before Maintenance

performance parameter, technical characters,

Preparing work steps are introduced in the

operational principle, structural composition, safe

9.Guidebook of Identifying Common

Preparing Work before Maintenance part.

operation, transportation, lubrication and

Malfunction

maintenance of SANY Container reach stacker.

Common mechanical/hydraulic/electric system

3.Maintenance Cycle of the Whole

In order to ensure a better operation of the reach

malfunction are introduced in this part, which point

stacker, we strongly recommend you to read this

Machine

out direction for diagnosing common malfunction of

manual carefully before operation. It will:

Maintenance cycle of key parts of the machine are

the equipment.

□Help you understand the reach stacker;

showed in this part which provide references to

□Protect you from danger owning to improper

maintain the machine in a regular time.

10.Track Record of Maintenance

operation;

Taking track record provide convenience to the

□

Enhance the reliability of the reach stacker;

4.Maintenance of the Equipment

maintaining staff to keep track of the status of

□Enhance the service life of the reach stacker;

Maintenance detailed specification of key parts

maintenance and is easy to check the working

□Reduce the repair cost and the shutdown time.

such as engine, transmission, driving axle and

condition of the equipment.

Please put this manual at an easily reachable

spreader etc. is showed in this part which indicate

position for your reference at any time. Only after

the direction of maintenance work of the

11.Explanation of Signs

fully understanding this manual, can you operate

equipment.

the reach stacker skillfully and safely.

Danger

5.Lubricating

The sign of “Danger” means the direct danger,

Necessary lubricating materials to enable normal

which may cause death or serious injury if no

preventive measure is taken.

TABLE OF CONTENTS

Container Reach Stacker Maintenance Manual

1. Preparing Work before Maintenance

1-1

9. Maintenance of Equipment Tracking Sheet

9-1

2. Maintenance Cycle Table of the Whole Machine

2-1

3. Maintenance of the Equipment

3-1

3.1 Repairing and Maintenance of the Engine

3-1

3.2 Repairing and Maintenance of Transmission

3-5

3.3 Repairing and Maintenance of the Drive Axle

3-6

3.4 Repairing and Maintenance of the Steering Axle

3-7

3.5 Repairing and Maintenance of the Spreader

3-8

3.6 Repairing and Maintenance of the Jib System

3-10

3.7 Repairing and Maintenance of the Air Conditioner System

3-11

3.8 Repairing and Maintenance of Tyres

3-11

3.9 Repairing and Maintenance of Hydraulic System

3-13

3.10 Repairing and Maintenance of Electric System

3-14

Font-Arial Size:10pt

4. Lubricating

4-1

4.1 Lubrication

4-1

4.2 Lubricating Table

5. Functional Oil

5-1

5.1 Oil Specification

5-1

5.2 Oil Capacity

5-2

5.3 Check and Change of Hydraulic Oil

5-2

5.4 Using Principle of Oil

5-3

6. Checking of Key Bolts

6-1

7. Safty Regulations during Maintenance Work

7-1

8. Common Faults and Measures

7-1

8.1 General

7-1

8.2 Common Faults of Mechanical Systems and Measures

8-1

8.3 Common Faults of Hydraulic System and Measures

8-4

8.4 Common Faults of Electrical Control System and Measures

8-6

PREPARING WORK BEFORE MAINTENANCE

MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE

Container Reach Stacker Maintenance Manual

In order to avoid unnecessary break down of reach

Maintenance Cycle Table of the Whole Machine

stacker, enhance the reliability and

maneuverability, reduce repair cost, client should

have a whole maintenance plan before operating.

Plan Of Maintenance

In the run-in period, reach stacker can only stand

the medium or less load work. After working its first

Maintenance

Serial No.

Maintenance items

Applicable plan

parts

50 to

100 h work, reach stacker must take a

maneuverability maintenance. One should take the

★Walk one circle around the engine, check if there

Check air cleaning status indicator

A B

fist maintenance according to C maintenance

exists damage and leakage.

Replace air filter core

A B

including adjustment of engine valve clearance.

Replace engine oil and engine oil filter core

A B

★The function test should be conducted to.

Replace diesel filter core

A B

Specification: We have already done the

Check cooling water quality and amount

A B

maneuverability maintenance of the equipment for

you.

Clean foreign matters on the surface of the radiator

A B

Check belt and belt wheel

A B

Engine

Check start, stop, and operation of engine

A B

Check if oil, diesel, and water leakage exists

A B

Check if turbocharger and exhaust gas tube have leakage

A B

★Close the main switch, and take away the key.

Replace oil-water separator filter core

Clean oil stain in the oil cleaner

Replace cooling water filter core

Check if damping pad and fixed bolt are loose and

brokenCheck and adjust clearance of intake valve and

Preventive Maintenance A-250hrs

Preventive Maintenance A-500

hrs

exhaust valve

Preventive Maintenance A-1000

hrs Preventive Maintenance A-2000

hrs

★Set the limit stop in the front and back of the

Check and add transmission oil

tyre, so as to prevent accidental movement of

Check if fixed bolt of the transmission shaft is loose and

engine.

Gearbox and

Broken

Check rotary speed inductor

transmission

Replace transmission filter core

shaft

Replace transmission oil

1.Preparing Work before

Check if fixed bolt and fixed seat are loose and broken

Maintenance

Check fixed bolt of drive axle tightness degree

Check if bolts of pressure plate of tyre are loose or broken

Before repairing and maintenance of the Container

★Hang the warning brand of “stop, in repairing” on

reach stacker, preparations should be well done

the engine.

Check if drive axle and brake components have oil

Drive axle

strictly according to the following steps:

(One is hung on the steering wheel and one is

Leakage

and brake

hung at the end of engine)

Check and add oil of drive axle differential and planet

★Ensure engine will be stopped in the safe

system

Replace oil of drive axle differential and planet gear case

working site. If necessary, use the colored ribbon

Clean venthole adaptor

to separate the safety isolated belt.

Check hand brake sheet and hand brake function

1-1

2-1

MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE

Container Reach Stacker Maintenance Manual

Maintenance

Applicable plan

Serial No.

Maintenance items

Serial No.

Maintenance items

parts

Check if steering axial component has abnormal

Replace main hydraulic oil tank and brake oil tank

clearance and damage

ventilation filter core

Check anti-tilting inductor

Check if battery water is sufficient

Circuit

Check if bolts of tyre pressure plate are loose and broken

Check all working lights and indicator lights

Steering

axle

Check if tyre is deflective

Check tyre pressure plate and nut tightness degree

Check if steering wheel bearing and fixed nut are loose

Check tyre status and air pressure

General

or broken

items

Check horn, reversing buzzer, and alarm light

Check if spherical pin and fixed nut are loose and broken

Lubricate all slide blocks and lubrication points

Check twist-lock and relevant components

Test anti-tilting protective system

Check twist-lock inductor and indicator

Test twist-lock safety interlocking device system

Function

Check and adjust 20 /40 chain and limit

test

Test integrated function of hydraulic system

Check crane spreader rotary decelerator gear oil and

Check and treat places with oil or water leakage

Crane

lubricating oil amount

spreader

Replace crane spreader rotary decelerator gear oil

Check if fixed bolt of crane spreader rotary gear case

is loose and broken

Check if slide block on the crane spreader is abraded

to the limit

Check if crane spreader has cracks by general vision

Check if fixed seat and lock pin on the basic boom are

loose, broken, and worn

Contraction

Check if fixed seat and lock pin on the pitch oil cylinder

and pitch

are loose, broken, and worn

system

Check if slide block on basic boom is abraded to the limit

Check if basic boom has cracks by general vision

Check oil amount in main hydraulic oil tank and brake oil

tank

Check accumulator pressure

Hydraulic

Check if hydraulic pressure on the hydraulic nameplate

system

is consistent

Replace all high-pressure filter cores

Replace brake oil and brake cooling oil filter core

Replace hydraulic oil and hydraulic system filter core

2-2

2-3

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

。

Take care of the filling-up amount of the engine oil

Engine oil filter core

as charging. If the level is too high, the foam may

come out, lube ability may be decreased.

