QUY260 Operators Manual 20140603
QUY260F/20.CY
ZOOMLION ® Crawler Crane
QUY260
QUY260/20.CY
QUY260S/20.1
CRAWLER CRANE
QUY260
Operating manual
QUY260CR/20.1
2013.10
The operating manual is part of the crane!
Always keep on hand!
Comply with road travel and crane operating
regulations!
Zoomlion Heavy Industry Science & Technology Co.,Ltd
QUY260YM/20.1
Contents
0 Foreword ..................................................................................
0066340-200-00Y.C
1 Safety instructions...................................................................
0066340-200-01Y.C
2 Description of the crane..........................................................
0066340-200-02Y.C
2.1 Product model
2.1.1 Product name plate and its position
2.1.2 Engine type and its manufacturer
2.2 Terminology
2.2.1 Boom configuration
2.2.2 Description of component parts
2.3 Product description
2.3.1 Crawler travel gear
2.3.2 Crane superstructure
2.3.3 Overall dimensions
2.4 Technical data
2.4.1 Main technical parameter
2.4.2 Type of load hook and applicable rope reeving
2.4.3 Hoisting rope reeving and specification of wire rope
2.4.4 Lifting height
2.4.5 Lifting capacity charts
3 Safety Guidelines.........................................................................
3.1 Operational planning
3.2 Safety—Technical Notes
3.2.1 Safety Instructions
3.2.2 Selecting an operating site
3.2.3 Slopes and trenches
3.2.4 Permissible ground pressure
3.2.5 Checking safety measures
3.2.6 Crane operation with a load
3.2.7 Electromagnetic influences
3.2.8 Safety signs
I
0066340-200-03Y.C
QUY260YM/20.1
3.2.9 Hand signals for controlling crane operations
4 Crane operation .........................................................................
0066340-200-04Y.C
4.1 Operating and control instruments
4.1.1 Overview of crane operator’s cab
4.1.2 Left control box
4.1.3 Right control box
4.1.4 Control panel assy
4.2 Instruction for digital display system
4.2.1 Load moment limiter
4.2.2 Display of control system
4.3 Startup of crane
4.3.1 Adjustment of crane operator’s seat
4.3.2 Checks before startup
4.3.3 Turn on power supply
4.3.4 Start engine
4.4 Safety devices
4.4.1 Emergency stop button
4.4.2 Battery master switch
4.4.3 Load moment limiter
4.4.4 Boom angle indicator
4.4.5 Derrick limiter
4.4.6 Lowering limiter
4.4.7 Hoisting limiter
4.4.8 Support cylinder locking device
4.4.9 Overflow valve
4.4.10 Anemometer
4.5 Crane operation
4.5.1 Operation of traveling mechanism
4.5.2 Operation of crane winches
4.5.3 Operation of synchronizing A-frame and main boom derricking winch and
II
QUY260YM/20.1
synchronizing reeving winch and working winch
4.5.4 Operation of slewing mechanism
4.5.5 Simultaneous operation
4.5.6 Operation of movements of crane operator’s cab
4.5.7 Auxiliary remote control box
4.5.8 Undercarriage remote control box
4.5.9 Operation of A-frame erection cylinder and mounting cylinder on A-frame
4.5.10 Emergency control box
4.6 Rope reeving
4.6.1 Heavy duty boom (S)
4.6.2 Light duty boom (SL)
4.6.3 Fixed jib on heavy duty boom (SF)
4.6.4 Luffing jib on heavy duty boom (SW)
4.6.5 Main boom derricking rope guidance and reeving
4.6.6 luffing jib derricking rope guidance and reeving
5 Assembly and dismantling................ ........................................
0066340-200-05Y.C
5.1 Safety-technical notes
5.1.1 Notes on assembly
5.1.2 Checking safety measures
5.1.3 Inspection of wire rope, load hook, rope pulley and anchoring rods
5.1.4 Connecting or disconnecting the hydraulic lines with quick-release couplings
5.1.5 Setting-up and taking-down
5.2 A-frame
5.2.1 Connecting the hydraulic lines to mounting cylinder on A-frame
5.2.2 Operation of A-frame
5.3 Attaching the crawler carriers
5.3.1 Unloading of basic machine
5.3.2 Attaching the first crawler carrier
5.3.3 Attaching the second crawler carrier
