Operation and Maintenance Manual of Special Truck Crane Chassis BCW5481JQZ Emission Level EURO Ⅲ.doc

operation and maintenance manual of special truck crane chassis bcw5481jqzemission level: euro bq-tadano crane (beijing) co., ltd.forewordthis manual has been prepared to provide technical document about the performance, structure, operation, maintenance and adjustment of the 75 t serial chassis designed by bq-tadano crane (beijing) co., ltd. chassis driver of crane truck and maintenance workers could reference it. obtaining normal service life of the chassis, please read the manual carefully and familiarize you with the theory and operation procedures, only in this way it is possible to ensure proper operation and maintenance.this manual is applied to the following crane truck chassis:bcw5481jqz (75 t chassis with imported cummins isme385 30)as the continuous upgrading and improvements, this manual may different from the crane. cranes are subject to change without prior notice.welcome your suggestions and opinions to our crane truck chassis.contentsintroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11. security identifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. new vehicles breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1vehicle number and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. vehicle identification code and nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12. engine nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 controls in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. the interior devices in the cab are consist of controls, instruments, signal displays etc . . . . . . . . . . . .1(1) interior devices in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1(2) instruments panel in the cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2(3) indicator lamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3(4) indicator lamp 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4(5) switch group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42. main functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4(1) instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4(2) indicator lamp and warning lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7(3) switches and controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9(4) others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 starting and driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141. start of engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14(1) the operation of the starter switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14(2) process of starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14(3) preheating of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15(4) stop of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152. start and gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15(1) shifting gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15(2) upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15(3) downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16(4) to stop and park the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163. clutch operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16(1) the adjustment of clutch system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164. brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17(1) service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17(2) emergency brake or parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17(3) engine brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175. driving in the slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176. attentions in winter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17(1) cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17(2) brake apparatus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18(3) battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187. inspections and replacement of wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18(1) inspections of tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18(2) inspections of tire rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18(3) replacing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188. breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19(1) cautions in breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 daily checkups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191. inspect the following items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19(1) please park the vehicle on the flat floor to make the inspection safe and easy. . . . . . . . . . . . . 19(2) make sure that the ignition switch is off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19(3) make sure that the parking brake is applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20(4) make sure that the gearshift lever is in neutral position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202. routine inspection items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20(1) whether the abnormalities are solved which were found yesterday. . . . . . . . . . . . . . . . . . . . . .20(2) outer inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20(3) inspection items for cab interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20(4) inspection items after starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20(5) inspections when traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211. for routine inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212. for replacement interval of oil in each assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213. the key points of task and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21(1) daily maintenance items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21(2) for maintenance items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22(3) oils and greases table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 the principle diagram of brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251. the illustration of the principle diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 the tightening torque for main bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 structural features and technical parameters of carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27introduction1. security identifierthe term of “warnings” used to remind you to avoid danger that may make you and others injured. the term of “cautions” relates to