Maintenance of Crawler Crane

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 CONTENTS

Chapter 1 General Description

Chapter 2 Preferred Principle for Lubrication Oil

Chapter 3 Maintenance Method

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 Chapter 1

General Description

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 General Description
1.1 Personnel for maintenance

The maintenance should be operated by specialized personnel only,

especially, the maintenance for electrical system, hydraulic system,
engine system and each braking device.

1.2. The danger of maintenance work

 Danger of being smashed, being squeezed

 Danger of hands being wrung, traipsed

 Danger of high temperature

 Danger of gas, dust, smog

 Danger of residual energy in hydraulic system

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 General Description

Fire Prevention

Keep the crane clean, especially from

inflammable materials. During
maintenance of the hydraulic system,
the engine, and the fuel system, clean
the crane thoroughly. Remove all
residual lubricating oil, fuel or detergent.

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 General Description
1.3 Notice
1.3.1 Initial maintenance
After 50 hours operating, some key parts of crane should be maintained.
--Check connecting bolt of rotary supporting, do the
maintenance for connecting bolt of rotary supporting.
--Check gear oil, replace gear oil in time.
--Check oil return filter core of hydraulic oil tank, and
replace it.
--Check hydraulic oil filter core of servo system, and
replace it.
--Check each pin and axles’ lubrication, ensure the
sufficient lubrication.
--Check each connecting bolt, replace and maintain the
failed bolt.

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 General Description

1.3.2 Notice before lubrication

--Keep the operator informed, and appoint a
supervisor!
--Shut down the engine!
--Park the crane.
--Lock the power switch and startup switch of electrical system
--Clean the crane, especially, clean up the lubrication oil, fuel and any
additives of connector and clutch.
--Cover the port which will be effected by water, steam or additives before
cleaning.
--Remove the cover, and check whether there is water in these area.
--After cleaning, check whether there is leakage from fuel pipeline, gear oil
pipeline, hydraulic oil pipeline and whether the connector is loosen and there
is crack section or failed part.
--Solve the problem in time.
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 General Description

When doing maintenance and assembly,

lubrication oil maybe overflow, so suitable
container and bond should be prepared.

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 General Description

1.3.3 Notice during lubrication

1.Cover the specific area carefully.
2.If some big components need to be replaced, it should be set on auxiliary
device placidly, to ensure it won’t be in any dangers or be damaged.
3.Only these auxiliary device which works in normal condition and be with
adequate carrying capacity could be adopt.
4.Do not stand, walk or operate below suspended weight.
5.Only experienced personnel could be appointed to load weight, and should
send signal to crane driver! Signaler must stand in crane drivers’ ken, or stand
where he can communicate with crane driver.
6.Loosen bolt should be connected when doing maintenance.
7.If it is necessary to disassembly safety device during maintenance, it should be
mounted again and checked carefully after maintenance.
8.It should ensure that oil cloth and flammable material be away from where
there is danger of fire, be careful when moving.
9.Electrical device of crane should be checked regularly. Repair or replace the
loosen connector and cable with burned mark.

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 General Description
10.It is required a qualified electrician to do the maintenance for electrical
system according to the regulation, or under the supervision of a qualified
electrician.
11.Only original fuse that meets the requirements could be adopted! Shut down
the crane the moment power failure occurs.
12.Regularly check whether there is leakage from all the pipe and connectors,
replace it if there is.
13.Lubrication and maintenance for hydraulic system should be operated by
qualified personnel with hydraulic specific knowledge and experience. (relieve
the system pressure before maintenance)
14.Oil blowout will hurt you and cause fire.
15.When dealing with lubrication oil, lubrication grease and other chemical
material, it requires to obey the related regulation.
16.Do not excessive lubrication, or it not only wastes oil but also does bad to
system.
17.Be careful when dealing with heat consumables. (there is danger of scald)
18. Ensure there is not any tools left in the device after work, the off and
protruding tools will cause danger to life and body.

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 General Description

1.3.4 Lubrication hour

In some nasty working condition, such

as dusty, corrosive air, abnormal
atmosphere temperature, extreme loads,
frequent or long-time cycle operation and
etc, lubrication interval should be shorten.