Otherwise, if too low of the oil level and there may

be not enough engine oil into the lube system.

The filter core of the engine oil plays a part of

filtering the engine oil. When the filter has been

Filter cover

Dust collector

Safety filter core

blocked, the engine oil may be blocked into the

system, the cooling and lube ability of the engine

★Change the diesel filter core

oil may be decreased. So that engine oil filter core

Filter indicator

The diesel may be blocked into the injection

must be changed.

system by jammed and unclean filter, which make

As changing the filter core, something. Should be

the diesel deficient atomization, lowering the

taken out as follows:

working efficiency of engine.

Fresh engine oil and new filter should be used, the

Attention while changing the diesel filter core:

Main filter core

seal rings of the filter should be infiltrated by the

The seal rings of the filter should be infiltrated by

fresh engine oil; tighten it by hand and then screw

the fresh fuel oil; tighten it by hand till touching and

★Change the engine oil and engine oil filter oil

three-fourths coil.

then screw it half coil.

Function of the engine oil:

Oil drain plug

Diesel filter

―

Cleaning: Wash away the wear scraps and

carbon in the system.

―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

Before oil charging

viscosity of the water、

diesel and engine oil has

Diesel oil filter core

been decreased. Besides, as the contamination of

the carbon, the acidity of the engine oil will be

increased, which may generate chemical reaction

with metals, so that the metal goes rusty. Because

of the reasons above, the engine oil should be

Filling the oil

Fuel inlet

Oil dipstick

changed after the usage of a period to ensure the

system normal.

We have to check the status of engine oil regularly.

Once abnormal situation is found, prompt

treatment should be taken.

★Change the oil-and-water trap filter core

Notice

No.

Phenomenon

Cause

The main function of oil-and-water trap is to

Engine oil level arising

The lube system is infiltrated with

Engine oil filter

separate the impurity and water from the oil, and

water or coolant

so that it can provide clean fuel to the engine.

Engine oil with metal pellet

Surface of the spool with is large area

Firstly detach the core from the top, then loose the

damaged

bottom valve, clean the inner of the oil cup, replace

Piston ring damaged, the engine oil

Quick reduction of the

come into the combustion chamber,

another new one (take care to change all the seal

engine oil

engine oil leakage from the edge and

O-rings), at last charging the fresh fuel oil.

joints

3-1

3-2

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

please change all the damaged seal rings

、

buff when start-up of the engine.

Notice

There may be bad influence to the

connected pipe. Once the vent of crankcase is

As changing the filter core, it is necessary

coolant of the engine, normal working of the air

blocked, the pressure will higher, the oil may

to clean the bottom oil cup, so that it is obvious to

condition and generator if the belt loose.

pressed into the gas handing system of booster

know whether the oil cup is clean.

Bolt

Automatic tension pulley.

and engine.

Check the tightness of the spring device.

Notice

Shock pad

Check the inner shaft of the device.

Never start the engine in the case of

disengaged of turbocharger and exhaust pipe.

Framework

★Check the start-up、halt and operation of the

engine

Follow steps should be abide by before start-up:

★Check and adjust the gap of inlet and

★Inspect the quality and quantity of the

―Check all the oil level(engine

、gearbox

、

exhaust valve

cooling water

hydraulic oil、drive axle、planet gear、brake

Observe the cooling water on one's own eyes. It is

coolant);

necessary that the cooling water should be

―Exhaust the air of fuel system;

changed when it become worse. When the .cooling

―Turn the fire-key to start-up position, release it

water is not enough, you should recharge for fear

as the engine enable.

of overheat of the engine.

Do not let the engine work on the state of cold,

Rule of thickness

Shell anti-freeze (ice point:-45℃) 50L

neither too the critical low speed, working for 2-3

minutes on the state of 1200-1500rpm till the

temperature gets normal is ok.

★change the filter core of cooling water

★Clean the contamination attached on the

Firstly close the stop valve, get out the old core,

surface of the radiator

Notice

It is important for the warm-up of the

lube the o-rings with lubrication, then tighten the

In order to the cool the air thoroughly, periodical

engine, which may ensure the smooth run of the

new one by hand, screw it by half coil. In the end,

clear away of the contamination is necessary.

engine oil before the high speed run of the turbine.

open the stop valve.

Ways of clear away the contaminations:

―Take away the radiator cover;

Notice

The liquid level of the expansion tank

The open and close time of gas gate may be

―Wipe out all the exotics on the radiator fins;

should be checked, refill that in time.

relevant to the gas gate cap.

―Clean the radiator with abluent;

It will be late if the cap big, and be earlier if narrow.

―Inspect the damaged radiator fins and rubber

Way of adjusting the gap:

seal components.

Cut-off valve

Turn the crankshaft to the position that the inlet

Notice

valve just open but the outlet valve incomplete

Filter

open. Check the valve gap, adjust it if necessary.

Do not wash the radiator with high

★Check oil、diesel or water leakage

pressure water.

Notice

Go around the machine, inspect the leakage of

The check sequence of the air valve is 1-

oil、diesel or water. If any part leaking, marking

2-3-4-5-6, and the observe sequence of rotational

and cut off the power instantly.

crankshaft is 6-5-4-3-2-1.

★Check belt and pulley

★Check the damping pad and fixed bolt if they

Belt checking mode:

are loose

See User's Guide of

“VOLVO Engine

”and

Press down each section of the belt, the downward

★Check the leakage of the turbocharger and

It is essential to check if the damping pad

“Cummins Engine” for more details of use and

distance should not exceed 10mm.

exhaust pipe

damaged or the loose of the bolts before the start-

maintenance.

If the belt loose, to tighten it.

You must check the leakage situation of the pipe of

up of engine.

If still loose, replace that.

turbocharger as well as the connectors of each gas

Function of damping pad:

If belt abrasion, change another one.

hose before the start-up of engine. If leaking,

Fasten the engine onto the frame work,which can

3-3

3-4

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

3.2 Repairing and Maintenance of

★Change the gearbox filter

Check items: fixed seating、damping pad、bolts

Oil-immersed disc brake

Block of filter will reduce oil volume of gear shift

Transmission

and lubrication.

★Check and add the drive shaft oil

Change the filter core of gearbox:

Let the engine run slowly,then draw the dipstick to

Firstly detach the old core. Then the seal rings of

oil place of the gear-box.Add the oil as told when

the filter should be infiltrated by the fresh engine

Fixed bolt

the place is lower than the lowest station.

oil; tighten it by hand and then screw it tow-thirds

Differential

Damp pad

Framework

Notice

coil.

Select the right lubricating oil ,according

3.3

Repairing and Maintenance of the

to the type of the gear-box.

Drive Axle

★Check the tightness of the fixed bolts of

★Check the fixed bolts of the drive shaft

driving axle

Driving axle

The loose bolts may be easily sheared in the

Loose bolts may easily be cracked with load and

action of load and vibration. The fixed bolts should

vibration.

★Change the gearbox oil

be inspected carefully for fear of any accident.

Fracture of bolts may do a serious impact to our

Check if there is any prill in the old oil to see the

device, and may even cause injuries and deaths.

working condition of gearbox components. If it has

been polluted, open the fuel outlet, and give it off.

Parking brake system

As it is finished, first plug the outlet, then fill the oil

to the min position level. Start the engine, let the oil

reach the normal temperature, then check the oil

Fixed bolt Universal joint bearing

dipstick, refill the oil to the max level position of oil

dipstick.

Fastening bolt of driving axle

Check measures:

To see if the fixed bolts loose.

Driving wheel

if the universal joint shaft damaged.

Relighted the loose shaft bolts with 200NM

moment.

