Guia Guindastes 50t Ate 75t

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    STC75 Truck Crane

    Users Guide

    Hunan SANY Auto Hoist ing Machinery Co., Ltd.

    Hunan SANY Auto Hoisting Machinery Co., Ltd.

    AddressChangsha Jinzhou Development Zone, Hunan, China Postal Code: 410600

    http://www.sanygroup.com Tel0731.85831153 Fax0731.84031999.523

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    II

    Preface

    Hunan SANY Auto Hoisting Machinery Co., Ltd. sincerely thanks you for purchasing SANY

    fully-hydraulic truck crane. Sany is dedicated to providing you with first-rate products, first-rate quality and

    first-rate service.This Users Guide contains the specifications you will need to comply with safety, understand the

    technology and operate and maintain your new STC75 truck crane. In order to ensure the

    highest-efficiency performance of the truck crane, we strongly recommend that you read and understand

    this Users Guide carefully for before operating. This will help you:

    get to know the structure and performance of the truck crane

    avoid danger or malfunction due to improper operation

    increase the reliability and prolong the service life of the truck crane

    reduce the maintenance cost and down time

    It is also recommended that you keep this guide within reach during operation. Only when you completely

    understand the Users Guide can you operate the machine expertly and safely.

    Thank you for your trust in SANY, and we wish you great success in your business.

    Special Instructions:

    Anyone planning to operate this truck crane must be experienced and t rained in its operation. If the

    operator i s not fully trained, then they shall bear the responsibility for any accident.

    The technical maintenance must strictly comply with the Users Guide so as to reduce the

    occurrence of malfunction, enhance the operating safety and increase the service life.

    Al l safety devices must be inspected periodical ly to ensure their normal performance. If any

    abnormalities are found, this should be fed back to after-sales service personnel of Sany. If any

    serious problems arise, the machine should be shut down until a licensed service technician can

    assess and resolve the problem. This is for your safety.

    This Users Guide must be kept within easy reach during operation for the operators reference.

    The user should contact us with any questions regarding th is Users Guide.

    In case the truck crane malfunctions, please contact the local branch or the service station of

    Hunan SANY Auto Hoisting Machinery Co., Ltd. Immediately. They will then provide you with timely

    and complete service.

    The engine should be maintained strictly according to the instructions w ithin th is users guide.

    This Users Guide has been updated to the newest edition. However, with the rapid development of

    SANY products, if anything in this guide appears outdated, please contact us and we will provide

    you the latest information for reference.

    Hunan SANY Auto Hoisting Machinery Co., Ltd.

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    I

    Reading Guidance

    1. Information

    This Users Guide is provided to facilitate your use and maintenance of the machine. It should always

    be in the cab for your reference at any time. If it is damaged or lost, you should order another one

    from Hunan SANY Auto Hoisting Machinery Co., Ltd.

    The Users Guide covers the information and instructions for safety, technology, operation,

    transportation, lubrication and maintenance. Some photos or figured details or optional components

    shown in the Users Guide may differ from your machine. In some diagrams, the protective plate and

    machine cover have been removed for clarity.

    This Users Guide may not include the latest updates to the machine as a result of gradual

    improvement and upgrading in the product design. So be sure to carefully read and study it prior to

    operation.

    For any questions on the machine or the Users Guide, please contact us for the latest information.

    2. Technical Specifications

    This part includes such content as performance parameters, technical characteristics, operating

    principles and structural composition, which helps you full understand the machine.

    3. Operation

    This part is the guide for new operators and also an important reference for experienced operators. It

    details a variety of instruments, switches, operating mechanisms of the machine, optional parts,

    delivery and traction.The photos and figures provide the guidance for operators to inspect, start, operate and shut down the

    machine according to the correct procedures.

    This Users Guide provides only the basic operating instructions. So, the operators skills will be

    improved with the deepening of his familiarity with the machine.

    4. Machine Capabil ity

    The newly-added optional or refitted parts unrecognized by SANY Automobile Manufacture Co., Ltd.

    may go beyond the advanced default capability of the machine, and accordingly produce bad effect

    on its performance including stability and system compatibility, especially the brake function and thesteering function. For any safety accident owing to the addition or the refitting mentioned above, we

    shall not bear any responsibility. However, if the addition of components or the partial refitting is

    required under special case or claimed by the user, the user shall contact us in advance, and we will

    provide the most reasonable opinions and suggestions.

    5. Explanation of Signs

    This is the sign for the attention of safety. When you see this sign on the machine or in the Users

    Guide, it indicates the possible injury of personnel. Please obey the precautions and methods

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    II

    suggested for the safe operation.

    On the sign boards, such signs that mean the hazard as Danger, Warning or Caution are used

    together with the . The sign of Danger means the direct danger, which may cause death or

    serious injury if no preventive measure is taken.

    It means the potential danger, which may cause death or serious injury if no preventive measure is

    taken.

    It means the potential danger, which may cause slight or moderate injury if no preventive measure is

    taken.

    The sign of Danger or Warning shall be established nearby the place where the special hazard is

    easy to occur, while the general precautions shall be listed on the sign of Caution.

    In the Users Guide, the sign of Caution is also used to call attention to the safety indication.

    In order to avoid the confusion between the indication for machine protection and that for personnel

    safety, the sign of Important is established, which means the machine may be damaged in case of

    misoperation.

    It is used to give the additional instructions to some specific information.

    It is used to give the directive instructions to some specific information.

    It indicates that the current operation fails to comply with the safety regulations or is prohibited, or it is

    easy to cause casualty.

    It indicates the current operation complies with the safety regulations.

    Notes

    Important

    Caution

    Warning

    Danger

    Prompt

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    Users Guide for Truck Crane

    IIIHunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Contents

    Preface...........................................................................................................................................................I

    Chapter I Technical Specif ications ........................................................................................................... 6

    1.1 Overall Structure................................................................................................................................. 7

    1.2 Overall Dimensions and Technical Parameters.................................................................................. 8

    Chapter II General Safety Operation Regulations of Crane ................................................................. 16

    2.1 Basic Rules...........................................................................................................

    2.1.1 Marks of Safety Prompt............................................................................

    2.1.2 Running-in Rules for New Truck Crane....................................................

    2.2 Specification and Requirements on Crane Operation ..........................................

    2.2.1 Requirements on Properly Using the Crane ............................................

    2.2.2 Examples of Results Due to Improper Usage..........................................

    2.2.3 Requirements on Crane Owner and Other Authorized Relevant Personnel

    2.2.4 Requirements on Crane Driver.................................................................

    2.2.5 Requirements on Crane Signaler.............................................................

    2.2.6 Operation Planning...................................................................................

    2.3 Safety Control Specifications................................................................................

    2.3.1 Worksite Requirements ............................................................................

    2.3.2 Overall Supporting....................................................................................

    2-3-3 Precautions for Lifting ..............................................................................

    2.4 Safety Device........................................................................................................

    2.4.1 Moment Limiter.........................................................................................

    2.4.2 Three-layer Overrelaxing Protector..........................................................

    2-4-3 System Master Switch .............................................................................

    2.4.4 Alarming of the Hydraulic Oil Filter ...........................................................

    2-5 Safety in Power Utilization....................................................................................

    2.5.1 Countermeasures Against Electric Shock of Crane .................................

    2.5.2 Preventive Measures Against Blast of Storage Battery............................

    2.5.3 Proper Welding.........................................................................................

    Chapter III Operating Method for L ift ing ....................................................................

