MAINTENANCE MANUAL


C O N TA I N E R R E A CH S TA C KE R

CONTENTS

1 . Preparing Work before Maintenance

2 . Maintenance Cycle Table of the Whole Machine
3. Maintenance of the Equipment
4 . Lubricating
5 . Functional Oil
6 . Checking of Key Bolts
7 . Safty Regulations during Maintenance Work
8 . Common Faults and Measures
9 . Maintenance of Equipment Tracking Sheet
 

Reading Guidance

Warning

It means the potential danger, which may cause

death or serious injury if no preventive measure is
taken.

Caution

It means the potential danger, which may cause

slight or moderate injury if no preventive measure
is taken.

Caution

There is no safety indication. If you ignore this

indication, there will be some potential danger to
induce loss of property.

Notice

It awarks people to take attention to the operation

and maintenance.
 

TABLE OF CONTENTS TABLE OF CONTENTS

Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual

1. Preparing Work before Maintenance 1-1   9. Maintenance of Equipment Tracking Sheet   9-1

2. Maintenance Cycle Table of the Whole Machine 2-1

3. Maintenance of the Equipment 3-1

3.1 Repairing and Maintenance of the Engine 3-1
3.2 Repairing and Maintenance of Transmission 3-5
3.3 Repairing and Maintenance of the Drive Axle 3-6
3.4 Repairing and Maintenance of the Steering Axle 3-7
3.5 Repairing and Maintenance of the Spreader  3-8
3.6 Repairing and Maintenance of the Jib System 3-10
3.7 Repairing and Maintenance of the Air Conditioner System 3-11
3.8 Repairing and Maintenance of Tyres 3-11
3.9 Repairing and Maintenance of Hydraulic System 3-13
3.10 Repairing and Maintenance of Electric System 3-14

Font -Arial Size:10pt

4. Lubricating 4-1
4.1 Lubrication 4-1
4.2 Lubricating Table 4-1

5. Functional Oil 5-1

5.1 Oil Specification 5-1
5.2 Oil Capacity 5-2
5.3 Check and Change of Hydraulic Oil 5-2
5.4 Using Principle of Oil 5-3

6. Checking of Key Bolts 6-1

7. Safty Regulations during Maintenance Work 7-1

8. Common Faults and Measures 7-1

8.1 General 7-1
8.2 Common Faults of Mechanical Systems and Measures 8-1

8.3 Common Faults of Hydraulic System and Measures

8-4
8.4 Common Faults of Electrical Control System and Measures 8-6

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MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE
Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

  Maintenance   Applicable plan   Maintenance   Applicable plan

Serial No.   Maintenance items Serial No.   Maintenance items
 par ts  par ts
29 Check if steering axial component has abnormal A B C D 53 Replace main hydraulic oil tank and brake oil tank D
clearance and damage ventilation filter core

30 Check anti-tilting inductor A B C D 54 Check if battery water is sufficient A B C D

Circuit
31 Check if bolts of tyre pressure plate are loose and br oken A B C D 55 Check all working lights and indicator lights A B C D
Steering
32 axle Check if tyre is deflective A B C D 56 Check tyre pressure plate and nut tightness degree A B C D

33 Check if steering wheel bearing and fixed nut are loose C D 57 Check tyre status and air pressure A B C D
General
or broken 58 items Check horn, reversing buzzer, and alarm light A B C D
34 Check if spherical pin and fixed nut are loose and broken C D 59 Lubricate all slide blocks and lubrication points A B C D
35 Check twist-lock and relevant components A B C D 60 Test anti-tilting protective system A B C D
36 Check twist-lock inductor and indicator A B C D 61 Function Test twist-lock safety interlocking device system A B C D
37 Check and adjust 20 /40 chain and limit A B C D 62 test Test integrated function of hydraulic system A B C D
38 Check crane spreader rotary decelerator gear oil and B C D 63 Check and treat places with oil or water leakage A B C D
Crane
lubricating oil amount
spreader  Replace crane spreader rotary decelerator gear oil
39 C D

40 Check if fixed bolt of crane spreader rotary gear case C D

is loose and broken

41 Check if slide block on the crane spreader is abraded C D

to the limit

42 Check if crane spreader has cracks by general vision C D

43 Check if fixed seat and lock pin on the basic boom are A B C D

Contraction loose, broken, and worn

44 Check if fixed seat and lock pin on the pitch oil cylinder A B C D
and pitch
are loose, broken, and worn
system
45 Check if slide block on basic boom is abraded to the li mit B C D