★Check the speed sensor

Fastening bolt of transmission shaft

Check the speed sensor and its support to see if

Notice

★Clean the connector of vent hole

the speed signal can be transferred correctly into

Tightness of bolts of drive axle: moment

The purpose of cleaning the connector of vent hole

the control system by the inductor. For the

1200NM

is to let the steam in the drive axle escape for fear

Oil drain plug

Prefilter

protection of driving device, make sure that only

of high pressure in the drive axle. If not, may bring

when low speed can the gear position be shifted.

Notice

about leakage of seal components.

★Check the leakage of driving axle and brake

Shell DonaxTD5W-30 shafting oil is

components

adopted for DANA Clark 36000.

Check items:

Oil dipped disk brake and its connecting tube、

Universal joint bearing

parking brake system and its connecting tube、

★Check if the fixed bolts and fixed seating are

differential mechanism、

drive wheel and drive

loose

axle.

Action of fixed seating and damp pad:

Transmission shaft

Vent

Rotation speed sensor

It plays a part of damping the vibration as the

start-up, operation or halt of gearbox.

3-5

3-6

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

★Check the hand brake block and hand brake

―Detach the lock cushion ring and lock nuts;

causes carriage tail to tilt, the clearance between

3.5

Repairing and Maintenance of the

function

inductor and induce block will be enlarged, the

―Tighten the nuts with the moment of 350NM;

Spreader

Start up the engine; do not stop it until the

induction will send no signal. With this mode, a

rotate the wheel hub for 10 loops;

★Check the rotary-lock and its components

accumulator charging. Stop the engine, turn the

kind of overload signal mill be formed, which make

―Tighten the nuts with the moment of 350NM

Check the rotary-lock components if damaged,

fire key to position 1.release the parking brake,

the container retain to current state for fear of

again; check the spacer ring of wheel hub if it lies

change it if necessary.

inspect that if the parking brake nipper can shift on

accidents.

on the wheel axle. If not, retighten it;

Check the position of rotary-lock link rod if correct

the bracket, as well as the cap of brake gasket and

Before the machine lifting, please carefully inspect

―Mount on the lock nuts, tighten it with the

and firm, adjust that if necessary.

Brake disk if it satisfied to the requirement, adjust it

the reliability of inductor.

moment of 350NM;

Notice

if necessary.

To find out if the sensor damaged as well as the

―Film the grease on the safety cover of shaft,

It is important to check the rotary-lock and

reliability of angle-bar of induce

then fixed on.

its components because it plays a key role of lifting

block or bolts and if the space of inductor normal.

the containers correctly and safety.

Danger

There may be danger of crush if machine

Fixed nut

Steering wheel shaft

shift freely, so in order to avoid accidents, make

Notice

sure that the truck may not move even if the brake

is released.

Take care of the abrasion state of shaft,

change that immediately if damaged.

3.4 Repairing and Maintenance of the

★

Check if the knuckle-pin and fixed nut are

Steering Axle

loose

★Check if there exists the gap or damage of

Clear out and check the shaft bearing. Check the

components of steering axle

★Check the tyre if deviate

knuckle-pin if it can roll smoothly, and the max

Check steering cylinder、joint shaft and joint

In normal cases, all the wheels should swing to the

rotate distance is not allowed to exceed

bearing、steering link rod、damping pad、and

★ Check the status of rotary-lock inductor and

same direction, and be parallel of the back wheel.

0.25mm.Free stroke can be adjusted by the nuts.

counterweight, if any component loose or any

indicator

If there is something serious, please check the

abnormal cap and damage as well as the leakage

Check items:

linking structure.

of the steering axle. if one of the cases occurred,

Each inductor and its connection status;

deal with it immediately.

Each inductor if not firmed or damaged;

If the gap of inductor block normal;

If the indication lights are in the normal operation

state.

Knuckle pin

Bearing

Notice

Find out the abrasion and loose

★Check if the steering wheel shaft and fixed

components as early as possible and take some

bolts loose

measures to give a precaution for fear of

Check measures:

accelerate failure of some components.

★Check the anti-tipper inductor

―Detach the wheel hub cover;

Indicator lamp

Function of anti-tipper inductor:

―Clean out the grease of wheel hub cover and

In normal condition, anti-tipper inductor is in

steering wheel shaft;

normally closed state.When hoisting overload

3-7

3-8

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

3.6

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

Inductor

the key components connected with frame and

spreader. And the stability of structure and welding

of fixed seating, pin roll, bearing of pin hole and

★Check abrasion status of the slide blocks in

fixed bolts should be checked periodically. Please

the spreader

color them if necessary.

There are two kinds of slide blocks on the

spreader: side-slide blocks and 20'-40' extension

Inductor

blocks, which do an action of sustention and

guiding.

Firstly detach the bottom strap, shim and slide

Inductor

block, then measure the thickness of slide blocks

★General observations of cracks

as well as the gap of slide block and slide

The spreader is the direct container-lifting device

components, adjust and change the shim if

of the machine, usually inspection of the important

necessary, at last reinstall the strap.

components, to find out the cracks as early as

possible is necessary.

★Check if there exists the gap or damage of

components of steering axle

★Check the fixed seating and pin roll of the

Regularly inspection on the fixed bolts is

pitch cylinder if loose or abrasion

necessary for fear of accidents caused by loose of

Check if there is any crack around the fixed

bolts.

seating; please color it for next inspection if

Rotary motor is composed of hydraulic motor, disk

necessary.

brake, planetary gear set, who are connected by

fixed bolts.

The hydraulic motor lies on the upper of disk

brake, which provides rotary power. 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, so that the output of motor and disk

brake will be enlarged.

★Check if the slide block of basic boom wears

to extreme

Firstly detach the strap, shim and slide block, then

3-9

3-10

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

measure the thickness of slide blocks as well as

―Check if the fixation of pipes is in good condition,

★The Dismantlement of Tyre

the gap of slide block and slide components, adjust

pipes is over close to the heating component,

―Before dismantling tire, deflate the tire to reduce

and change the shim if necessary, at last reinstall

rotary component and control rocker arm;

the air pressure;

the strap.

―Check if the connector of circuit harness is in

―While dismantling tire, do not use sharp tools; do

good condition, harness fixation is solid. Pay

not pry the tire bead forcibly; do not hit the tire with

special attention to the compressor clutch plug;

a big hammer.;

―Check if the fixed bolt of compressor is

―While dismantling tire, replace the O-shape loop.

fastening;

Before installing felly, check the O-shape loop to

―Check the fixed bolt of air conditioner is

see whether there are any defects and apply

fastening;

lubricant on it;

―Take off fresh air filter core, blow the dust off

―While dismantling tire, use the bead detacher or

from backside, and reinstall it.

tire detacher. Forcible prying and smashing should

★General observations of cracks of basic

Main checking items within 100 hours:

be prohibited to avoid damage to the sealing layer

boom

―Recheck the above checking items;

Notice

in the tire and bead. To facilitate the installation,

Usual inspection of the usage of basic boom, to

―Blow the condenser with compressed air. Don't

Don't over charge the tyre, keep the tyre

neutral soap lye or special lubricant can be applied

find out the cracks as early as possible, then deal

use the high-pressure squirt gun;

pressure in a normal condition.

to the bead bottom and ring support of the felly.

with that immediately for fear of deeper damage.

―Clean out of the dirt on the condenser.

some lubricants, such as grease lubricant, which

Main checking items within 200 hours:

affect the quality of the tire, should not be adopted.

―Recheck the above checking items;

★Check the tyre platen and nut tightness

―Change the fresh air filter core;

Check the tyre nut tightness, Screw the rear axle

―Adjust the transmission strap tightness of

nut with 350NM moment, front axle with 450NM

★Installation of Tyres

compressor.

moment.