    3.1 Startup and Flameout of Engine....................................................................................................... 17

    3.1.1 Startup of Engine...................................................................................................................17

    3.1.2 Warm-up of Engine................................................................................................................17

    3.1.3 Flameout of Engine ...............................................................................................................17

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    Users Guide for Truck Crane

    IV

    3.2 Operation of PTO.............................................................................................................................. 17

    3.2.1 Precautions............................................................................................................................17

    3.2.2 Steps for Switching on PTO ..................................................................................................17

    3.2.3 Steps for Switching off PTO...................................................................................................18

    3.3 Operation of Outrigger ...................................................................................................................... 18

    3.3.1 Precautions............................................................................................................................18

    3.3.2 Operation of Outrigger...........................................................................................................19

    3.4 Operation of Throttle

    3.5 Operation of Lifting Mechanism........................................................................................................ 20

    3.5.1 Precautions............................................................................................................................20

    3.5.2 Operation of Lifting Mechanism.............................................................................................21

    3.6 Extension and Retraction of Main Boom .......................................................................................... 22

    3.6.1 Precautions............................................................................................................................22

    3.6.2 Extension and Retraction of Main Boom...............................................................................22

    3.7 Luffing Operation of Main Boom....................................................................................................... 23

    3.7.1 Precautions............................................................................................................................23

    3.7.2 Luffing Operation of Main Boom............................................................................................23

    3.8 Operation of Slewing Mechanism..................................................................................................... 23

    3.8.1 Precautions............................................................................................................................23

    3.8.2 Operation of Slewing Mechanism .........................................................................................23

    Chapter IV Instal lation and Operation of Lif ting Accessories ............................................................. 25

    4.1 Installation and Disassembling of Jib ............................................................................................... 26

    4.2 Change of Multiplying Power............................................................................................................ 28

    Chapter V Electrical System of Superstructure .................................................................................... 29

    5.1 Electrical Appliances in Operating Room ......................................................................................... 30

    5.1.1 Arrangement of Electrical Appliances in Operating Room (Fig. 5.1).....................................30

    5.1.2 Description of Control Panel (Fig. 5.2) ..................................................................................31

    5.1.3 Description of Electric Control Cabinet (Fig. 5.3)..................................................................32

    5.2 Instructions for Display (Fig. 5.4)...................................................................................................... 33

    5.3 Safety Device.................................................................................................................................... 34

    5.3.1 Moment Limiter......................................................................................................................34

    5.3.2 Three-layer Overrelaxing Protector .......................................................................................35

    5.3.3 Master Switch of System.......................................................................................................35

    5.3.4 Height Limiter ........................................................................................................................35

    Chapter VI Accessories and Others ....................................................................................................... 43

    6.1 Description on Name Plate............................................................................................................... 44

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    Users Guide for Truck Crane

    VHunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    6.1.1 Name Plate............................................................................................................................44

    6.1.2 Name Plate of Lifting Capacity..............................................................................................44

    6.1.3 Marking Position of Vehicle Identification Number (VIN) ......................................................44

    6.2 Main Accessories.............................................................................................................................. 45

    6.3 Attached Tools and Accessories ....................................................................................................... 45

    6.4 Transportation by Railway ................................................................................................................ 47

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    Users Guide for QY50C Truck Crane

    6

    Chapter I Technical Specifications

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    Users Guide for QY50C Truck Crane

    7Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    1. This chapter mainly helps you understand the structure, main technical parameters, and hydraulic,

    electrical and other control devices of STC75 truck crane.

    1.1 Overall Structure

    The STC75 truck crane mainly consists of boom, chassis, electrical system, hydraulic system, operatingroom of superstructure and slewing table assembly.

    1. Boom 2. Chassis 3. Electrical system 4. Hydraulic system 5. Operating room of

    superstructure 6. Turntable assembly

    Fig. 1.1 Schematic Diagram for Complete Machine

    1. Boom

    The boom is composed of main boom, jib, telescopic mechanism, sheave and various labels.

    2. Chassis

    The chassis is composed of body structure, power system, transmission system, traveling system,

    steering system, brake system, cab, electrical equipment and various labels.

    3. Electrical System

    The electrical system of complete machine primarily consists of electrical system of chassis and electrical

    system of superstructure, including electrical system of cab, electrical system of engine and gearbox,

    electrical system of lamp, overwinding protection mechanism, three-layer overrelaxing protection, moment

    limiter, height limiter, labels and various intelligent protective device.

    4. Hydraulic System

    The hydraulic system of complete machine primarily consists of hydraulic system of undercarriage and

    hydraulic system of superstructure, of which the former mainly includes main oil pump and circuit of

    outrigger of undercarriage, and the latter mainly includes main valve, circuit of luffing mechanism, circuit of

    telescopic mechanism, circuits of main & auxiliary hoists and control circuit of air conditioner.

    5. Operating Room of Superstruc ture

    The operating room of superstructure is composed of operating room, operating mechanism, control

    cabinet, air conditioner of superstructure and various labels.6. Turntable Assembly

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    Users Guide for QY50C Truck Crane

    8

    The turntable assembly mainly consists of turntable, hoist reducer, lifting steel wire rope, main hook,

    auxiliary hook, slewing bearing, slewing reducer, turntable lock pin and various labels.

    1.2 Overall Dimensions and Technical Parameters

    (1) Overall Dimensions

    Fig. 1.2 Outl ine Drawing fo r Complete Machine

    (2) Technical Parameters

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    Users Guide for QY50C Truck Crane

    9Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Table 1.1 Main Technical Parameters of STC75 Truck Crane under Traveling State

    Classification Item Unit Parameter

    Overall length mm 14100

    Overall width mm 2750

    Overall height mm 3700Wheel base (first -

    second)mm 1520

    Wheel base (second -

    third)mm 4440Wheel base

    Wheel base (third -

    fourth)mm 1350

    Wheel track (front) mm 2300

    Dimensions

    Wheel track Wheel track (middle &

    rear)mm 2055

    Gross weight kg 45000Axle load (first &

    second)kg 20000

    WeightAxle load

    Axle load (third &

    fourth)kg 26000

    Dongfeng Cummins

    ISLe310 30275/2200

    Weichai WP10.336 276/2200

    Rated power

    of engine

    SDEC SC9DK320Q3

    kW/(r/min)

    275/2200

    Dongfeng Cummins

    ISLe310 30 1550/1200~1400

    Weichai WP10.336 1450/1000~1500

    Power

    Rated torque

    of engine

    SDEC SC9DK320Q3

    N.m/(r/min)

    1500/1400

    Traveling

    speedMax. traveling speed km/h 80

    Min. turning radius m 12

    Turning radius Min. turning radius of

    boom headm 14.5

    Min. ground clearance mm 290

    Approach angle 18

    Departure angle 12

    Brake distance (with speed of 30km/h) m 10

    Max. gradeability % 40

    Traveling

    Parameters

    Fuel consumption per 100km l 45

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    Users Guide for QY50C Truck Crane

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    Table 1.2 Main Technical Parameters of STC75 Truck Crane under Working State