5.3.4 Connecting the hydraulic lines to the crawler carrier
5.4 Attaching the central counterweight
5.5 Assembling the rear counterweight
III
QUY260YM/20.1
5.6 Available boom configurations for crawler crane QUY260
5.7 Boom configuration
5.7.1 Heavy duty boom (S)
5.7.2 Light duty boom (SL)
5.7.3 Fixed jib on heavy duty boom (SF)
5.7.4 Heavy fixed jib on heavy duty boom (SFV)
5.7.5 Luffing jib on heavy duty boom (SW)
5.8 Assembly and dismantling of heavy duty boom (S)
5.8.1 Preparations for assembly
5.8.2 Assembling main boom
5.8.3 Connect electrics to main boom
5.8.4 Erecting main boom
5.8.5 Lowering and disassembling the main boom
5.9 Assembly and dismantling of main boom with luffing jib (SW)
5.9.1 Preparations for assembling luffing jib
5.9.2 Assembling main boom with luffing jib
5.9.3 Connect electrics to luffing jib
5.9.4 Erection and set-down of main boom with luffing jib
5.10 Assembly and dismantling of light duty boom (SL)
5.11 Assembly and dismantling of main boom with fixed jib (SF)
5.11.1 Preparations
5.11.2 Assembling main boom with fixed jib
5.11.3 Connect electrics to fixed jib
5.11.4 Erecting and lowering main boom with fixed jib
5.12 Assembly and dismantling of main boom with heavy fixed jib (SFV)
5.13 Assembly and dismantling of tip boom
5.14 Transport dimensions and weights of main components
5.15 Requirement for crane transport
6 Maintenance ..............................................................................
6.1 General
6.1.1 Crane maintenance
6.1.2 Requirements for crane inspection
6.1.3 Attached tools for maintenance
6.2 Superstructure maintenance and inspection plan
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0066340-200-06Y.C
QUY260YM/20.1
6.2.1 Maintain and inspect superstructure every day or every 5 hours
6.2.2 Maintain and inspect superstructure every month or every 100 hours
6.2.3 Maintain and inspect superstructure every 3 months or every 250 hours
6.2.4 Maintain and inspect superstructure every 6 months or every 600 hours
6.3 Undercarriage maintenance and inspection plan
6.3.1 Maintain and inspect undercarriage every day or every 5 hours
6.3.2 Maintain and inspect undercarriage every month or every 100 hours
6.3.3 Maintain and inspect undercarriage every 3 months or every 250 hours
6.3.4 Maintain and inspect undercarriage every 6 months or every 600 hours
6.4 Boom frame maintenance and inspection plan
6.5 Maintenance and inspection for engine
6.6 Instructions for lubrication and oil change
6.6.1 Hydraulic oil
6.6.2 Gear oil
6.6.3 Lubricating grease
6.6.4 Engine oil
6.6.5 Fuel
6.6.6 Coolant
6.6.7 Lubrication and maintenance of crane in irregular conditions
7 Crane inspections .....................................................................
7.1 General
7.2 Inspection of steel bearing structures
7.3 Inspection of hosting and luffing winches
7.3.1 Inspections
7.3.2 Requirements for monitoring the winches
7.4 Inspection of load hook
7.5 Inspection of rope pulleys
7.6 Inspection and maintenance of anchoring rods
7.7 Inspection and maintenance of wire rope
7.7.1 Handling and transport of wire rope
V
0066340-200-07Y.C
QUY260YM/20.1
7.7.2 Inspection of wire rope
7.7.3 Discard of wire rope
7.7.4 Maintenance and care of wire rope
7.8 Inspection of oil and fuel tanks
7.9 Inspection of load bearing components
7.10 Inspection of engine
8 Additional equipment. ...............................................................
8.1 Air conditioning
8.1.1 Control panel for air conditioning
8.1.2 Methods for operating air conditioning
8.1.3 Maintenance of air conditioning system
8.2 Media Player
9、Crane inspection log
VI
0066340-200-08Y.C
0066340-200-00-20CY
Foreword
Thank you for purchasing ZOOMLION crawler crane produced by Changsha Zoomlion Heavy
Industry Science & Technology Development Co., Ltd. We are glad to provide high quality and
high-efficiency service for you.