If it is found bearing and sleeve is

overheat, motion parts is loosed, motion
is rust and etc. These mean that those
part is lack of lubrication, and the
lubrication interval of those abnormal
parts should be shorten.

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 Chapter 2

Preferred Principle for Lubrication Oil

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 Preferred Principle for Lubrication Oil

2.1 Preferred principle for lubrication oil

1. Recommendation of engine lubrication oil

 Select the good quality lubrication oil in priority. The recommend level is CH-4, CI-4.

 Adopting high viscosity lubrication oil could improve the gear oil consumption, it helps
engine working in cold weather and keeps lubrication at high working temperature. And
SAE15W-40 is recommended in most atmosphere.

 Adopting low viscosity lubrication oil to some extend, such as adopting SAE10W-30 in
there atmosphere which is below -5 ℃, it helps engine start and provides adequate gear oil
flow. But adopting low viscosity oil will shorten engine life.

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 Preferred Principle for Lubrication Oil

2. Fuel recommendation light diesel (GB252-2000)

In most condition, it is economic and efficient to adopt fuel ASTH2 and fuel whose
min cetane number is 40. In the condition whose temperature is very low and altitude
is high, it is required fuel whose cetane number is over 40 to avoid flameout and
smoky.
If it is adopted fuel containing sulfur, whose expected combustion temperature
should be 10℃ over its hot point.
Adopt the general used type fuel, whose sulfur proportion should be below 0.5%.
Keep the fuel clean and avoid moisture content and other impurity when filling fuel.

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 Preferred Principle for Lubrication Oil

3. Recommendation of lubrication grease

Max working temperature of lubrication grease should be 20-30 ℃ below its dropping points

4. Recommendation of gear oil

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 Preferred Principle for Lubrication Oil

5. Recommendation of hydraulic oil

Temperature shown in the sheet is the atmosphere temperature

Notice:
 Oil L-HV46, low temperature anti-wear hydraulic oil, which could adapt to a wide range of temperature,
be adopted in the whole year.
 Oil L-HV32, low temperature anti-wear hydraulic oil, which could be adopted in extreme cold region, such
as Russia, east-north part of China.
 Oil L-HM68, anti-wear hydraulic oil, which is adopted in tropic region, such as Middle East, India, etc.
 Please choose the hydraulic oil according to crane’s working region. Before delivery, changing oil is in the
charge of our company (it is charged), and after delivery it is in the charge of clients.

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 Chapter 3

Maintenance method

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 Maintenance method

3.1 Lubrication for boom pin

•Lubricate the related pin before

assembly the crawler crane

•Main pin of upper and chassis

•Connecting pin of boom and platform

•Pin of boom root

•Lubrication for A type connecting pin

•Crawler pin

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 Maintenance method

3.2 Lubrication for hook

That lubricate bearings and pulley of hook according to regulated interval could
decrease wear and corrosion effectively, therefore, it maintains hook’s
performance and extends its life.

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 Maintenance method

3.3 Lubrication for wire rope

Lubricate the wire rope back and forth, it not only
prevents wire rope not to be rust, but also
improve the friction between wire rope and pulley
or wire rope and wrench or inner of wire rope.
1.Check the visible part of wire rope on every
working day to check whether there is any failure.
2.Check the wire rope regularly by personnel in
charge according to the law.
3.Do specific check for general part and the end
of rope.

Regular cleaning of wire rope

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 Maintenance method

3.4 Lubrication for bearing of pulley

Lubricate bearings according to

regulated interval to extend its life.
Shown in figure.

3.5 Lubrication for oil cylinder piston rod

Although our product’s quality is very good, the surface is still easy to
be corrosion in the aggressive condition.
Coat acid free lubrication grease onto the exposed surface to avoid
being corrosion, if the crawler crane does work over 1 day.