    Classification Item Unit Parameter

    Max. rated lifting capacity t 75

    Min. rated reach m 3

    Tail slewing radius of slewing table mm 4000Base boom kN.m 2400

    Fully-extended boom kN.m 941Max. lifting moment

    Fully-extended boom + jib kN.m 318

    Longitudinal m 6.1Outrigger span

    Transversal m 7.6

    Base boom m 12

    Fully-extended boom m 45Lifting height

    Fully-extended boom + jib m 61

    Base boom m 11.8

    Fully-extended boom m 45Length of boom

    Fully-extended boom + jib m 61

    Main

    Performance

    Parameters

    Installation angle of jib 0, 15 and 30

    Lifting s 80Lifting/descending

    time of boom Descending s 60

    Full extension s 120Extending/retracting

    time of boom Full retraction s 100

    Max. slewing speed r/min 2.4

    Main hoist No-load m/min 130Max. hoisting speed

    (single rope) Auxiliary hoist No-load m/min 130

    Simultaneous

    extensions 40

    Horizontal

    outrigger Simultaneous

    retractions 20

    Simultaneous

    extensions 35

    Extending/retracting

    time of outrigger

    Vertical outriggerSimultaneous

    retractions 30

    Outside working sound power level dB(A) 91

    Working

    Speed

    Parameters

    Noise in operating room dB(A) 89

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    Users Guide for QY50C Truck Crane

    11Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Table 1.3 Lift ing Capacity of Main Boom of STC75 Truck Crane

    Rear and Side Working with Fully-extended OutriggersReach (m)

    11.8m 15.95m 20.1m 28.4m 36.7m 45m

    3.0 75000 54000 43000

    3.5 70000 54000 43000

    4.0 62000 54000 43000 30000

    4.5 56000 48000 43000 30000

    5.0 51000 45000 41000 30000

    5.5 47000 42000 38500 29000

    6.0 41500 39000 36500 27500 16000

    6.5 36000 35000 34000 26000 16000

    7.0 32000 30500 31000 25000 16000

    7.5 28000 27500 27000 23500 15000

    8.0 25000 24500 24000 22000 15000 11000

    9.0 19000 20000 20000 19500 15000 11000

    10.0 16500 17000 16000 14000 11000

    11.0 13500 14000 13600 13000 10500

    12.0 11500 12000 12000 12000 10000

    14.0 8500 9000 10000 9000

    16.0 6500 6800 7800 8000

    18.0 5000 6000 6500

    20.0 4000 4800 5100

    22.0 2900 3800 4100

    24.0 2200 2900 330026.0 2200 2600

    28.0 1700 2000

    30.0 1300 1500

    32.0 1200

    Wire rope rate 12 9 9 6 5 3

    Extension/Retraction Condition (%)

    Extending/RetractingMode

    , ,

    2nd

    section of boom 0 50 100 100 100 100

    3rd

    section of boom 0 0 0 33 66 100

    4thsection of boom 0 0 0 33 66 100

    5thsection of boom 0 0 0 33 66 100

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    Users Guide for QY50C Truck Crane

    12

    Table 1.4 Lift ing Capacity of Jib of STC75 Truck Crane

    Rear and Side Working with Fully-extended Outriggers

    45+9.2m jib 42.5+16m jibWorking Angle

    0 15 30 0 15 30

    80 3500 2400 2000 2800 1500 1100

    78 3500 2400 2000 2400 1450 1000

    77 3200 2300 1900 2400 1400 1000

    75 3000 2200 1800 2300 1300 950

    73 2700 2000 1700 2000 1200 850

    71 2500 1800 1600 1800 1100 850

    68 2200 1700 1400 1500 1000 800

    66 2000 1500 1300 1300 950 760

    63 1800 1400 1100 1100 850 720

    61 1500 1200 950 950 750 650

    58 1100 950 750 650 600 55056 700 650 550 500

    Min. elevationangle

    55

    Caution:

    The values in the tables refer to the rated lifting capacity of truck crane that is set horizontally on flat

    and solid ground. The values above the thick lines in the tables depend on the strength of truck crane,

    while those below the thick lines depend on the stability of truck crane.

    The reaches in the tables refer to the actual reaches after lifting.

    The rated load depending on stability shall be determined complying with ISO 4305.

    The rated lifting capacity in the tables includes the weight of lifting hook (main lifting hook I: 800kg;

    main lifting hook II: 280kg, auxiliary lifting hook: 90kg) and lifting appliance.

    When the fifth outrigger is extended properly, the values in the tables apply to all-sided (360) working.

    When using the sheave at the tip of boom, the rated lifting capacity shall not exceed 4000kg. After the

    jib is extended, the rated lifting capacity of main boom shall be reduced by 2300kg.

    If the actual length of boom and reach are between two values, take the rated lifting capacity

    determined by the values for the longer boom and larger reach for lifting.

    The table for lifting capacity of single sheave at the tip of boom is as follows:

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    Users Guide for QY50C Truck Crane

    13Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Table 1.5 Lifting Capacity of Single Sheave at the Tip of Boom

    Length ofMain Boom

    (m)11.8 15.95 20.1 28.4 36.75 45

    LiftingCapacity

    (kg)3500 3500 3500

    With 4~20m ofreach, the lifting

    capacity is3500kg; for otherconditions, pleaserefer to the tablefor lifting capacity

    of main boom

    With 5.5~22m ofreach, the lifting

    capacity is3500kg; for otherconditions, pleaserefer to the tablefor lifting capacity

    of main boom

    With 8~22m ofreach, the lifting

    capacity is3500kg; for otherconditions, pleaserefer to the tablefor lifting capacity

    of main boom

    The Curve of Lifting Height is given in Fig. 1.3. In case of malfunction with moment limiter but in need of

    urgent working, it is necessary to work according to the lifting conditions indicated in this figure.

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    14

    Fig. 1.3 Curve of Lifting Height

    LiftingHeight(m)

    Reach (m)

    Curve of Lifting Height of QY50C Truck Crane

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    Users Guide for QY50C Truck Crane

    15Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    The working area division is given in the following figure, which can be referred for the working

    condition selection and the definitions of relevant terms involved in the following content.

    Fig. 1.4 Working Area Division of Crane

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    Users Guide for QY50C Truck Crane

    16

    Chapter II Operation Regulations of Crane

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    Users Guide for QY50C Truck Crane

    17Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    2. Operation o f crane

    2.1 Startup and Flameout of Engine

    2.1.1 Startup of Engine

    Start the engine in the following order (Please refer to the Users Guide for Engine).

    a. Set the gear lever at neutral position;

    b. Turn on the general switch of power supply to put through the circuit;

    c. Set the rocker switch of PTO at non-working position, keeping the PTO at neutral position;

    d. Press down the clutch pedal to reduce the engine starting resistance moment and relieve the load

    on startup motor;

    e. Slightly press down the accelerator pedal and turn the starting key at the same time to start the

    engine. (The time for every starting is required to be no more than 5~8s. If the engine cant be

    started in one time, the next starting shall be conducted after 1 minute. If the engine cant be

    started after trying for 3~5 times, find out the cause and do troubleshooting before the next

    starting;

    f. After starting the engine, reduce the oil supply at once to keep the engine running at idle speed for

    some time; dont jam on the accelerator pedal once engine is started.

    2.1.2 Warm-up of Engine

    After startup of engine, properly warm up the engine under idling and after the water temperature reaches

    60, start working. In winter or cold area, the time for warm-up of engine can be extended appropriately

    for heating up the cylinder and fully lubricating the surface with lubricating oil. Immediate working with load

    without warming up the engine will lead to severe abrasion of engine and shorten its service life.