―Install the tire in the felly, which is installed in the

wheel hub. The direction mark on the side of the

Notice

Add proper amount of coolant. Too much

tire should be in consistency with the forward

or too less would affect the cooling effect. Air

direction of the front-handling crane. The locating

conditioner should be started for several minutes

cone hole in the felly should match the outer cone

every week in order to lubricate each component

of the hub to ensure the superposition of the felly

even in winder.

center and the hub center;

―When the tire is pumped, the pumping pressure

★Attention when changing the tyres

should be ensured at around 1Mpa;

3.8

Repairing and Maintenance of

―If the tire treads at the 1/4 breadth of the tire is

―Install the pressure plate on the threaded stud of

worn in 2~3mm, replace the tire;

the hub and screw the hub nut. The hub nut should

Tyres

―Old tyres can be replaced with retread tyres;

be screwed down gradually with symmetrical force.

★Check the tyre condition and pressure

―Must use tyres appointed by Sany Group. Using

The moment of screwing down the hub nut is

Before starting the equipment, check if there is any

different type of tyres may cause early damage of

350~370Nm. When the nut is screwed down, make

cracks on the tyre surface, any corrosion and over-

tyres or tyre explosion and endanger people and

sure 2~3 circles of screw thread of the stud

wear. Change the over-wear tyre. Check and clean

equipment;

expose;

dirt on the tyres, such as glasses, etc. Check tyre

3.7

Repairing and Maintenance of the

―Changing dangers is companied with danger.

―Test the installed tire by spinning it. Make sure

pressure, add it when it's too low. Low tyre

Air Conditioner System

Trained workers must follow the operation steps

the right-left amplitude of swing at the maximum

pressure may have bad influence on stability and

Main checking items within 50 hours:

with proper tools. Any operation doesn't follow the

outside diameter of the tire is less than 3mm.

load capacity of the equipment.

―Check transmission strap tightness of

standard schedule may cause explosion which has

compressor and adjust it promptly;

enough power to hurt even kill someone;

―Check the leakage of each pipe connector.

―Anyone without formally training is strictly

There might be leakage when the refrigerant

forbade to install or dismantle tyres.

connector has grease dirt;

3-11

3-12

MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual

3.9 Repairing and Maintenance of

the measured value (the max charging pressure)

such as dust, sand, liquid and gas, the pressure of

Accumulator of brake system

as the accumulator has been charged completely,

oil tank may be higher if the breather filter blocked,

Hydraulic System

then get another valve as the accumulator being

so periodically change the breather filter.

★Check the oil volume of main hydraulic tank

recharged(initial charging pressure).

and brake tank

The accumulator measured pressure is composed

Check the oil volume of hydraulic tank and brake

Accumulator of control system

of brake system and control system testing

★ Change the return oil filter

tank if it is sufficient by the window (the oil level

pressure, whose rated pressure are 10

0.5MPa

The flow may be hampered if the filter blocked,

height should exceed the red line, at the position of

and 2.5

0.5Mpa individually.

which bring about high pressure of outlet and burst

3/4 of the window), if deficient please fill in.

of oil tube.

★Check the if hydraulic pressure is consistent

with the hydraulic rating plate

―Spreader system pressure testing

―Test of the main system pressure

The spreader system pressure is 14

0.5Mpa.

3.10 Repairing and Maintenance of

Electric System

★Check if there is enough battery water

Observation

★

Change the entire high pressure filter

Check the voltage of battery, which should be 23-

Main hydraulic oil tank

Brake oil tank

window

for oil volume

Blocked filter may lower the flow of hydraulic oil,

25V as the engine halted 27-29V as the max

the movement speed of cylinder may be affected,

speed.

besides, it will bring about to greater oil pump

Notice

As the engine powered off, turn off the main

pressure to make the tube easy to burst.

As checking the oil volume, all of the

switch, tidy the battery, tie line and joints. Check all

The hydraulic system is sensitive to the impurity;

cylinder should retract to the original position.

the connectors if they are tightened. Smear the

the tight damage of chromium piston rod may bring

grease on the binding post and connectors, put a

about the leakage of seal components.

rubber gasket under the battery for fear of drain,

★Check the pressure of accumulator

Notice

and check the height of electrolyte, which should

Replace all the seal O-rings; change a

There are two accumulators of hydraulic system:

be 10-15mm higher than the battery, fill with the

new filter core with the moment of 140NM.

Brake system accumulator and control system

plasma water when it is not enough.

Diagram of hydraulic rating plate

accumulator;

Start the engine, to keep it in idle speed; there are

Start the engine; let it rotate at idle speed for 5

two main pressure testing points, whose testing

★Change the hydraulic oil and brake oil

minutes (the accumulator may not be charged

pressure should be the same. The result will be

The oil may be worsened gradually by the effect of

completely until the charging valve of brake system

displayed on the screen.

pollution and heat; metamorphous oil may

accumulator shift to coolant loop). As the engine

accelerate the abrasion and erosion of

halted, turn over the start-up key to position 1,and

―Brake pressure testing

components such as pump and valve, take

Battery

Add electrolyte

then step on the brake pedal iteratively with under

Brake pressure should be 14.5±0.5Mpa

periodical examination, change the hydraulic oil

Test voltage

square mode and to keep a small period of time at

Notice

and brake oil.

stepping position each time. There can be at least

Please step on the brake pedal as testing

Please adopt for the VG68G hydraulic oil at the

20 times brake before the warning light on, if not

the pressure of brake system.

tropical zone or long-time use place.

there may be some problems in the system; you'd

better give a further inspection. There are also

Notice

―Steering pressure testing

Do not forget to fill in the oil for main

pressures testing joints, which can be measured

To keep the engine with medium speed, turn the

pump case first before you have finished the whole

directly.

steering wheel to only one direction. the max

renewing of the oil.

★Check all the work light and indication light

pressure you have got in this process is steering

Generally, the accumulator pressure of control

Turn on all the work lights and indication lights, to

pressure. The valve is 1.75±0.5MPa.

system is satisfied to the requirement of control

see if they are normal.

★Change the breather filter of main hydraulic

system.

―Accumulator pressure testing

tank and brake tank

Start the engine, release the pressure, and get

The hydraulic system is sensitive to the impurity

3-13

3-14

LUBRICATING

Container Reach Stacker Maintenance Manual

★Test the overall function of hydraulic system

Operate the electro-hydraulic control handler; test

Lubricating Table of the Machine

all the hydraulic functions such as pitch and

contraction of jib, expansion, contraction and

sideshift of spreader. Find out parts that need

Lubricating points

Brand

Amounts

Cycle

adjustment.

Steer axle

Front headlamp

Rear headlamp

Boom lamp

Pitching cylinder fulcrum

Lubricating pump

Jib extension and contraction

lubricating block

Extension and contraction surface of

spreader

★Check horn, reverse buzzer and rotary

Pivot of jib and spreader

warning light

4.Lubricating

Damping cylinder lug of spreader

60 h or every

Turn on the horn, reverse buzzer and rotary

Mobil lubricating

warning light to check they are working.

Sideshift cylinder lug of spreader

week

grease EP2

4.1 Lubrication

Sideshift surface of spreader

Add lubricant coating in order to ensure the

Extension-contraction cylinder lug of

★ROPS system test

smooth rotation and sliding parts, not sufficient

spreader

Test if the ROPS system is working. Once the

lubrication can cause issuing and excessive wear

Rotary lock of spreader

controller get the front tilting signal, it would lock

parts. Lubricant is to guarantee the normal

the motion immediately (except contraction), give a

operation of machine of lubricating necessary

Turntable slewing bearing of spreader

warning and flash the red light. The signal would

materials.

Transmission axle

get through relay to control the front red acousto-

Reach stacker use Mobil EP2 hanging type

Parking brake

optical alarm prompt. Once the controller gets the

automobile universal lithium grease, banning the

Shell Diesel engine

signal, that red light would turned on, display

use nonspecified lubricant by Sany Group.