46 Check if basic boom has cracks by general vision D

47 Check oil amount in main hydraulic oil tank and brake oil A B C D
tank

48 Check accumulator pressure A B C D

49 Hydraulic Check if hydraulic pressure on the hydraulic nameplate C D

system is consistent

50 Replace all high-pressure filter cores C D

51 Replace brake oil and brake cooling oil filter core C D

52 Replace hydraulic oil and hydraulic system filter core C D

2-2 2-3
 

MAINTENANCE OF THE EQUIPMENT   MAINTENANCE OF THE EQUIPMENT

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

3.6 Repairing and Maintenance of the

Jib System
★Check the fixed seating and pin roll of the
basic boom if loose or abrasion
The fixed seating and pin roll of the basic boom is
Inductor
the key components connected with frame and
spreader. And the stability of structure and welding
of fixed seating, pin roll, bearing of pin hole and
★Check abrasion status of the slide blocks in
fixed bolts should be checked periodically. Please
the spreader 
color them if necessary.
There are two kinds of slide blocks on the
spreader: side-slide blocks and 20'-40' extension
Inductor blocks, which do an action of sustention and
guiding.
Firstly detach the bottom strap, shim and slide
Inductor block, then measure the thickness of slide blocks ★General observations of cracks
as well as the gap of slide block and slide The spreader is the direct container-lifting device
components, adjust and change the shim if  of the machine, usually inspection of the important
necessary, at last reinstall the strap. components, to find out the cracks as early as
possible is necessary.

★Check if there exists the gap or damage of 

components of steering axle ★Check the fixed seating and pin roll of the
Regularly inspection on the fixed bolts is pitch cylinder if loose or abrasion
necessary for fear of accidents caused by loose of  Check if there is any crack around the fixed
bolts. seating; please color it for next inspection if 
Rotary motor is composed of hydraulic motor, disk necessary.
brake, planetary gear set, who are connected by
fixed bolts.
The hydraulic motor lies on the upper of disk
brake, which provides rotary power. Disk brake is
something that avoids accidental rotation and
followed by the rotation of hydraulic motor, which
makes the brake released and spreader planetary
gear rotated, so that the output of motor and disk
brake will be enlarged.

★Check if the slide block of basic boom wears

to extreme
Firstly detach the strap, shim and slide block, then

3- 9 3-10
 

LUBRICATING LUBRICATING
Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

★Test the overall function of hydraulic system

Operate the electro-hydraulic control handler; test Lubricating Table of the Machine
all the hydraulic functions such as pitch and
contraction of jib, expansion, contraction and
sideshift of spreader. Find out parts that need Lubricating points Brand Amounts Cycle
adjustment. Steer axle 15
Front headlamp   Rear headlamp
Boom lamp Pitching cylinder fulcrum 2
Lubricating pump 4
Jib extension and contraction
14
lubricating block
Extension and contraction surface of 
6
spreader 
★Check horn, reverse buzzer and rotary
Pivot of jib and spreader 2
warning light
4.Lubricating Damping cylinder lug of spreader 4 60 h or every
Turn on the horn, reverse buzzer and rotary
Mobil lubricating
warning light to check they are working. Sideshift cylinder lug of spreader 4 week
grease EP2
4.1 Lubrication Sideshift surface of spreader 4
 Add lubricant coating in order to ensure the
Extension-contraction cylinder lug of 
★ROPS system test smooth rotation and sliding parts, not sufficient 4
spreader 
Test if the ROPS system is working. Once the lubrication can cause issuing and excessive wear 
controller get the front tilting signal, it would lock Rotary lock of spreader 8
parts. Lubricant is to guarantee the normal
the motion immediately (except contraction), give a operation of machine of lubricating necessary Turntable slewing bearing of spreader 4
warning and flash the red light. The signal would materials. Transmission axle 3
get through relay to control the front red acousto- Reach stacker use Mobil EP2 hanging type
Parking brake 1
optical alarm prompt. Once the controller gets the automobile universal lithium grease, banning the
Shell Diesel engine
signal, that red light would turned on, display use nonspecified lubricant by Sany Group. Diesel engine 1 250 h
screen will also have the malfunction warning CG-415W40
Lubricating (butter) method:
signal. Firstly clean the grease fitting, do not stop to inject Shell transmission oil 1000 h or one
Brake oil tank 1
the butter with the grease gun until the old grease DonaxTD5W-30 year 
is forced out. Shell gear oil VG150 1000 h or one
Reducer of driving axle   2
（>0?   ） year 
Shell gear oil VG150 1000 h or one
Differential of driving axle   1
4.2 Lubricating Table （>0?   ） year 
Shell anti-wear  2000 h or one
Hydraulic oil tank 1
hydraulic oil VG46T year 
Shell multi-function
★Test the Rotary-lock safe interlocking device 2000 h or one
Torque converter  transmission oil Donax 1
system year 
Before turning on the rotary lock, check if all the TD 5W-30
standby lights (green) is on; while the rotary Shell antifreeze
Engine radiator  1 one year  
isworking , check if all the sensor light (yellow) is (freezing point-45°C)
on; check if clearance between sensor and
sensing block is normal, if there is any sign of 
abnormal, treatment should be taken promptly.