The operating manual are intended to put you in a position to operate the crane safely and utilize
its capabilities to the fullest extend possible.
Certain terms are used in the operating manual, and in order to avoid misunderstandings while
operating, these terms should be used consistently.
Danger: Only qualified and especially trained personnel are permitted to work on the crane!
If this is not assured, the chance of causing a serious accident is greatly
increased!
All regulations and guidelines applicable to the job site, such as accident prevention regulations
and all guidelines and regulations stated in the Operating Manual must be strictly adhered to.
All accident prevention and operating guidelines and regulations, etc. assume that the crane is
strictly used for lifting and transporting of loads, which are not stuck. Any other application or use
does not constitute specified and proper use.
Any risks associated with unspecified and improper use are the sole responsibility of the crane’s
owner, operator or user.
Using this instructions in the manual:
·makes it easier to become familiar with the crane
··avoids malfunctions due to improper operation
Observing these instructions in the manual:
·increases reliability in operations
·extends the service life of the crane
·reduces repair costs and down-time
Always keep the operating manual handy in the driver’s and crane cab-it is an integral part of the
crane. Operate this crane if you are well familiarized with the capabilities and limitations of the
crane, and always follow these operating instructions.
If you have received additional information about the crane from us, e.g. in the form of technical
information letters, then this information must also be followed and kept with the operating manual.
If there is anything in the operating manual or the individual chapters that you do not understand,
please do no hesitate to ask us or our agents before you begin operation.
No parts of the operating manual may be copied or distributed, nor used for competitive purposes.
0066340-200-00-20CY
All rights are expressly reserved in accordance with copyright laws.
The content with respect to the safety is marked with“
”, the safety instructions involved in the
book are only the conventional contents.
The operating manual must be read and the regulations in it must be observed by all persons
operating, maintaining, or otherwise working in any capacity on this crane.
The employer shall comply with the manufacturer's specifications and limitations applicable to
the operation of any and all cranes and derricks. Where manufacturer's specifications are not
available, the limitations assigned to the equipment shall be based on the determinations of a
qualified engineer competent in this field and such determinations will be appropriately
documented and recorded. Attachments used with cranes shall not exceed the capacity, rating, or
scope recommended by the manufacturer.
A thorough, annual inspection of the hoisting machinery shall be made by a competent
person, or by a government or private agency recognized by the U.S. Department of Labor. The
employer shall maintain a record of the dates and results of inspections for each hoisting machine
and piece of equipment.
Notes:
The following terms that are used in the operating manual “Note”, “Caution”, and “Danger” are
intended to point out certain important rules of conduct to all persons who work with the crane.
The term “Note” is used whenever the observance of certain instructions or notes is economically
meaningful to the utilization of the crane.
The term “Caution” is used whenever damage to the crane can occur if the operating instruction(s)
is not observed and adhered to.
The term “Danger” is used whenever the nonobservance of the warning given may insure or lead
to the death of persons and damaged to the crane.
Safety device
The safety devices built into the crane system deserve your special attention. They must always
be checked to see that they are functioning properly. If they do not function or function incorrectly,
the crane may not be operated. Your motto must always be Safety First.
Caution:
When welding work is conducted on crane, the operator should unplug all power source plugs of
controllers, otherwise, he should bear all consequences incurred.
Chapter1
Safety instructions
0066340-200-01Y.C
1.1 Notes
a) Read this manual and familiarize yourself with any associated documentation before
operating this product.
b) Ensure that a copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
Training should be provided to ensure safe working practices.