Diesel engine

250 h

CG-415W40

screen will also have the malfunction warning

Lubricating (butter) method:

Shell transmission oil

1000 h or one

signal.

Firstly clean the grease fitting, do not stop to inject

Brake oil tank

DonaxTD5W-30

year

the butter with the grease gun until the old grease

is forced out.

Shell gear oil VG150

1000 h or one

Reducer of driving axle

（>0? ）

year

Shell gear oil VG150

1000 h or one

Differential of driving axle

4.2

Lubricating Table

（>0? ）

year

Shell anti-wear

2000 h or one

Hydraulic oil tank

hydraulic oil VG46T

year

Shell multi-function

★Test the Rotary-lock safe interlocking device

2000 h or one

Torque converter

transmission oil Donax

system

year

TD 5W-30

Before turning on the rotary lock, check if all the

standby lights (green) is on; while the rotary

Shell antifreeze

Engine radiator

one year

isworking , check if all the sensor light (yellow) is

(freezing point-45°C)

on; check if clearance between sensor and

sensing block is normal, if there is any sign of

abnormal, treatment should be taken promptly.

4-1

4-2

FUNCTIONAL OIL

Container Reach Stacker Maintenance Manual

The quality analysis refers to regular laboratory tests

5.2 Oil Capacity

made on various items, including the viscosity,

You must use the right Fuel、Hydraulic Liquid

、

oxidization, water content, additives and cleanliness.

Cooling Liquid as SANY test says, and check the

They will be compared with the normal value to

quality and quantity of all the liquid often. Only all

determine whether the hydraulic liquid needs to be

the liquid has good quality and enough quantity,

replaced. Among the items, the cleanliness is the major

the engine is able to work.

one which indicates the quantity and size of the solid

particles in the hydraulic liquid.

This system's requirement on the cleanliness of the

Capacity Table

hydraulic liquid equals to level 8 or level 9 in NAS1638

Item

Capacity (L)

which is comparable to 17/14 level of ISO standard.

The Fuel Tank

470

Please see the two tables:

The Hydraulic Liquid

900

-30

-20

-10

NAS1638 Standard

Type

Brand

Specification

The Engine Cooling Liquid

The Gear-box and Torque Converter

The Level Of

The Size of Solid Particles (μm)

Fuel

The Driving Axle

Diesel oil

-20#

Cleanliness

The Wheel Reductor

2 11

5～15

15～25

25～50

50～100

>150

Shell diesel engine

SAE10

SAE30

API Classification

Engine oil

The Engine Oi

Level 7

32,000

5,700

1,012

180

CG-415W/40

SAE10W/30

SAE20W

CC or above

The Brake Oil

150

Level 8

64,000

11,400

2,025

360

Shell gear oil

Level 9

128,00

22,800

4,050

720

128

Driving axle

VG150(>0℃).

GL5

SAE80W

SAE90

Notice

oil

VG100(≤0℃)

The capacities in the above table are for

Notice

reference.

The level 8 in the NAS1638 indicates that,

Transmission

Shell transmission oil

The oil level indicator is placed on the side of the

in the 100ml oil sample, the number of the particles

SAE10W/30

torque

DonaxTD5W-30

oil tank in order to check the oil level in the tank.

with the size of 5~15m will not exceed 64,000; the

converter oil

number of those with the size of 15~25m will not

Shell anti-wear

exceed 11,400, so on and so forth.

Hydraulic oil

hydraulic oil

SAE10～20W

SAE30～40

5.3 Check and Change of Hydraulic Oil

The ISO Standard

VG46T（>0℃）Shell

The Shell brand antiwar hydraulic liquid is adopted

(DIS4406, SAEJ1165)

for this machine. The hydraulic liquid in the tank

transmission oil

Transmission

should be checked every 6 months in the forms of

DonaxTD5W-30

SAE10W

SAE20W/40

cooling oil

the appearance appraisal and quality analysis.

Level of

The Size of the Solid Particles（μm）

The appearance appraisal refers to estimating

Cleanliness

General lithiumed oil

>15

Lubricatiing

whether the performance of the hydraulic liquid

Maypoles oil EP2

oil

16,000

8,000

deteriorates. Please see the following table:

16/13

17/14

125,000

Shell antifreeze

Antifreeze

-45℃

Appearance Appraisal of Hydraulic Liquid

18/15

250,000

32,000

(freezing point-45

19/16

500,000

64,000

Phenomenon

Contaminant

Oil features are different from different manufacturer, so client should use recommended oil.

Darkening Color

Oxygen

Notice

The cleanliness level 17/14 in ISO

Milky White

Water or Bubbles

standard indicates that, in the 100ml oil sample,

Bubbles

Air

the number of the particles with the size above 5m

Floating Impurities or Sediments

Solid Particles

should not exceed 130,000; the number of those

Separation of Oil and WaterSeparation

Water

above 15m should not exceed 16,000.

of Oil and Water

5-1

5-2

FUNCTIONAL OIL

CHECKING OF KEY BOLTS

Container Reach Stacker Maintenance Manual

During utilization, the particle contamination level

Proportion: + 5.8%～6.5%（Suitable environment

Bolts' Fastening Torque of Main

6.Checking of Key Bolts

in the hydraulic liquid in the tank should not exceed

temperature

＞-5℃）

Components (Undetermined)

18/15 (which is comparable to NAS10 level)

Before start, carefully check fastening status of key

Recommended

The hydraulic system of this machine has the

Hydraulic oil type:

Bolt dimension

Shell hydraulic oil No.68（Suitable environment

bolts. Loose bolts will possibly cause acute

fastening torque(Nm)

following items for oil change:

shaking, damaged parts, weak function, broken

Variations of viscosity: 10

temperature≥35℃）

M12 1 20Fixed bolt of engine

755

Shell hydraulic oil No.46（Suitable environment

bolts, and other dangerous phenomena, and,

The increase of acid number: 0.1~0.25mgKOH/g

M16

periodic check will avoid accidents.

200

Moisture: <0.1%

temperature 35℃～-5℃）

Fixed bolt of torque converter

Shell hydraulic oil No.32T（Suitable environment

The following items of the bolt should be carefully

Mechanical Impurities: 5%

M12

130

Variations of density (15C/4C): 0.05

temperature≤-5℃）

checked:

Fixed bolt of transmission axle

Copper sheet erosion: disqualification

―

Checking of fixed bolt of engine

M24

360Fixed bolt of driving axle

1150

Southern area of China（All year long）

Rust preventing ability: disqualification

―

Checking of fixed bolt of torque-converter

Brake oil—Hydraulic oil No.46+AdditiveLZ9990A，

M24

2 Fixed bolt of tyre platen

980

Ash content: 0.05%

―

Checking of fixed bolt of transmission shaft

Proportion: 5.8%～6.5%

M30 2

Variations of surface tension: 15 dyne/cm

―

Checking of fixed bolt of drive axle

4751

Residue carbon: 0.05~0.10

Hydraulic oil—Shell hydraulic oil No.46

Fixed bolt of steering cylinder

―

Checking of fixed bolt of crane spreader rotary

Variation of color (Union grade): above +2

M30 1 40

gear case

16001

Guangdong province (China), Southeast Asia,

Fixed bolt of up/down counter weight

―

Checking of fixed bolt of tyre pressure plate

Brazil, New Zealand etc, areas

The hydraulic liquid, the checking results of which

Brake oil—Hydraulic oil No.46+Additive

Notice

are not up to the requirement, should be changed

Notice

LZ9990A，Proportion: 5.8%～6.5%

in time. The change of oil should follow the

If the bolts are loose, please check it with torque

Hydraulic oil—Shell hydraulic oil NO.68

following steps:

spanner and screw the bolts and nuts to torques

―

Make sure thread on the bolts and nuts are

―Remove the plug on the bottom of the hydraulic

according to figures in the following table. If bolts

clean before install them.