    2.1.3 Flameout of Enginea. Release the accelerator pedal and press down the foot brake pedal, and after stopping the truck

    completely, pull the parking brake control handle backwards until it is locked;

    b. Shift transmission to neutral position;

    c. Add oil for two or three times under idling condition before flaming out the engine to lubricate all

    parts fully. After turning off the switches for air-conditioners in cabs of superstructure and

    undercarriage, turn off the key switch to flame out the engine (for the engine manufactured by

    Hangzhou Engine Co., Ltd., the exhaust brake switch shall be used for flameout).

    d. Turn off the general switch of power supply to avoid discharge of storage battery.

    2.2 Operation of PTO

    2.2.1 Precautions

    Before switching on the PTO, make sure each control handle in the operating room of

    superstructure is at neutral position.

    2.2.2 Steps for Switching on PTO

    a. Make the parking brake in braking;

    b. Make sure the gear lever and PTO switch are at Neutral position and Off position respectively;

    c. Turn the chassis starting switch to start the engine. In case of cold weather, warm up the engine

    before starting it;

    d. Press down the clutch pedal to the end;

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    Users Guide for QY50C Truck Crane

    18

    e. Switch on the PTO;

    f. Slowly release the clutch pedal.

    For working in winter, after starting the engine, keep it running w ithout load for 15~20 minutes.

    2.2.3 Steps for Switching off PTO

    a. Press down the clutch pedal to the end;

    b. Switch off the PTO;

    c. Release the clutch pedal;

    d. Shut down the engine;

    e. Turn the chassis starting switch to Off position.

    After switching on the PTO, the operator can start the engine by the start ing lock and shut down

    it by the flameout switch.

    2.3 Operation of Outr igger

    2.3.1 Precautions

    1. Ensuring Sufficient Space for Full Extension of Outriggers

    The working truck crane shall be laid at a clear place so as to protect the outriggers from any obstacle

    during extending or moving. Only after all the outriggers are fully extended, can the operation of

    superstructure be conducted to complete the lifting favorably.

    Fig. 3.1 Diagram for Extended Outriggers

    2. Selection of Supporting Ground

    1) In principle, the truck crane must be set horizontally on flat and solid ground. If the outriggers

    have to be set on soft or gradient ground, the outrigger must be horizontal in spite of the

    conditions of supporting ground, and if necessary, a horizontal supporting surface shall be

    shaped or the truck crane shall be leveled with backup plate correspondent to the ground. In

    addition, dont lay any outrigger on a hole at any time.

    2) For the front, rear, left and right horizontal planes of complete machine, the maximum deflection

    Caution

    Caution

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    19Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    angle shall not exceed 0.5. All tyres shall be off the ground and suspended, and any possible

    subsidence is forbidden. The stability of the supporting ground shall be monitored always during

    the working.

    3) In case of any factor that reduces the stability of supporting ground, lay down the heavy stuff and

    retract the boom at once, and after eliminating such factor, support the truck crane as requiredagain. The factors reducing stability include change of ground conditions due to rain, snow water

    or other water sources, subsidence of ground at the side of outrigger and leakage in outrigger

    cylinder.

    Dont lay the supporting block on hole; ensure the supporting block is without deformation

    (unevenness); select proper supporting mode; avoid supporting the truck crane on a slope; and dont

    support the truck crane until the horizontal outriggers are fully extended.

    3. Supporting of Outriggers on Special Ground

    If the truck crane has to work by the river or road shoulder, special attention is required. As the soil by the

    river or road shoulder is soft, it is dangerous for the outriggers of truck crane. Before working under such

    condition, set several piles nearby the foundation at the outriggers for reinforcing the supporting ground;

    and then backfill rough or chip stones to enlarge the supporting area, and if necessary, use sleepers.

    4. Load of Supporting Ground

    The truck crane must be supported on solid ground, and before working, the bearing capacity of ground

    must be checked.

    For this machine, the compressive strength of ground is required to be 3MPa, which refers to the

    compressive strength of ground needed for l ifting the maximum rated load. If the load to be lifted is

    light, the requirement for ground will be lowered correspondingly.

    5. Supporting of the 5th

    Outrigger

    Only after the left and right vertical outriggers (four) are extended and adjusted well, can the 5thoutrigger

    be extended until its supporting leg disc touches the ground. Dont extend the 5thoutrigger so long that the

    two front outriggers are loose and free of supporting. When retracting the outriggers, retract the 5th

    outrigger fully at first, and then retract the left and right movable outriggers (four).

    2.3.2 Operation of Outrigger

    1. Adjusting of Horizontal Outrigger

    As shown in Fig.2.2, press palm-shaped symbol button to start the panel, through which you can

    adjust horizontal outrigger. The upper and lower buttons represent the extension/retraction of vertical

    telescopic cylinder, while the left and right ones stand for the extension/retraction of horizontal

    cylinder.

    Caution

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    Fig 2.2 Control panel for outrigger2. The lifting of vertical cylinder

    The extension and retraction of vertical cylinder can be realized separately as shown in the panel,

    or the simultaneous extension and retraction of vertical cylinder cab be realized through button in the

    panel.

    3. Leveling of Truck Crane

    Please refer to the level indicating light in the middle of panel to see whether the truck crane is at

    level. The position where red light lights up is at a higher position, and then we should have the

    related vertical outrigger adjusted till the red light flames out.

    Please make sure that all the tyres are off ground and every outrigger is connected with ground

    firmly.

    Please press OFF button to shut of f the panel after each time operation.

    2.4 Operation of Lifting Mechanism

    2.4.1 Precautions

    1. Dont operate the control handle of lifting mechanism sharply.

    2. Before lifting, check the brake to ensure it is in normal condition. When the load to be lifted is still on

    ground, dont lift it off the ground by lifting or extending the boom. At this time, only hook lifting is

    allowed.

    3. Select proper multiplying power of steel wire rope according to the length of boom and the table for

    lifting capacity.

    4. If the lifting hook rotates owing to twisted steel wire rope, uncoil the steel wire rope first before lifting.

    5. When descending the hook, leave at least 3 circles of steel wire rope on the hoist drum.

    Caution

    Caution

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    21Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    6. Only lifting load vertically is allowed. Dont drag the load that is still on the ground, and try to avoid

    side loading.

    2.4.2 Operation of Lifting Mechanism

    Pilot Control

    2.3

    (1) Operation of Main Hoisting

    Push the operating rod of main hoist forwards and the lifting hook descends; pull the operating rod of

    main hoist backwards and the lifting hook lifts. The lifting/descending speed is adjusted by the

    operating rod and throttle.

    (2) Operation of Auxiliary Hoisting

    Push the operating rod of auxiliary hoist forwards and the lifting hook descends; pull the operating rod

    of auxiliary hoist backwards and the lifting hook lifts. The lifting/descending speed is adjusted by the

    operating rod and throttle.

    Piloted Control

    Fig. 2.3 Diagram for Piloted Control Handle

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    (1) Operation of Main Hoisting

    After pressing down the master switch, push the right control handle forwards and the lifting hook

    descends; pull the right control handle backwards and the lifting hook lifts. The lifting/descending

    speed is adjusted by the right control handle and throttle.

    (2) Operation of Auxiliary HoistingAfter pressing down the master switch and switch S11 (refer to 4.1.2), push the left control handle

    forwards and the auxiliary lifting hook descends; pull the left control handle backwards and the

    auxiliary lifting hook lifts. The lifting/descending speed is adjusted by the left control handle and

    throttle.