Initial commissioning and staring must only be undertaken by a competent person who
has read and fully understands the information provided in the manual pack.
c) To avoid the risk of electric shock always isolate this equipment from the supply prior to
carrying out any maintenance adjustment or removing any guards or covers.
d) Always follow the procedures outlined in the operating and maintenance instruction.
e) If in doubt ask, do not take personal risk.
f)
Only trained personal can be allowed to install, set, operate, maintain, and decommission
this equipment.
1.2 Alarms and warnings
a) You can be injured if you do not obey the safety instructions as indicated on warning
stickers.
b) Ensure that safety instructions and warnings attached to the plant are always complete
and perfectly legible
c) Keep warnings and instruction labels clean.
d) Replace unreadable or missing labels with new ones before operating the plant. Make
sure replacement parts include warning or instruction labels where necessary.
Caution:
To assure personnel safety, all safety instructions and warnings should be observed; for the
position of labels and warnings, please refer to Chapter 3 “Safety Guidelines”
1.3 Component Safety Features
a) Do not use this equipment with guards removed or incorrectly fastened.
b) Do not use this equipment with safety devices maladjusted or removed.
c)
Do not use this equipment before the portable fire extinguisher with a basic minimum
extinguisher rating of 5 BC is installed in the cab and minimum 10 BC outside the cab.
1.4 Features for Operator Saf
a) Safety components – crane emergency stop buttons. Ensure all Guards are bolted down.
0066340-200-01Y.C
b) Steps, handrails, tread plates and fixed guards are provided where personnel are
required to climb on the machine.
1.5 Environmental safety
a) It is essential that the service intervals detailed in the maintenance procedures are
followed to ensure that engine emission are kept to a minimum.
b) Consumable materials
1) Diesel spillages must be dealt with immediately.
2) Only use the Lubricating Oils recommended in the maintenance schedule.
3) Local and National regulations must be observed when disposing of waste.
4) Improperly disposing of waste can threaten the environment and ecology and is
illegal.
5) Potentially harmful waste used on this equipment includes such items as oil, fuel,
coolant, filters and batteries, ect.
6) Use leak proof containers when draining fluids. Do not use food or beverage
containers that may mislead someone into drinking from them.
7) Do not pour waste onto the ground, down a drain or into any water source.
8) Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
c) Machine disposal. This machine must only be disposed of at a specialist machine
breaker.
1.6 Personal protective Equipment (PPE)
a)
Loose or baggy clothing can get caught in running machinery.
b)
Where possible when working close to engines or machinery, only do so when they are
stopped. If this is not practical, remember to keep tools, test equipment and all other parts
of your body well away from the moving parts.
c)
For reasons of safety, long hair must be tied back or otherwise secured, garments must
be close fitting and no jewellery such as rings may be worn.
d)
Always wear correctly fitting personal protective equipment.
e)
Recommended personal protective equipment includes:
1) Hard Hat
2) Safety Glasses/Goggles
3) Hearing Protection
4) Close Fitting Overalls
5) Safety Boots
0066340-200-01Y.C
6) Industrial Gloves
7) High Visibility Vest or Jacket
1.7 Measured Noise Level
The product and local conditions will affect the noise levels.
The sound pressure level and sound power level, measured using EN13000 Annex G and
2000/14/ EC standards is respectively 73.9dB (A) and 107dB (A)
The sound pressure level measured using ISO 7731 at the position 3′3″ away from the warning
device is 97.7dB(A).
1.8 Vibration Levels
Suitable seating has been installed to reduce the risk of whole body vibrations, in line with
current industry standards.