4- 1 4-2
 

COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

Category Faults C ause of faults M easu res Category Faults C ause of faults M easures
①Without key switch ①Turn on the key switch Communication fault of the The engine works but no speed Check whether the wire broken or
Nutation emergency is failed ②Magnetic valve of Nutation ②Overhaul the magnetic valve engine and the controller information on the screen with water
emergency failure ③Check connector and wire There is length and angle indication

③Connectors loose or drop Controller and I/O extended on the screen but without gear Check whether the wire broken or

①Reverse plug of rod and rodless ①Joint the wire correctly block information, and the red light of the with water
Inaccuracy of weight- pressure sensor ②Change the pressure sensor I/O extended block always on
measuring ②Pressure sensor damaged ①Check whether the wire is broken
③Check connector and wire
③Connector lug loose of drop Communi or water intake;
cation wire Controller and screen The screen is ok but no content on it ②Check whether terminal
①Rough road surface ①Smooth the road surface
②Distance of Proximity switch ②Adjust the distance of Proximity resistance burn out or bad
ROPS give an alarm connects, The terminal resistance
improper switch
locates on its plugs.
③Proximity switch damaged ③Change the Proximity switch
①Check whether the wire is broken
④Connector lug loose of drop ④Check connector and wire
or water intake;
①Too much redundancy data ①Refresh the page
Abnormal show of the screen， Controller and length and angle The indication of the length and ②Check whether terminal
②The screen is disturbed by ②Eliminate the interference source
figures distorted sensor angle of the boom is abnormal the resistance burn out or bad connect
Electricity magnetism ③Change the screen
others are ok .As the terminal resistance locates
component ③The screen damaged
in the length angle sensor ,the
the page data of the screen is
①Bus failure ①Check the wire and recovery

abnormal ②Bus terminal resistance damaged ②Change the resistance and

or lead fell off check the wire and recovery

①Power fuse burn out

②Power fuse burn-out on the enter ①Change the fuse
point ②Change the fuse
③Power fuse burn-out on the enter ③Check and recovery
No operation of controller point ④Check、recovery and refresh the
④To judge the state of the program program
according to the instruction book ⑤Change the controller
⑤Controller damaged
①Power fuse burn-out ①Change the fuse
②No blinking of communication ②Check and recovery
No operation of extended block indication light communication wire
③There is light on the input、 output ③Change the extended block
points but no operation
①No key switch ①Check the switch
Cab can not move
②Magnetic valve damaged ②Check and repair magnetic valve
③Connector lug loose or drop ③Check connector and wire

8-12 8-13
 

MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

9.Maintenance of Equipment Tracking Sheet

Maintenance of equipment tracking sheet 2
Maintenance of equipment tracking sheet 1

Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date

Maintenance Contents Maintenance Contents

Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator  No. Materials Operator 
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MAINTENANCE OF EQUIPMENT TRACKING SHEET   MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

Maintenance of equipment tracking sheet 3 Maintenance of equipment tracking sheet 4

Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date

Maintenance Contents Maintenance Contents

Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator  No. Materials Operator 
Part type quantity Source date time Part type quantity Source date time

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MAINTENANCE OF EQUIPMENT TRACKING SHEET   MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

Maintenance of equipment tracking sheet 5 Maintenance of equipment tracking sheet 6

Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date

Maintenance Contents Maintenance Contents

Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator  No. Materials Operator 
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MAINTENANCE OF EQUIPMENT TRACKING SHEET   MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

Maintenance of equipment tracking sheet 7 Maintenance of equipment tracking sheet 8

Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date

Maintenance Contents Maintenance Contents

Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator  No. Materials Operator 
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MAINTENANCE OF EQUIPMENT TRACKING SHEET   MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual   Container Reach Stacker Maintenance Manual

Maintenance of equipment tracking sheet 9 Maintenance of equipment tracking sheet 10

Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date

Maintenance Contents Maintenance Contents

Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator  No. Materials Operator 
Part type quantity Source date time Part type quantity Source date time

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MAINTENANCE OF EQUIPMENT TRACKING SHEET

Container Reach Stacker Maintenance Manual

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Equipment Manufacture Using Start

Working Place
Name No. Date

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Maintenance Materials Materials Materials Maintenance Using

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