Northern area of China, Germany, Sweden,

oil tank to drain the hydraulic oil in the tank and

or nuts are broke, they should be replaced with

―Lubricate the bolts and nuts to stablize their

America, Australia etc, areas

pipe.

equal or higher standard bolts or nuts.

friction coefficient.

Brake oil—Hydraulic oil No.32T + Additive

―Open the hydraulic oil tank to clean the hole cap.

―If the bolts of counter-weight are loose, screw up

LZ9990A，Proportion: 5.8%～6.5%

―Use the cleaning liquid (diesel, etc.) and paste to

immediately; please connect your nearest and

Fastening Torque Standard

Hydraulic oil—Shell hydraulic oil NO.32T

clean the oil tank.

Sany service engineer.

―If it is qualified after being checked and cleaned,

Standard Nut and Bolt

―Standard measurement of torque is Nm:

Severe cold region (temperature lower than-25

the cleaned hole lip should be installed back.

Screw

Standard

Screw

Standard

For example: Screw bolt or nut with a spanner(1m)

℃）,Russian, Canada etc, area

―Add oil to the tank: Open the air filter lip on the

Thread

Fastening

Thread

Fastening

with 120N force twisting the spanner end, which

Brake oil—Hydraulic oil No.32T + Additive

top of the oil tank. Add the hydraulic oil filtered by

dimension

Torque（N.m）

dimension

Torque（N.m）

would generate following torque: 1m*120N

LZ9990A，Proportion: 5.8%～6.5%

5m filter (filtering car) to the oil tank through the

=120Nm

M14

Hydraulic oil—Shell hydraulic oil No.32T

filter element until reaching the full scale of the oil

Same torque by using a 0.25m spanner:

indicator.

M16

0.25m*y=120Nm

Changing period:

M10

M20

Needed force: y=120Nm\0.25m=480N

Hydraulic oil—Running-in of new equipment:

M12

100

M30

100

change it after 50 h ;second time: 500h ，following

5.4 Using Principle of Oil

changing period: 1000h

Working temperature of brake oil and hydraulic oil

Hydraulic oil—Running-in of new equipment:

don't exceed 80℃,selecting principles are：

Change it after 50h; following changing period:

Brake oil:

2000h

Hydraulic oil No.46 + Additive LZ9990A，

Proportion: + 5.8%～6.5%（Suitable environment

Notice

when the environment temperature is

temperature

＞-5℃）

under 0℃，equipment has to be warming-up for

Hydraulic oil No.32T +Additive LZ9990A,

one hour.

5-3

6-1

SAFTY REGULATIONS DURING MAINTENANCE WORK

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

7.Safty Regulations during

8.Common Faults and Measures

8.2 Common Faults of Mechanical Systems and Measures

Maintenance Work

Table 8-1 Common Faults of Mechanical Systems and Measures

8.1 General

The machine can finish the operations such as

Safety regulation while maintenance, checking and

Category

Faults

Cause of faults

Measures

pile; fetch containers and operating with

lubricating.

containers. It must bring some certain impacts to

Temperature is too low ; preheating

users on the progress of work, economic and

Difficult to start up

time is short; Air filters or air intake

★Safety regulations in working place：

social benefits, etc. when the faults occur. With a

―Make sure equipment parked in a safe place；

jammed; Thermostat is failure;

timely diagnosis and elimination, the customers

―Segregate a safe area with a ribbon if

Starting voltage is insufficient

can restore the economic losses and keep our

necessary;

corporate image. This section will state the

―Arrange a signaler to assist the work if

Engine high-speed

EDC fuel control unit has problem

Engine high-speed

common faults of machine and give elaboration

necessary.

Bellows cracks with air-leakage

Self-faults

Replace

corresponding to the measures in three major

aspects of mechanical system, hydraulic system,

Engine speed up with difficulty

EDC fuel control unit with problem

Check the EDC fuel control unit

★Safety regulations of product:

and electrical control system.

No oil in tank; oil-pipe plugs ; air

Check whether the fuel is out;

―Use warning sign;

―Cut off or lock the electric power switch to

Engine parking by itself

enters into oil-pipe

Check whether oil line plugs or

prevent unauthorized reenergize;

enters with air

―Release the electric power or discharge the

Check whether coolant water is

storage energy liquid power, gas power or electric

Engine

Lack of water coolant; Thermostat

enough;

power;

Engine temperature is too high

failure; The fan belt is loose; The

Check thermostat;

―Regarding to information of certain situations

abnormal

water pump is damaged

Check whether the fan belt is loose;

and working conditions which haven't included in

Check water pump

this manual, please ask manufacturer for help.

The water with oil but oil without

Engine Oil Cooler is damaged

Check whether the oil cooler

★Safe protection of persionnel：

water

is damaged

―Must wear working clouth, helmet and safe

Replace;

shoes while working;

Cylinder head Cracks

Self-faults / coolant is not enough

Check whether the coolant is

―Safty belt must be weared while working in high

enough

position;

Check whether cylinder head or

―Hang the warning brand of “stop, in repairing” on

Fuel level of oil sump tank (with

Cylinder head or cylinder body

cylinder body crack;

the equipement.

water)

cracked; cylinder liner water

Check whether cylinder circle

damage

Lubricating oil pressure is too

Low-oil level; oil filter jammed;

Add or replace lubricating oil;

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

Insufficient fuel; Diesel does not

flows smoothly;

Engine power is not enough

meet the quality requirements; The

Check whether the air intake is

air intake jammed

smooth;

Use the appointed fuel

7-1

8-1

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

Category

Faults

Cause of faults

Measures

Category

Faults

Cause of faults

Measures

Automatic deceleration of the

Check whether the fuel circuit flows

Oil supply is not smooth

Check the signal of gearbox

engine

smoothly

Gearbox

control unit if it is normal、 check

The diesel rough filter and

Use the clean diesel;

Diesel is too dirty; the cleanliness of

Gearbox cannot shift

Gearbox control unit with problem

the magnetic coil of gearbox

second filter of engine jammed

Clean the oil tank

abnormal

diesel box is not enough

magnetic valve if it is burn-out、

Engine exhaust pipe leakage

Check the leakage position and

Exhaust pipe is damaged; exhaust

the valve core if it is blocked

pipe joint is not sealed enough

repair

Low brake oil pressure、oil brake

Engine fan belt broken

Replace the belt;

Self-faults; the belt is too tight

circuit with air、brake block

Check weather brake oil leakage

Engine

Adjust the belt tension

Drive axle

Footbrakeforcenotenough

abrasion and invalidation

Replace air valve or guide tube;

Wear intensity between air valve and

Check the fans of cooler system

abnormal

Engine with blue-smog

abnormal

guide tube becomes larger; oil

Replace oil scraper.

High temperature of brake oil

change the flabellum if they were

scraper ring is damaged

damaged

Engine speed up with difficulty

EDC fuel control unit with problem

Check the EDC fuel control unit

Bignoise

Replace the wear and damaged

Gear damaged、shaft bearing wear

Engine supercharger with oil

Replace the sealing components

Supercharger sealing component is

or damaged

components

leakage

damaged

gear change

Manualshiftis incapable

Inspect the contact

Contact Failure

Fuel meter shows wrongly

Check fuel meter and liquid level

handle

Fuel meter or liquid level sensor is

Joystickfailure

Inspect the contact

sensor

Work Handle

Contact Failure

damaged

Oil seal of engine front

Traversing

Angleadjustmentfailure

Retaining mechanism Failure

Check the retaining mechanism

Self-faults

Replace

machine

crankshaft with leakage

Cab mobile

Cabcannotmove

Check the oil circuit of brake

Check the oil level；

Brake cylinder cannot release

Low oil pressure、low oil level、

mechanism

Clutchslipping

cylinder

charging pump is damaged、

Check the charging pump；

Cab shock

Cabvibration;bignoise

Tighten loose bolt

Change the clutch

Tighten the loose bolt

Clutch abrasion and invalidation

damper

Check the charging pump；

Low oil level、charging pump is

Check the oil level of luboil；

damaged、high oil level、too much

To avoid to make the torque

Gearbox

working hours on fallback condition

converter work on the condition of

Highoiltemperature

abnormal

of torque converter、the clutch

fall-back mode;