    2.5 Extension and Retraction of Main Boom

    2.5.1 Precautions

    1. When extending or retracting the main boom, the lifting hook will lift or descend at the same time. Thus,

    when extending or retracting the main boom, it is required to conduct lifting to make the lifting hook at a

    proper height. After the main boom is extended, the change in hydraulic oil temperature may result in

    slight extension/retraction of main boom. For example, when the main boom is extended for 5m, if the

    temperature of hydraulic oil drops by 10, the main boom will retract by 40mm.

    2. Besides the change in hydraulic oil temperature, there are some other factors affecting the natural

    extension allowance, including extension status of main boom, elevation angle of main boom, and

    lubrication status. To avoid natural retraction of main boom, pay attention to the following points:

    Dont make the hydraulic oil too hot;

    In case of natural retraction of main boom, adjust its length to the required value through proper

    extension or retraction.

    3. Before extending the boom, make sure the lifting hook has been descended fully.

    4. If the main boom is fully retracted, confirm the length of main boom is within the specified range, with

    reference to the display of moment limiter, and then extend it.

    Dont extend or retract the main boom wi th load at any time.

    2.5.2 Extension and Retraction of Main Boom(a) Piloted Operation

    After pressing down the master switch, push the left control handle forwards and the main boom

    extends; pull the left control handle backwards and the main boom retracts. The speed is adjusted by

    the control handle and throttle.

    (b) Pull-rod Type Operation

    Push the extension/retraction operating rod forwards and the main boom extends; pull the

    extension/retraction operating rod backwards and the main boom retracts. The speed is adjusted by

    the operating rod and throttle.

    Caution

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    23Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    2.6 Luffing Operation of Main Boom

    2.6.1 Precautions

    1. Only lifting load vertically is allowed. Dont drag the load that is still on the ground, and try to avoid side

    loading.

    2. The elevation angle of main boom shall be set properly within the limited scope (range of use).3. The luffing operation shall be started and stopped slowly but not sharply.

    2.6.2 Luffing Operation of Main Boom

    1. Luffing Operation of Main Boom

    (a) Piloted Operation

    After pressing down the master switch, push the right control handle rightwards and the main boom

    descends; pull the right control handle leftwards and the main boom lifts. The luffing speed is adjusted

    by the control handle and throttle.

    (b) Pull-rod Type Operation

    Push the luffing operating rod forwards and the main boom descends; pull the luffing operating rod

    backwards and the main boom lifts. The luffing speed is adjusted by the operating rod and throttle.

    2. Relation between the Elevation Angle, Total Lifting Capacity and Working Radius of Main

    Boom

    When the boom descending, the working radius will be enlarged, and thus the rated total lifting

    capacity shall be reduced. When the boom lifting, the working radius will be shortened, and thus the

    rated total lifting capacity can be increased.

    2.7 Operation of Slewing Mechanism

    2.7.1 Precautions

    Only lifting load vertically is allowed. Dont drag the load that is stil l on the ground, and try to avoid

    side loading.

    1. Before slewing operation, check the transversal spans of outriggers to ensure they meet the

    requirement.

    2. Ensure enough working space.

    3. Start and stop the slewing operation slowly but not sharply.

    4. Dont pull the luffing control handle of boom sharply.

    Before slewing operation, it is necessary to disengage the mechanical lock ing device of slewing

    table.

    2.7.2 Operation of Slewing Mechanism

    (a) Piloted Operation

    Before slewing operation, disengage the mechanical locking device first. Then, pull the left control

    handle rightwards and the slewing table turns right; pull the left control handle leftwards and the

    slewing table turns left.

    (b) Pulling-rod Type Operation

    Before slewing operation, disengage the mechanical locking device first. Then, push the operating rod

    Caution

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    forwards and the slewing table turns right; pull the operating rod backwards and the slewing table

    turns left.

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    25Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Chapter III Installation and Operation of L ifting Accessories

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    3. Installation and operation of lifting accessories

    3.1 Installation and Disassembling of J ib

    The jib is a truss type jib of square structure, which is featured by simple and reasonable structure, high

    strength, and convenience in installation and operation.

    The instructions for installation and operation are listed as follows:1. The jib shall be used only after both main boom and outriggers are extended full y.

    2. Installation of Jib

    a. Fully retract the main boom and descend it at the rear side of the complete machine (see Fig.

    4.1).

    b. Dismount the No.1 axis pin of jib, and then rotate with the No. 2 axis pin as the axis of rotation to

    align the pinhole of jib with that of main boom, finally plug the axis pin A (see Fig. 3.2).

    c. Dismount the No. 2 axis pin, and then rotate the whole jib with the axis pin A as the axis of

    rotation to align the pinhole on the other side of the jib with the relevant pinhole of main boom,

    finally plug the axis pin A (see Fig. 3.3).

    d. Take the steel wire rope out of the middle sheave at the head of main boom.

    e. Put the steel wire rope through the contact roller of jib and the sheave at the head of jib.

    f. Connect the plug of jib with the connection socket at the head of main boom, and then mount the

    lifting limit switch cam.

    g. Mount the auxiliary hook.

    3. Angle Changing of Jib by 15 or 30

    Mount the jib with angle of 0, and then descend the jib to make its head touch the ground; dismount

    the axis pin B, and fix it in the hole related to 15 or 30 (see Fig. 3.4 and Fig. 3.5); and then slowly lift

    the main boom to make the jib under working status.

    4. Disassembling of Jib

    After the jib is used, it can be dismounted in the reverse order with the steps mentioned above, and

    then be fixed at the right side of main boom (see Fig. 3.6).

    Thus, the jib is under safe retraction status.

    Fig. 3.1 Jib

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    27Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Fig. 3.2 Jib

    Fig.3.3 Jib

    Fig. 3.4 Jib

    Fig.3.5 Jib

    Fig. 3.6 Jib

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    3.2 Change of Multiplying Power

    1. Working Conditions

    a. Arrange outriggers properly, fully retract the boom and turn it to the side or rear area.

    b. Descend the boom to make the lifting hook on the ground.

    c. Dismount the rope block at the head of boom and that of lifting hook respectively.d. Dismount the weight dropper for overwinding protection device.

    e. Dismount the wedge sleeve.

    f. Change the multiplying power of steel wire rope.

    2. Precautions

    (1) The installation position of the weight dropper for overwinding protection device changes with the

    parity variation in multiplying power of steel wire rope.

    When the multiplying power is an even number, the weight dropper shall be installed on the branch of

    steel wire rope with wedge sleeve;

    When the multiplying power is an odd number, the weight dropper shall be installed on the adjacent

    branch of steel wire rope with wedge sleeve.

    (2) Dont wrap the wire rope disorderly.

    The wedge sleeve and rope clamp shall be mounted as shown in Fig. 3.7.

    Fig. 3.7 Installation of Wedge Sleeve and Rope Clamp

    Dont descend the hook to the ground by operating the lifting mechanism.