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 Maintenance method

3.6 Lubrication point of upper and chassis’ main part

1-slewing mechanism; 2-
hydraulic system; 3-
engine system; 4-cab; 5-
pulley device; 6-wire
rope

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 Maintenance method

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 Maintenance method
No. Item Maintenance content (every 8 hours or
everyday)
1 Slewing bearing gear surface Check the lub is adequate or not, smear
industrial gear oil, if necessary.
2 Fuel filling Fill the fuel to the proper level

3 Hydraulic oil level Fill the hydraulic oil to the proper level

4 Engine Air filter core Change if damaged

5 Fuel tank-clean the residues Clean the system timely and fill the coolant
to the proper level
6 Cooling system-check the coolant level and clean the cooling system Clean the system timely and fill the coolant
to the proper level
7 Hydraulic system-pressure pipe check and pipe fasten Check the pressure pipe is damaged or not,
check the fastener is loose or not before
operation
8 Fan belt tension check Check the fan belt is tensed or not

9 Visual check the reducer assembly by eyes Visual check before using

10 Steel wire rope Check the rope is damaged or not

11 Check the key bolts (counterweight install bolts, slewing bearing Check the bolts are loose or not, tighten
connection bolts, engine install bolts.) them timely.
12 Rain wiper check Clean the front windshield to ensure the clear
working vision
13 Check the lighting system Check the lighting system work properly or
not, repair it timely.
14 Check the pulley Check the pulley is damaged or not, bearing
lub is adequate or not.

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 Maintenance method

NO. Item

1 Engine oil volume check

2 Main and aux. hoisting,

main and aux. luffing
hoisting-check the
connection bolts.

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 Maintenance method

No. Item Maintenance content (every 250 hours or every month)

1 Check the lub of connection pin of the track Check the pins are intact or not, lub is adequate or not, add the
grease timely.
2 Adjust the track tension device Check the tension of the track is suitable or not, adjust as needed.
3 Check air filter Replace air filter

4 Lub the slewing bearing gear surface Centralized lub to the gear surface

5 Slewing reducer-check the oil lever Add lub oil for reducer

6 Check hoist oil level Add lub oil for hoist bearing and reducer
7 Check the traveling reducer oil level Add the lub oil for traveling reducer

8 Check the limiter Action is sensible or not, replace it if the sensibility is bad.

9 Check pulley and lub Check the pulley is intact or not, add lub oil timely.

Track drive wheel upper guide wheel supporting wheel guide wheel

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 Maintenance method

No. Item Maintenance content (every 1000 hours

or every half year)
1 Fuel tank filter clean Clean the filter of fuel tank
2 Fuel system pipes Check the pipes of the fuel system,
replace the damaged or leakage pipe.
3 Clean the radiator’s inside surface (1 Clean the radiator’s inside surface, make
part) the radiating better
4 Oil replacing for slewing reducer Replace the lub oil of slewing reducer
5 Oil replacing for lifting and luffing hoist Replace the lub oil of hoist reducer

6 Brake of lifting and luffing hoist Check the brake’s sensibility, replace it
timely
7 Bearing lub of lifting and luffing hoist Check the bearing lub, add the lub oil
timly and lub the bearing adequately.
8 Lub oil of traveling reducer Replace the lub oil of traveling reducer
9 Check the leakage of the hydraulic Check the pipes are damaged/leakage or
system not, replace them timely.
10 Pressure pipe Check the pressure pipe, replace the
aging or damaged pipe.

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 Maintenance method

No. Item Maintenance content (every 2000

hours or every year)
1 Hydraulic oil filter core replace Replace the oil filter core
2 Hydraulic oil replace Replace the hydraulic oil
3 Leakage of hydraulic system Check the hydraulic pipe is aging,
damaged or not, replace it timely.
4 Initial air pressure of accumulator Check the air pressure of
accumulator
5 Hydraulic return oil filter core Replace the return oil filter core
6 Steel wire rope Check the rope, replace the
damaged or failure rope

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 Maintenance method
3.7 Central lubrication system
Lubrication oil filling in method:
1.Check the oil level of oil tank before each operation.
2.Re-fill lubrication oil before oil level drop to lowest scale.
3.Clean the lubrication grease filling in port of pump case.
4.Fill in oil to oil tank through lubrication grease filling-in port by oil gun.
5.Fill in oil until the oil level reaches the highest scale of the oil tank.

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 Quality Changes the
World!

Thank you!

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