Step on the clutch switch as brake,

cannot break away in the condition

check the clutch switch if it is

of long period brake

available

Check the gear mesh condition；

Gear mesh with problem、shaft

Bignoise

Change the damaged or abrasion

bearing abrasion or damaged

shaft bearing

Check the charging pump；

Low oil level、charging pump is

Deficiencypressureofoil

Check the pressure control valve；

damaged、pressure control valve of

pressuregauge

Change the damaged seal

clutch is damaged，oil seal

components

components of clutch is damaged

8-2

8-3

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

8.3 Common Faults of Hydraulic System and Measures

Category

Faults

Cause of faults

Measures

①Parking brake failure

①Clean the parking brake

Table 8-2 Common Faults of Hydraulic System and Measures

Without the handbrake or

②Magnetic valve failure

②clean the magnetic valve or

Brake

Category

Faults

Cause of faults

Measures

System

handbrake failure

③Feed pump Failure

change

Libration phenomena as the

Magnetic valve blocked

Clean the magnetic valve

④Shuttle Valve Failure

③check the return line

boom retraction

④Clean or Replace

①Internal drain of telescoping

①Strip inspection and change the

①Insufficient fuel supply

①check the system pressure

Automatic retraction of the

pitching cylinder

seal components

②Hydraulic steering gear failure

②clean and replace

Steering

boom

②Self-lock function of logic valve

②Check the logic valve

Poor or not to shift

System

③Serious leakage of steering

③change the seal components

invalidation

cylinder

④clean

①Low oil pressure

①Check and adjust the pressure

④Prefill valve Failure

Boom

②Logic valve with problem

valve of between pump and main

①cooler failed

①replace

System

No pitch、telescoping of the

③Only one movement of differential

valve

②Air-cooled hydraulic motor of

②change the hydraulic motor

boom

②Check the logic valve

magnetic valve

cooling circuit is damaged, made

③change the back pressure spring

③Check the electrify state of

inadequate wind

④change the reversing valve

High oil temperature

differential magnetic valve

Cooling

③Oil supply of loop feed pump is

⑤clean the cooler

System

①Low oil tank level

①Add the hydraulic oil to the tank

not enough

⑥swash the out radiator

The boom can not reach its

②Cushion protection distance of

②Minish the cushion protective

④Inter drain of change valve is

position

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

No pressure in the system

blocked

②Check the oil pump feedback

②Use the substandard viscosity

Spreader

②No output of oil pump

hydraulic oil

System

oilcircuit

③Long-term use of hydraulic oil

Check the mass of hydraulic oil;

①Electrical Fault

①Change the circuit

Without movement

without filter or change

Periodic filteration

②Magnetic valve is damaged or the

②Clean or change the magnetic

Hydraulic oil pollutes and goes

Hydraulic

④The constant input of dust, sand

Change the filter core periodically

spool is locked

valve

bad

Oil

and other debris

Change the hydraulic oil

①Adjust the distance of brake

⑤High temperature; oxidation

①Brake valve failure

valve

metamorphism

②Brake Failure

②Check the clearance of brake

Brake

Without foot brake valve the

⑥Enter with water and air, as a

③Pressure Relay Fault

block

System

result of cavitation erosion etc.

brake function failure

④Accumulator Failure

③Clean or Replace

⑦Filter plug

⑤Gear pump Fault

④Replace

①seal components damaged or

①change the seal components

⑥Brake valve block fault

⑤Replace the gear pump

Leakage of hydraulic oil

distorted

②tighten the loose parts

⑥Clean or Replace the valves

②joints

、pipelines are free

8-4

8-5

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

8.4 Common Faults of Electrical Control System and Measures

Category

Faults

Cause of faults

Measures

Big error of movements of

①Adjusting valve of pressure switch

①Reset

Due to the complexity of malfunction of electric-control system, careful observation and

pressure switch

inaccuracy

②Change

research and rich experience are needed to determine the real cause of malfunctions.

②Invalidation of pressure switch

After determine the cause of malfunctions, eliminate them from the easy ones to hard

①Broken circuit

①Check and recovery

ones.