    Caution

    Wedge-shaped rope coupling

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    29Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Chapter IV Electrical System of Superstructure

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    4. Electrical system of superstructure

    4.1 Electrical Appliances in Operating Room

    4.1.1 Arrangement of Electrical Appliances in Operating Room (Fig. 4.1)

    Fig. 4.1

    A - Pedal switch B Main body of moment limiter

    C - Buzzer D Display of moment limiter

    E Front windshield wiper motor F Skylight wiper motor

    G - Ceiling lamp H - Fan

    I - Control panel J Overload release switch

    K - Electric control cabinet

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    31Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    4.1.2 Description of Control Panel (Fig. 4.2)

    Fig. 4.2

    H1 Height limit indicator lamp S1 Ignition switch

    H2 Indicator lamp for too high water temperature S3 Engine shutdown switch

    H3 Indicator lamp for main power supply S4 Outline lamp switch

    H4 Indicator lamp for extension/retraction of boom S5 Working lamp switch

    H5 Indicator lamp for three-layer overrelaxing protection S6 Wiper switch

    H6 Indicator lamp for too low oil pressure S9 Oil cooler switch

    H7 Alarm indicator lamp S10 Master switchH8 Indicator lamp for auxiliary hoist S11 Switch for shifting between telescopic boom

    and auxiliary hoist

    S12 Overwinding release switch S13 Overhaul switch

    S14 Switch for shifting between I# and II# oil cylinders S15 Free slide switch

    S17 Washer switch

    Description of functions of each switch:

    Ignition switch: Insert the startup key into the ignition switch, and turn it clockwise to I position to get

    through the power supply for the control system of superstructure. Continue to turn the key to III position to

    start the engine. The time of each startup shall be not longer than 5s, with the startup interval not more

    than 15s. If the engine cant be started after trying for 2-3 times, check and find out the cause;

    Engine shutdown switch: press the switch, and the engine will stop after 1-2s delay; release the switch,

    and it will reset automatically;

    Outline lamp switch: When pressing this switch, the outline lamps of superstructure and undercarriage and

    the top lamp of boom will light up;

    Working lamp switch: When setting this switch to I position, the working lamp of operating room will light up;

    when setting it to II position, the working lamps of boom and operating room will light up at the same time;

    Wiper switch: When setting this switch to I position, the front windshield wiper will work at low speed; when

    setting it to II position, the wiper will work at high speed;

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    Washer switch: When pressing this switch, the washer motor will begin to work, and the nozzle of wiper will

    eject the washing liquid;

    Caution: In case of sunny day, using the wiper without washing liquid may cause damage of glass; if no

    washing liquid is available, the continuous running time of wiper shall be not more than 5s, or else, the

    washer motor may be burned out. Thus, dont use the wiper if no washing liquid is available;Oil cooler switch: When pressing this switch, the oil cooling fan begins to work;

    Note: When the temperature of hydraulic oil exceeds a certain value, the temperature control switch

    adopted by oil cooler will be enabled automatically, and the oil cooling fan will begin to work even though

    this switch is not pressed down;

    Overwinding release switch: When pressing this switch, both the height limit protection and the protection

    for extension/retraction with load will be released. So, it should be used carefully;

    Overload release switch: When pressing this switch, the overload protection will be cancelled. It is used

    only for overhaul and commissioning, and cant be pressed during the normal working of crane, or else, for

    any damage due to the breach, our company shall not bear any responsibility.

    Master switch: only after turning on this switch, can pressure be set up in the system, so that the crane can

    work normally;

    Hoist speed control switch: Applying this switch when the moment percentage is within 10~55% will

    enhance the working speed of hoist;

    Switch for shifting between telescopic boom and auxiliary hoist: this switch is used for shifting between the

    working conditions of auxiliary hoist and telescopic boom;

    Free slide switch: When the steel wire rope is not perpendicular to the weight, just press this switch. Then

    the slewing table will move automatically to set the wire rope perpendicular to the weight;

    Overhaul switch: When pressing this switch at the base boom mode, only the 3rd, 4th, 5th sections of

    boom will work; when pressing this switch at any mode rather than base boom mode, the buzzer will give

    an alarm, the display will indicate that Please shift under the base boom mode, and all operations for

    extension or retraction will be interrupted;

    Switch for shifting between I# and II# oil cylinders: When the I# oil cylinder is fully extended, the II# oil

    cylinder can be shifted to by applying this switch;

    4.1.3 Descrip tion of Electr ic Cont rol Cabinet (Fig. 4.3)

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    33Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Fig. 4.3

    K1 Power control for display K2 Power control for working lamp

    K3 Power control for oil cooler K4, K5- Protective control for flameout

    F1 Fuse of display power F2 Fuse of main power

    F3 Fuse of instrument lamp power F4 Fuse of outline lamp power

    F5 Fuse of working lamp power F6 Power of wiper power

    F7 Fuse of horn and fan power F8 Fuse of oil cooler power

    F9 Fuse of A/C power F10 Fuse of main control valve power

    4.2 Instructions for Display (Fig. 4.4)

    Main body of moment

    limiter

    Relay

    FuseTerminal block

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    Fig. 4.4To use the display, turn on the power supply switch at first, and then the crane monitoring status (namely

    the main interface) will be shown automatically after power is supplied to the system.

    The following information will be shown on the main interface:

    Moment percentage: to show the actual moment value by means of bar chart and percentage;

    Measuring information: to show the real-time data such as boom length, angle, reach, rated weight

    and actual weight;

    Information on working condition: to show the status of hook and current multiplying power;

    Auxiliary information: to show the real-time information on malfunction and alarm and the current time;

    Mute: to mute the alarm by F7 (mute key) when a prompt is provided through alarm;

    Enforcement: to release some protections by applying F8 (enforcement key) when protections for

    dangerous actions are provided.

    Setting of working condition: F2 is used to shift the working condition. One working condition will be

    changed after F2 is pressed once and the shifting order is as follows: main hook of main boom, auxiliary

    hook of main boom, one-section jib with installation angle of 0/15/30 and two-section jib with installation

    angle of 0/15/30;

    Setting of multiplying power: F3 is used to shift the multiplying power, which will be increased by one by

    pressing F3 once. When the value exceeds 12, it will be reset to 1.

    4.3 Safety Device

    4.3.1 Moment Limi ter

    This crane is equipped with the special moment limiter for safety guard. Before operation, please read the

    Users Guide for Moment Limitercarefully to know well how to operate it.

    Note: The crane is equipped with an overload release switch, which can be used to release the

    protection provided by moment limiter. This function shall be applied under the instruction of

    service personnel appointed by our company. For any damage due to incorrect operation of user,

    SANY Truck Crane

    Moment

    Working condition:

    Multiplying power:

    Boom Length: 10.3 Rated weight:

    Actual weight:

    Angle:

    Reach: 3.0 m

    May 20, 200711:20

    Menu Workingcondition

    Multiplying power

    Information Mute Enforceme

    nt

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    35Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    our company shall not bear any responsibi lity.

    The improper operation of moment limiter may bring the serious truck damage or physical

    injury.

    4.3.2 Three-layer Overrelaxing Protector

    To avoid the overrelaxing of steel wire rope for hoisting, the descending of hook will be limited when only 3

    layers of rope are left. By lifting the hook, the protection can be released.

    4.3.3 Master Switch of System

    It is set to avoid the false operation resulted from touching the control handle by mistake. Always turn on

    the master switch S10 before operation and turn off it after operation so as to get off the crane.

    4.3.4 Height Limi ter

    To avoid the collision of hook and sheave of boom head during lifting, the lifting of hook will be limited when

    the hook is lifted to certain height. By descending the hook or applying S12 overwinding release switch, the

    protection can be released.

    Danger

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    Chapter V Hydraulic System

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    37Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    5.1 Precautions for Operation and Maintenance of Hydraulic System

    (a) For replacing the hydraulic elements and dismounting the oil tube, shut down the machine and

    release the pressure of hydraulic oil circuit so as to avoid the damage due to injection of pressure oil.