The crane body vibrations, measured using ISO 2631-1 under normal operating condition, is A(1):
1.3m/s2,A(4):0.6m/s2,A(8):0.4m/s2
1.9 Organizational Safety Measures
a) This vehicle must only be driven and the crane operated by a suitably qualified operative
who holds a current license in line with National/ International legislation.
b) Understand the service procedure before doing work. Keep area clean and dry.
c) Never lubricate, clean, service or adjust machinery while it is moving(excluding central
lubrication).
d) Keep hands, feet and clothing clear of power driven parts and in running nip-points.
e) Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Removed any build up of grease, oil and
debris.
f)
Disconnect battery ground cable before making adjustments on electrical systems.
g) Disconnect battery ground cable and ECM connecting cable and unplug all plugs of
controllers before welding on machine.
h) During maintenance only use the correct tool for the job.
i)
Never make any modifications, additions or conversions which might affect safety without
the manufacturer’s approval.
j)
In the event of safety relevant modifications or changes in the behavior of the machine
during operation, stop the machine and lock out immediately and report the malfunction
to the competent authority/ person.
k) No modifications or additions which affect the capacity or safe operation of the equipment
shall be made by the employer without the manufacturer's written approval. If such
modifications or changes are made, the capacity, operation, and maintenance instruction
0066340-200-01Y.C
plates, tags, or decals, shall be changed accordingly. In no case shall the original safety
factor of the equipment be reduced.
1.10 Personnel Qualification, Requirements and Responsibilities
a) Any work on and/ or with the machine must be executed by trained, reliable and
authorized personnel only.
b) Maintenance work must only be undertaken by suitable qualified engineers with specialist
knowledge of this equipment.
c) Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
1.11 Safety Advice Regarding Specific Operational Phases
a) Standard operation
1) Take necessary precautions to ensure that the machine is used only when in a safe
and reliable state.
2) Operate the machine only for it’s designed purpose and only if all guarding, protective
and safety orientated devices, emergency shut-off equipment, sound proofing
elements and exhausts, are in place and fully functional.
3) Ensure that any local barriers erected to stop unauthorized entry to this equipment
are in place.
4) Before starting the engine ensures it is safe to do so.
b) Malfunction
In the event of any malfunction or operational difficulty, stop the machine immediately.
c) Unguarded areas
1) In-running nip points on moving machinery can cause serious injury or even death.
2) Do not reach into unguarded machinery. Your arm could be pulled in and amputated.
3) Switch off the machine before removing any safety devices or guarding.
4) Limit access to the machine and its surrounds where appropriate erect barrier guards
to reduce the risk of residual mechanical hazards, falling lifted loads.
1.12 Machine maintenance and repairs
Observe the adjusting, maintenance and intervals set out in these operating instructions,
except where:
1) Warning, horn/ light/ gauge or indicator calls for immediate action.
2) Adverse conditions necessitate more frequent servicing.
3) Always read instructions supplied with replacement of parts and equipment. Ensure
0066340-200-01Y.C
only properly trained personnel undertake these tasks.
a) Isolation
When undertaking maintenance and repair work, the plant must be first made safe.
1) Switch off the engine and remove the ignition key.
2) Attaching a warning sign(s) to the plant in appropriate positions.
b) Maintenance site conditions
Prior to staring any maintenance work, ensure the machine is positioned on stable and
level ground and has been secured against inadvertent movement and bucking.
c) Replacement and removal of components
1) Always observe handling instructions itemized in this manual, the Original Equipment
Manufacturer’s Manuals or the Spare Parts Supplier’s instructions.
2) Never allow untrained staff to attempt to remove or replace any part of the plant.
3) The removal of large or heavy components without adequate lifting equipment is
prohibited.
4) To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured. Use
only suitable and technically adequate lifting gear supplied or approved by the
supplier.
5) Never work or stand under suspended loads.
6) Limit access to the machine and its surrounds where appropriate erect barrier guards
to reduce the risk of residual mechanical hazards, falling lifted loads.
d) Climbing, falling
1) Falling from and/ or onto this machine could cause injury or even death.
2) Never climb on the machine whilst it is in operation.
3) Always keep the area around the machine clear of debris and trip hazards.
4) Beware of moving equipment in the vicinity of the machine.
5) For carrying out overhead assembly work always use specially designed or otherwise
safety-oriented ladders and working platforms.
6) Only use any walkway/ platforms provided on the machine or on an approved safe
and secure platform.
7) Only use CE certified safety harness when reaching any points 3′3″ or more above
the ground level.