vehicle damage or the possibility of personal injury, the contents of “warning” and “caution” was printed in bold type figure.2. new vehicles breaking-in periodin order to extend the service life and improve reliability, the breaking in mileage provisions for 1,500 km. before breaking-in, routine inspections to ensure the vehicle is in proper working condition, during the first 30 hours of travel, keep the rotated speed in the range of 75% of the rated rotate speed.for special illustrations about breaking-in period, please refer to “start and steer of the vehicle”. after the first a few days of breaking-in period, routine inspections and maintenance in accordance with the manual and ensure the reliability of travel. vehicle number and engine number1. vehicle identification code and nameplatesvehicle identification code is in the longer on the front right side of the frame. nameplates are on the right side of the rear part of the frame. as follows:identifioridentification code ： le7d4827 2. engine nameplatenameplate is on the left of the cylinder cover, which indicates the important information of the engine. do not replace the nameplate without the permission of the engine manufacturer. controls in the cab1. the interior devices in the cab are consist of controls, instruments, signal displays etc.(1) interior devices in the cabfigure 3-1 interior devices in the cab1.steering wheel 2.switch group 3.air blow louver 4.starter switch 5.clutch pedal 6.brake pedal7.seat 8.instrument panel 9.horn switch 10. radio-cassette player 11.accelerator pedal 12.shift lever 13.parking brake lever 14. air conditioner switch 15. ashtray 16.cigarette lighter (2) instruments panel in the cabfigure 3-2 instruments panel in the cab1. speedometer and odometer 2. indicator lamp 1 3. tachometer 4. pto hour meter5. indicator lamp 2 6.adjustment switch of rear-view mirror 7. voltmeter 8.group switch9. engine oil gauge 10. fuel gauge 11. water temperature gauge 12. air pressure gauge(3) indicator lamp 1figure 3-3-1 indicator lamp 11. left-turn signal lamp 2. rear fog lamp 3. parking brake warning lamp 4. engine hydraulic pressure warning lamp 5. low battery warning lamp6. front axle air pressure warning lamp 7. auxiliary air pressure warning lamp8. right-turn signal lamp 9. engine brake indicator lamp 10. low fuel warning lamp11. warning lamp for engine coolant temperature 12. high beam lamp 13. warning lamp for middle and rear axle air pressure 14. parking brake air pressure warning lamp(4) indicator lamp 2figure 3-3-2 indicator lamp 21. front fog lamp 2. engine fatal failure warning lamp（red）3. engine general failure warning lamp（yellow）4. low gear indicator lamp 5.steering flow failure warning lamp 6. air cleaner warning lamp 7. low beam lamp 8. engine standby lamp（green）9. turn signal indicator lamp in emergency10. top gear indicator lamp 11.cruise control button 12. cruise control switch(5) switch groupfigure 3-3-3 switch group 11.air horn switch 2. fog lamp switch 3. pto switch 4. differential lock between axles switch 5. differential lock between wheels switch 6. diagnostic switch 7. rear-view mirror heating switch 8. engine power selecting switch2. main functions(1) instruments speedometer and odometer (no 1 in figure 3-2)instruments consist of speedometer and odometer. speedometer shows the vehicle speed in the form of kilometers per hour. odometer records the total traveling distance of the vehicle. keep the maximum speed less than the rated speed at any gear. engine tachometer (no 3 in figure 3-2)engine tachometer has hour meter; the pointer indicates the engine speed in 1 minute. hour meter indicates engine operating hours. the rated speed of the engine is 1900r/m; do not overrun the engine at any time. pto hour meter (no 4 in figure 3-2)it indicates pto operating hours. voltmeter (no 7 in figure 3-2)the voltmeter indicates the voltage. engine oil gauge (no 9 in figure 3-2)it indicates the engine oil pressure. notice that if the pointer is in normal range. fuel gauge (no 10 in figure 3-2)the fuel gauge approximately indicates the remaining fuel amount of the fuel tank. when the vehicle is traveling during uphill and downhill or the speed is changed sharply, the pointer of the fuel gauge will be moved. coolant temperature gauge (no 11 in figure 3-2)this gauge indicates the temperature of engine cooling system. when the vehicle was traveling with normal conditions, the pointer stays in the middle of the range, it means the normal temperature of the engine cooling water is nearly 82-93.the pointer will reaches the red sector when traveling in high-temperature region at high speed or climbing steep slopes. please slow down until the coolant temperature fall back to the normal. the vehicle must be stopped when the coolant temperature is too high. run the engine at idle speed so as tomake the temperature normal. air pressure gauge (with two pointers) (no 12 in figure 3-2)air pressure gauge indicates the air pressure of the front and rear brake circuit. the normal operating pressure ranging from 0.45 to 0.8 mpa. if the pressure is less than 0.45 mpa, stop the vehicle and check the air circuit.(2) indicator lamp and warning lamp direction indicator lamp.1 left-turn signal lamp（no 1 in figure3-3-1） before turning left, pull the left switch group 2 back, the lamp will light up.2 right-turn signal lamp（no 8 in figure 3-3-1） before turning right, push the left switch group 2 forward, the lamp will light up. fog lamp.1 front fog lamp (no 1 in figure 3-3-2)this lamp indicates when the front fog lamp is applied.2 rear fog lamp (no 2 in figure 3-3-1)this lamp indicates when the rear fog lamp is applied. parking brake warning lamp（no 3 in figure 3-3-1）this lamp indicates when the parking brake is applied. please make sure that this lamp is off before travelling. engine hydraulic pressure warning lamp（no 4 in figure 3-3-1)）if this warning lamp lights up, it indicates that the oil pressure is less than the normal pressure, immediately stop the vehicle and turn off the engine. low battery warning lamp（no 5 in figure 3-3-1）this lamp indicates when the battery voltage is low; please charge as soon as possible. front axle air pressure warning lamp（no 6 in figure 3-3-1）this lamp indicates when the air pressure in the braking circuit of front axle is too low. auxiliary air pressure warning lamp（no 7 in figure 3-3-1）this lamp indicates when the air pressure in the auxiliary air circuit is too low. engine brake indicator lamp（no 9 in figure 3-3-1）this lamp indicates