    (b) For adjustment of system pressure and main oil pump as well as the disassembling and replacement

    of valve block, the instructions given by the hydraulic engineer or the after-sales engineer of ourcompany should be followed; it is forbidden for common personnel to adjust such devices.

    (c) For dismounting oil tube, make sure the oil outlet is sealed and the hydraulic pipeline is clean. It is

    forbidden to dismount the oil tube or valve in the environment with dust or sand storm. Please dont

    wear gloves during working.

    (d) Check the filter for replacement of filter core regularly. When the high-pressure filter is blocked up, the

    alarm above the filter will turn red from green (normal color) during working of system, which indicates

    that the filter core shall be replaced in time.

    (e) As the hydraulic elements are very important for the system, please use the original spare parts

    specified by our company.

    (f) Frequently check the hydraulic oil for deterioration or over-limit of impurity. Replace the hydraulic oil in

    time or filter it completely regularly, so as to prolong the service life of hydraulic system, reduce the

    frequency of malfunction, save your working time and decrease the economic loss.

    5.2 Hydraulic System of Superstructure

    The superstructure of STC75S adopts 2 types of hydraulic systems according to different control methods:

    S type (manual push rod type) and Y type (hydraulic-control piloted type), and both are open systems.

    5.2.1 Hydraulic System of Superstructure of STC75S

    The hydraulic system of STC75S is of load feedback variable type, and the main oil pump is composed of

    variable plunger pump and gear pump. The former supplies power to the superstructure for all the actions

    except slewing while the latter supplies power to the outriggers of undercarriage and for slewing of

    superstructure. The main valve is pressure-compensated proportional valve and used to control the

    actions of superstructure such as slewing, extension/retraction, luffing and hoisting. The primary and

    secondary overflow valves are set in each working oil circuit of the main valve, so as to keep each working

    mechanism working under the pressure within the allowable range.

    The slewing is carried out by a slewing reducer which is driven by the slewing motor to actuate the slewing

    table to slew round the center. The slewing cushion valve and one-way throttle valve with accumulator are

    set in the circuit to ensure stable and safe startup and stopping of slewing, so as to eliminate the impact

    during slewing.

    The extension/retraction is carried out by driving the second, third and fourth sections of boom to

    extend/retract by rope laying mechanism. The balanced valve for extension/retraction is set in the circuit to

    maintain the stability of retraction and to block the hydraulic oil in the telescopic cylinder in case of no

    extension/retraction action so as to maintain the working length of main boom.

    The luffing is carried out by controlling the lifting/descending of the first section of boom by extension/

    retraction of luffing cylinder. The balanced valve for luffing is set in the circuit to maintain the stability of

    descending and to block the hydraulic oil in the luffing cylinder in case of no luffing so as to maintain the

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    working length of main boom.

    The hoisting is carried out by driving the hoisting reducer by hoisting motor to actuate the rotary drum,

    steel wire rope and hook to lift or descend. The balanced valve for hoisting is set in the circuit to maintain

    the stability of hook descending and prevent stalling. The adopted high-low speed shifting system can

    assure high-speed hoisting in case of light load to maintain the working efficiency and the low-speedhoisting in case of heavy load to maintain the stability of working and the hoisting capacity.

    For safety requirement, when truck crane is bearing the limitation from height limiter, 3-layer protection and

    torque limiter, the related mechanism action will be limited at the same time.

    Considering the safety requirements of crane, when the safety protections such as height limit, three-layer

    overrelaxing protection and moment limit are applied, the actions of relevant mechanism will be limited.

    Moreover, the system is equipped with hydraulic oil cooler. When the system works continuously and the

    temperature of hydraulic oil exceeds 65, the cooler fan will be started automatically to cool the hydraulic

    oil compulsorily.

    The operating room of superstructure is equipped with A/C. The compressor of A/C is driven by hydraulic

    motor, and the control oil circuit and slewing oil circuit of A/C motor are connected serially in the system.

    5.2.2 Hydraulic System of Superstructure of STC75S

    The hydraulic system of STC75S is of load feedback variable type, and the main oil pump is composed of

    variable plunger pump and gear pump. The former supplies power to the superstructure for all the actions

    except slewing while the latter supplies power to the outriggers of undercarriage and for slewing of

    superstructure. The main valve is hydraulic piloted control valve with load feedback and used to control the

    actions such as slewing, extension/retraction, luffing and hoisting. Its control of working speed will not beaffected no matter whether the load is light or heavy. The primary and secondary overflow valves are set at

    essential positions in each working oil circuit of the main valve, so as to keep each working mechanism

    working under the pressure within the allowable range. The slewing is piloted by independent hydraulic-

    control slewing valve.

    The working principles of slewing, luffing, extension/retraction and hoisting are the same with that of

    STC75S.

    As for the hydraulic piloted control, the hydraulic piloted handle is applied to control the pressure of piloted

    oil circuit, so as to actuate the valve cores of main valve and slewing valve of superstructure to achieve all

    actions of the superstructure. The right piloted handle controls the extension/retraction of main boom and

    lifting/descending and slewing of auxiliary hook, while the right piloted handle controls the

    lifting/descending of main hook and the luffing of main boom. The left and right piloted handles are

    respectively located on the left and right armrest boxes of seat in operating room.

    The settings of safety guard, hydraulic oil cooler and A/C driving are the same with those for STC75S.

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    39Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Fig 5.1 Multiple-way valve of superstructure

    5.2.3 Working Principle of Hydraulic System of Superstructure

    The Fig. 5.2 and 5.3 are the basic diagrams for hydraulic systems of STC75S and STC75Y respectively.

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    40

    Fig. 5.2 Elementary Diagram for Hydraul ic System of STC75S Truck Crane

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    41Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Codhttp://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-1020086-731-4031622 0086-731-4031999-680

    Fig. 5.3 Elementary Diagram of Hydraulic System of STC75Y Truck Crane

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    5.3 Technical Parameters

    Max. working pressure of main oil circuit: 25Mpa (for setting pressure of each overflow valve, see the

    calibration value shown on the basic diagram)

    Max. working pressure of oil circuits of slewing mechanism and outrigger: 20Mpa

    Capacity of oil tank: 1000LPrecision of high-pressure oil filter: 10

    5.4 Instructions for Hydraulic Oil

    (a) Please use the hydraulic oil recommended by our company, and dont use any blended oil.

    (b) Use oil filling machine to fill the hydraulic oil and dont pour it in directly.

    (c) Make sure the hydraulic oil is clean, and replace the hydraulic oil strictly according to the working

    time.

    Hydraulic Oil Recommended by Our Company for Different Environments

    No. Use Condition Name of Oil Remarks

    1 Normal region (ambient temperature is within10~40)

    Caltex HD46

    Kunlun HV46

    Great Wall 6146

    Normal type

    2Lowe-temperature region (ambient temperature is up to

    30)

    Shell VG32

    (Tellus)

    Low-temperature

    type

    3High-temperature region (ambient temperature is

    higher than 40)Shell VG68

    High-temperature

    type

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    43Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    Chapter VI Accessories and Others

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    6. Accessories and others

    6.1 Descript ion on Name Plate

    6.1.1 Name Plate

    The manufacturer name plate is mounted on the side of the operating room of superstructure.

    The name, model, rated lifting capacity, manufacturing date and manufacturer of the truck crane aremarked on the name plate.

    6.1.2 Name Plate of Li fting Capacity

    The name plate of lifting capacity is mounted in the operating room.