8) Keep all handles, steps, handrails, platforms, landing and ladders free from dirt, oil,
0066340-200-01Y.C
snow and ice.
e) Safety consideration during advanced maintenance
1) Prior to undertaking all but normal planned maintenance activities, it is essential that
a method statement regarding safe working practices for the job in hand is produced.
2) Restrict access to the maintenance area to essential staff only. Where appropriate
erect barrier guards and post warnings.
3) The fastening of loads and instructing of crane operators should be entrusted to
qualified persons only.
4) If a marshal is used to provide instructions, the marshal must be within sight or sound
of the operator with an all round view of the operation.
5) Always ensure that any safety fitment such as locking wedges, securing chains, bars
or struts are utilized as indicated in the operating instructions.
6) Particularly make sure that any part of the plant raised for any reason is prevented
from falling by securing in a safe reliable manner.
7) Never work under unsupported equipment.
8) Never work alone.
f)
Safety consideration during cleaning
1) This equipment must be isolated prior to cleaning.
2) Do not direct power washers near or into control boxes and devices.
3) After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found must be rectified without
delay.
g) Removal of safety devices and guards
1) All safety devices (control device or guard) temporarily removed for set-up,
maintenance or repair purposes must be refitted and checked immediately upon
completion of the maintenance and repair work prior to operation.
2) Never operate the machine with safety devices and guards removed or unsecured.
3) Always report any defects regarding guards, safety device or control devices.
h) Safety when refilling
1) Only refuel with diesel from approved storage and supply equipment.
2) Diesel fuel is flammable.
3) Never remove the filler cop, or refuel, with the engine running.
4) Never add gasoline or any other fuels mixed to diesel because of increased fire or
0066340-200-01Y.C
explosion risks and damage to the engine.
5) Do not carry out maintenance on the fuel system near naked lights or sources of
sparks, such as welding equipment or whilst smoking.
6) To avoid spillages use drip trays.
7) Immediately clear up spilt fuel and dispose of correctly to minimize any environmental
impact.
1.13 Special Hazards
1.13.1 Electrical energy
a) External considerations and hazards
When working with the machine, maintain a safe distance form overhead electric lines.
If overhead cables are in the vicinity a risk assessment must be completed prior to
operating this equipment.
If your machine comes into contact with a live wire:
1) Vacate the area.
2) Warn others against approaching and touching the machine.
3) Report the incident and have the live wire de-energized.
b) Machine - Electrical
The electrical equipment of the plant is be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be
rectified immediately. Use only original fuses with the specified current rating. Switch off
the machine immediately if trouble occurs in the electrical system.
This plant is wired on a negative earth. Always observe correct polarity.
c) Battery
1) Always disconnect battery leads before carrying out any maintenance to the electrical
system.
2) Recharge the battery in a well ventilated area.
3) The battery contains sulphuric acid, an electrolyte which can cause severe burns and
produce explosive gases.
4) Avoid contact with the skin, eyes or clothing.
5) No smoking when maintaining battery.
6) Wear appropriate PPE.
0066340-200-01Y.C
1.13.2 Gas, dust, steam, smoke and noise
a) Always operate internal combustion engines out of doors or in a well ventilated area.
b) If plant is operated for maintenance purposes in an enclosed area, ensure that there is
sufficient ventilation or provide forced ventilation.
c) Observe the regulations in force at the respective site.
d) Dust found on the plant or produced during work on the plant must not be removed by
blowing with compressed air.
e) Toxic dust/ waste must only be handled by authorized persons dampened, placed in a
sealed container and marked, to ensure safe disposal.
1.13.3 Welding or naked flames
a) Welding, flame cutting and grinding work on the plant must only be carried out if this has
been expressly authorized, as there may be a risk of explosion and fire.
b) No welding should be undertaken on this equipment as it will affect its structural integrity.
c) Avoid all naked flames in the vicinity of this equipment.