No signal of pressure sensor

②Reverse of power line and signal

②Check and correct

line

Table 8-3 Common faults of electrical control system and measures

Electricity

①Line abrasion, there is contact

component

resistance between signal line and

①Check and recovery

Category

Faults

Cause of faults

Measures

Big Error of pressure sensor

①Broken circuit or short circuit

power line

②Change

②Rust-eaten of magnet

①Change loop

②Invalidation of sensor

Non-operation of Magnetic

③Spool abrasion or invalidation of

②Scrubbing magnet

Wrong signal of accelerator

valve

Reverse of pedal power wire and

seal-ring aging

③Change spool or seal ring

pedal, start-up the engine,

ground wire

Check and recovery

④Severe oil carbon pollution in the

④Scrubbing magnet

which reaches the max speed,

valve

⑤Change the spring

when step on the pedal, the

speed reduces

⑤Invalidation of deflection spring

Air Ejection from Magnetic valve

Change the magnetic valve

Invalidation of magnetic valve

①Check and recovery

Non-operation of wane switch

①Wane switch failed

①Change

①Short circuit

Water level alarm as full water

②Change

②Lead wire is off

②Check and recovery

②Fault of structure of water level

tank

③Full install，make sure that the

①Bulb broken

①Change the bulb

switch

switch close if there is water in the

Indicator light failed

②Something wrong with electricity

②Find out the reason then deal with

③Reverse of water level switch

water tank

wire

Electricity

①Check and recovery

①Too soft of contact spring

①Broken circuit

No indication of fuel level

component

①Adjust the elastic force

②Check and correct

②Ragged and protrude bottom

②Reverse of power line and signal

Contactor armature cannot fall

board

②Remove of the protrude part

line

when electricity failure

③Tightly seized of armature and

③Refit that to make it more flexible

①Line abrasion，there is contact

①Check and recovery

mechanical parts

④Change the contacts

resistance between signal line and

Inaccuracy of fuel oil level

Electricity

②Change

④Contacts are fusion welded

power line

component

together

②Invalidation of sensor

Contactor cannot fully close

Adjust the elastic force of the

Too soft of contact spring

①Fault of circuit

Non-operation of Temperature

①Check and recovery

when power on

spring

②Switch damaged

switch

②Change

①Find out the reasons then deal

①Load exceeds the rated capacity

①Inaccuracy of temperature switch

①Readjust

with it

②Large range of contacts

Big error of temperature switch

adjusting valve

②Change

Contact of relay generates heat

②Change the contacts

③Severe burning loss of contact

②Invalidation of temperature switch

③Change the contacts

④deficient pressure of contacts

Non-operation of pressure

①Fault of circuit

①Change

④Change the contacts

switch

②Switch damaged

②Check and recovery

8-6

8-7

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

Category

Faults

Cause of faults

Measures

Category

Faults

Cause of faults

Measures

①Find out the reason then deal with

①Circuit broken

①Check and recovery

①There is dust、dirt or burnout

②Burn-out of power fuse

②Change the fuse

Pool contact of relay

②Too soft of contact spring

②Inspection on spring force,

③The fuse of enter point power is

③Change the fuse

Electricity

Change that if necessary

No response of screen when the

burn-out

④Check and recovery

component

system is electrified

①Contact is not qualified

①Change the contacts

④Input-output circuit failure

⑤Check and recovery，refresh the

There is sparkle on the contact

②Too soft of contact spring

②Change the spring

⑤Endless loop of program

program

of relay when it is closed

③Burning loss of contact, poor

③Change

⑥The controller is damaged

⑥Change the controller

contact

①Retighten the contactors

①Pool connection of armature and

①Clean out the joint surface

①Loose of the lead wire contact

②Find out the reason then deal with

Exception noise of direct current

iron core

②Change the contact spring and

②Burn-out of fuse of control circuit

contactor

②Large pressure of contact

contactors if necessary

③Position handle not at neutral

③Put the position handle to neutral

The engine cannot setup when

pressure

position

rotate the key switch

①Contacts are welded together

①Change the contacts or switch

④Setup relay damaged

④Inspect on the relay，change

Cannot break away the

②Tightly seized of mechanical

②Repair it to make it flexible

⑤Failure of setup key switch

that after confirmation

accumulator switch

structure

⑤Check on the key switch and

Electricity

①Circuit broken

①Inspection and maintenance

change that as confirmed

Non-operation of preheating

component

②Heater damaged

②Change

①Pool contact of startup key switch

①Find out the reason then deal with

heater

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

circuit fuse

②Change the fuse body after

Electricity

Rotate the start-up key switch,

③Pool contact of lead wire or

Inspection

③No zero line in the control circuit,

that

componentnomovementof start-up relay

Press down the set-up button，

which cannot constitute control

③Re-connect the zero line

or start-up contractors

contactors

③Find out the reason then deal with

④Loose of the lugs of relay or

it of that

the wiper has no response

circuit

④Inspection on relay，change that

④Relay damaged

as being conformed to be damaged

contactors or something wrong with

④Find out the reason then deal with

the wire ring

⑤Priming button failure

⑤Inspection on button ,change that

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

①Short circuit of horn power wire

The horn chirping ceaselessly

the rated speed

②Output signal of gun with mistake

gun1.6V~3.8V

and control power line

①Check and recovery

when being electrified

③Connectors loose or drop

③Check connector and wire

②Fusion welding of contact of horn

②Change the relay

After starting the engine, and

controller

①Braking system has some mal

①Inspection and exclusion

engaging a gear, the crane can

①Lead wire break off or circuit

①Inspection and recovery

function, with a braking signal

②Open the parking button

Acousto-optic alarm failure

not move with the lights lighting.

broken

②Change

②Still with signal as parking

②Warner damaged

①Earth connection of power line

①Check and repair

No indication of the whole car

with problem

②Change

speed， and can only run at gear

②Velocity sensor is damaged

③Change the gate

，and change

one

③Breadboard is damaged

the frequency divider is necessary

8-8

8-9

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

Category

Faults

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

Duct pilot is short, for example,

②The lines of general oil supplying

③Check and resume it, change the

conducting wire insulation is short to

No movement of the spreader

valve have some malfunction

general oil supplying valve if

Power supply being on, the main

Find the causations and exclude

ground, electric coil is burnout,

③General oil supplying valve

necessary

cut-out switch of duct pilot trip

them

magnet coil is short, wire is wrongly

maybe has some malfunction

④Change

jointed, etc

④Spreader controller damaged

①The cut-out switch of its power

①Induction distance of location

①Adjust the distance of the four

supply trip

The yellow indication light

①Inspect the fault, and then close

sensor with problem

location sensor

②The on-off of freezing pressure

blinking or bright all the time as

the cut-out switch after you confirm

②Location sensor is damaged

②Change the sensor

Something wrong with Air

the spreader has not location

has some malfunction

③The yellow indication light is

③Change the yellow indication

conditioner

③Loose or off connection of the

②Check and Change

damaged

light

lines on air conditioning control

③Inspection and recovery

The spreader has released but

①Wrong induction distance of

①Adjust the two induction distance

panel, condenser maybe has some

no red indication light or

unlock sensor

of unlock sensor

malfunction

twinkling

②Location sensor is damaged

②Change the sensor

①The fuse of power supply is

Electricity

The spreader has unlocked, but

burned out

Electricity

component

①Change the fused body

no red indication light or

Red indication light is damaged

Change the red indication light

②Temperature switch is damaged

component

②Change

twinkling

Hydraulic cooling system

③Movement controlling relay

The spreader has locked in, but

③Change contacts

①The induction distance of lock in

①Adjust the two induction distance

cannot refrigerate automatically

contact is sweated

no red indication light or

sensor with problem

of tighten sensor

④Confirmed and recovery

④Cooler electromagnetic valve

twinkling

⑤Confirmed and change

②Tighten sensor is damaged

②Change the sensor

maybe has some malfunction

The spreader has locked in, but

⑤Radiator motor failure

no white indication light or

White indication light damaged

Change the white indication light

①Malfunction of lines, conducting

twinkling

wire is abraded

①Inspection and recovery

①Burn-out of power fuse of boom

②Corresponding electromagnetic

control

①Change the fusing body

②Tidy the magnetic valve

valve is locked

③Change the ring

②Circuit failure, no handle signal

②Change and recovery

No operation of the boom

③The ring of magnetic valve

Only part movements of

④Change

input of the screen or with

③Check according to the safety

damaged

proportion valve output signal,

spreader

protective table

⑤Check and maintain it, change

④Spreader controller damaged

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

malfunction

②Handle signal wire scored

reliable

The operation of the boom Lose

③Handle damaged

②Repair the handle

of control

④Electric proportional valve

③Change the handle

damaged

④Change the proportional valve

8-10

8-11

COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual

Category

Faults

Cause of faults

Measures

Category

Faults

Cause of faults

Measures

①Without key switch

①Turn on the key switch

Communication fault of the

The engine works but no speed

Check whether the wire broken or

Nutation emergency is failed

②Magnetic valve of Nutation

②Overhaul the magnetic valve

engine and the controller

information on the screen

with water

emergency failure

③Check connector and wire

There is length and angle indication

③Connectors loose or drop

Controller and I/O extended

on the screen but without gear

Check whether the wire broken or

①Reverse plug of rod and rodless

①Joint the wire correctly

block

information, and the red light of the

with water

Inaccuracy of weight-

I/O extended block always on

pressure sensor

②Change the pressure sensor

measuring

①Check whether the wire is broken

②Pressure sensor damaged

③Check connector and wire

Communi

or water intake;

③Connector lug loose of drop

cation

wire

Controller and screen

The screen is ok but no content on it

②Check whether terminal

①Rough road surface

①Smooth the road surface

resistance burn out or bad

②Distance of Proximity switch

②Adjust the distance of Proximity

ROPS give an alarm

connects, The terminal resistance

improper

switch

locates on its plugs.

③Proximity switch damaged

③Change the Proximity switch

①Check whether the wire is broken

④Connector lug loose of drop

④Check connector and wire

or water intake;

①Too much redundancy data

①Refresh the page

Abnormal show of the screen，

Controller and length and angle

The indication of the length and

②Check whether terminal

②The screen is disturbed by

②Eliminate the interference source

figures distorted

sensor

angle of the boom is abnormal the

resistance burn out or bad connect

Electricity

magnetism

③Change the screen

others are ok

.As the terminal resistance locates

component

③The screen damaged

in the length angle sensor ,the

①Bus failure

①Check the wire and recovery

the page data of the screen is

②Bus terminal resistance damaged

②Change the resistance and

abnormal

or lead fell off

check the wire and recovery

①Power fuse burn out

②Power fuse burn-out on the enter

①Change the fuse

point

②Change the fuse

③Power fuse burn-out on the enter

③Check and recovery

No operation of controller

point

④Check、recovery and refresh the

④To judge the state of the program

program

according to the instruction book

⑤Change the controller

⑤Controller damaged

①Power fuse burn-out

①Change the fuse

②No blinking of communication

②Check and recovery

No operation of extended block

indication light

communication wire

③There is light on the input

、output

③Change the extended block

points but no operation

①No key switch

①Check the switch

Cab can not move

②Magnetic valve damaged

②Check and repair magnetic valve

③Connector lug loose or drop

③Check connector and wire

8-12

8-13