    The main content of this name plate includes:

    Table of Rated Lifting Capacity of STC75 Truck Crane

    Curve of Lifting Height of STC75 Truck Crane

    During the operating of the crane, its reach is in accordance with the corresponding lifting capacity and

    height in the table of lifting capacity. Before lifting, the operator shall get to know the weight of the object

    and the working range, then choose the suitable operating condition. It is prohibited to go beyond the

    values in the table.

    6.1.3 Marking Position of Vehicle Identif ication Number (VIN)

    Fig. 6.1 Marking Position of Chassis Model and Identification Number

    The vehicle identification number (VIN) is marked on the name plate and frame. See the following figure

    for the marking position of VIN on the frame.

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    45Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    6.2 Main Accessor ies

    No. Name Model Qty. Location

    1Automobilechassis

    SYM5450J (EURO II) 1

    2 Slewing bearing 011.50.1600Z1 1 Slewing table----Support

    3 Slewing reducer JH17-79-01 1 Slewing mechanism

    4 Main pumpP2145R00D1D25TB20N55D3B2PParker

    1 PTO

    5 MotorA6VM107EZ4/63W-VAB020BRexroth

    1 Slewing mechanism

    6 Lifting reducer QJ3-66A 2Lifting mechanism(main, auxiliary)

    7 Motor

    A6V107EL2FZ20600 (QY25CS)/A6V107HA2FZ10700 (QY25CS)

    A6VM107EZ4/63W.VAB020BQY25CY)

    2Lifting mechanism

    (main, auxiliary)

    8 Main valve 7000CC-D34 1Hydraulic system ofsuperstructure

    235m Main lifting mechanism9 Steel wire rope 20-35W7-1960USZ

    135m Auxiliary lifting mechanism

    6.3 Attached Tools and Accessories

    The SANY truck crane is provided with a series of attached tools and accessories.

    Toolbox I:

    No. Work`s &Drawing No.

    Descript ion & Specification Unit Quantity

    1 B230103000319 Rubber hose 2SN10.DKOL.1650Q/SY1102 PC 2

    2 A229900002862 Pressure measuring connector 1.906.29.11.010 PC 1

    3 A230103000866Pressure measuring hose

    2.970.04.00.001/2.970.02.00.005*2400PC 1

    4 B250202000006 Pressure gauge NG063 (G1/4B 40MPa) PC 1

    5 B429900000016 Cere cleaning agent AP742 BOT 4

    6 10056705 Accessories of O-ring BAG 1

    7 60013280 Attached toolbox of crane PC 1

    8 10679577 Attached foam toolbox (1#) PC 1

    9 10652505 Tools for engine PC 110 A260401030089 Socket spanner with 27 pieces set GB3390.14.04 PC 1

    11 B260409000015 High-pressure consistent grease gun SL.451S.B PC 1

    12 A241100000010 Working lamp 24V/15W PC 1

    13 A230103000849 Air charging hose assembly 39N.01310.B PC 1

    14 A550300000068 Work clothes 170# PC 2

    15 10705341 Packing list of the toolbox I of STC75 Truck Crane PC 1

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    Toolbox II:

    No.Work`s &

    Drawing No.Descript ion & Specification Unit Quantity

    1 A260401030002 Double open-end spanner 810GB4388 PC 1

    2 A260401030091 Double open-end spanner 1315GB/T4388 PC 1

    3 A260401030028 Double open-end spanner 1618GB4388 PC 14 A260401030005 Double open-end spanner 1719GB4388 PC 1

    5 A260401030029 Double open-end spanner 1821GB4388 PC 1

    6 A260401030007 Double open-end spanner 2224GB4388 PC 1

    7 A260401030008 Double open-end spanner 2730GB4388 PC 1

    8 A260401030031 Double open-end spanner 3436GB4388 PC 1

    9 A260401030040 Double open-end spanner 4146GB4388 PC 1

    10 A260401030044 Double offset ring spanner 1316GB4388 PC 1

    11 A260401030045 Double offset ring spanner 1821GB4388 PC 1

    12 A260401040001 Monkey wrench 150GB4440 PC 1

    13 A260401040004 Monkey wrench 300GB4440 PC 1

    14 A260402010005Minus screw driver 1000.64.2CQB3863 (rubber

    handle)PC 1

    15 A260402010016Minus screw driver 2001.28.2CQB3863 (rubber

    handle)PC 1

    16 A260402020007 Cross screw driver 753.2CQB3864 (rubber handle) PC 1

    17 A260402020006Cross screw driver 2008.2CQB3864 (rubber

    handle)PC 1

    18 A260404000010 Sharp nose pliers 160QB2440.1 PC 1

    19 A260404000002 Wire pliers 180QB2442.1 PC 1

    20 A260401020001 Hexagon socket spanner with 10 pieces set GB5356 PC 1

    21 A260401030105 Single open-end spanner 70GB4388 PC 1

    22 A260403010003 Fitters hammer 0.8QB1290.3 PC 1

    23 A229900002672 Triangle warning plate JSP.A01 PC 1

    24 A260409000409 Tyre valve spanner 39D.01075 PC 1

    25 A250100000121 Tyre pressure gauge 0.1MPa02912D.010 PC 1

    26 A260401010096 Tyre sleeve 3233 PC 1

    27 A260409000457 Tyre crowbar with socket spanner handle 18500 PC 1

    28 60013280 Attached toolbox of crane PC 1

    29 10679578 Attached foam toolbox (2#) PC 1

    30 10651646 Users guide for STC75 truck crane PC 1

    31 10651604 Users guide for engine PC 1

    32 10651609 Acceptance certificate for truck crane PC 1

    33 10651614 Quality certificate for engine PC 1

    34 10651616 Quality certificate for main hook PC 1

    35 10651618 Quality certificate for steel wire rope PC 1

    36 10705344 Packing list of the toolbox II of STC75 Truck Crane PC 1

    37 10661468 Spare parts drawing volume for STC75 truck crane PC 1

    38 10661469 Maintenance manual for STC75 truck crane PC 1

    As the product is improved constantly, the attached accessories w il l change accordingly, and thepriority will be given to the dispatching list .

    Notes

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    47Hunan SANY Automobile Manufacture Co., Ltd.

    Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China Postal Code: 410100http://www.sanyauto.com.cn Tel: 0086-731-4031060 Fax: 0086-731-4031999-102

    0086-731-4031622 0086-731-4031999-680

    6.4 Transportation by Railway

    (1) When transporting the truck crane by railway, it can be placed on the flat truck, with tyre pressure of

    0.5MPa, and the wheels of such truck crane must be blocked with wood or cement block.

    (2) Use rope to fasten the truck crane with the flat truck without any looseness.(3) The center of gravity for loading shall be 3,650mm backward the center of front axle (truck tail

    direction) (see Fig. 2.39 Drawing for Loading Truck Crane).

    (4) After the truck crane is loaded, cut off the power supply of cab, set the braking device to the brake

    mode, and set the gear lever to the low gear position, then fasten the brake handle with the pull rod;

    make sure all control handles and switches of crane at the neutral position and cut-off position

    respectively.

    (5) After the loading is finished, lock all doors and windows of truck crane to avoid any sudden opening

    during transportation.

    Fig. 6.2 Drawing for Loading Truck Crane

    Loading Location Diagram

    S Centre of Gravity

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    Fig. 6.3 Position Layout for Truck Crane Transportation by Railway

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