1.13.4 Hydraulic equipment
a) Work on hydraulic system must be carried out by persons having special knowledge and
experience of hydraulic system.
b) Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury and fire.
c) Always relieve pressure from the hydraulic system before carrying out any kind of
maintenance or adjustment.
d) Depressurize all system sections and pressure pipes to be removed in accordance with
the specific instructions for the unit concerned before carrying out any repair work.
e) Hydraulic lines must be laid and fitted properly. Ensure that no connections are
interchanged. The fittings, lengths and quality of the hoses must comply with the
technical requirements.
f)
Only fit replacement components of a type provided by the manufacturer.
g) Always practice extreme cleanliness servicing hydraulic components.
h) Hydraulic fluid under pressure can penetrate the skin causing serious injury. Once the
fluid is injected under the skin, seek medical help immediately.
i)
If the fluid is injected under the skin, seek medical help immediately.
1.13.5. Necessary clothing and personal belongings shall be stored in such a manner as to not
interfere with access or operation.
1.13.6.Tools, oil cans, waste, extra fuses, and other necessary articles shall be stored in the tool
0066340-200-01Y.C
box, and shall not be permitted to lie loose in or about the cab.
1.13.7.The employer shall comply with Power Crane and Shovel Association Mobile Hydraulic
Crane Standard No. 2.
1.13.8.Operating and maintenance personnel shall be made familiar with the use and care of the
fire extinguishers provided.
1.13.9 Modified, altered and / or repaired cranes
the employer of the crane must conform with the requirements of 1926:1412
1.13.10 Wire rope inspections
the employer of the crane must conform with the requirements of wire rope inspections as per
the requirements of 1926.1413
1.13.11 Wire rope—selection and installation criteria
the employer of the crane must conform with the requirements of wire rope selection and
installation as per the requirements of 1926.1414
Chapter 2
Description of the crane
0066340-200-02Y.C
2.1 Product model
2.1.1 Product name plate and its position
0066340-200-02Y.C
2.1.2 Engine type and its manufacturer
QSL-C305——CUMMINS, USA
2.2 Terminology
2.2.1Boom configuration
S
SL
SW
SF
SFV
0066340-200-02Y.C
Instructions for boom configuration
Configuration
no.
Description
Parameters
S
Heavy duty boom
S =65′7″~272′3″
SL
Light duty boom
SL =282′1″~311′8″
SW
Luffing jib on heavy duty
boom
S=
75′5″~203′4″
W = 68′10″~196′10″
S = 95′1″~252′6″
SF
Fixed jib on heavy duty boom
F =34′9″~98′5″
SFV
Heavy fixed jib on heavy duty
S = 134′5″~252′6″
boom
FV =19′8″
0066340-200-02Y.C
2.2.2 Description of component parts
2.8
1.1
2.7
1.2
2.1
2.2
2.3
2.4
2.5
0066340-200-02Y.C
2.6
1.3
1.5
1.4
1.6
1.7
1.8
1.9
Description of component parts
Part No.
Description
Part No.
Description
1.1
Operator’s cab
2.1
Drive sprocket
1.2
Counterweight
2.2
Crawler carrier
1.3
Hoisting winch 1
2.3
Track carrier roller
1.4
Hoisting winch 2
2.4
Track roller
1.5
Slewing reducer
2.5
Driven sprocket
1.6
Main boom derricking winch
2.6
Central counterweight
1.7
Diesel oil tank
2.7
Track pad
1.8
Hydraulic oil tank
2.8
1.9
Engine
Note:
The luffing jib derricking winch (2.8) is optional.
Luffing jib derricking winch
0066340-200-02Y.C
2.3 Product description
2.3.1 Crawler travel gear
Travel gear
Maintenance-free crawler travel gear with 3′11″ track pad;
Distance between track center: 20′11″
Travel device
The crawlers driven independently through hydraulic motor and planetary reducer;
Allow such traveling moments available as traveling straight ahead/ backwards, turning on
the spot, turning with a crawler and differential steering
Drive performance
Infinitely variable speed from 0 to 0.98km/h
2.3.2 Crane superstructure
Slewing table
Self-manufactured and high-rigid welded structure of high-strength structural steel;
Connected to undercarriage via a 3-row roller slewing ring for 360°continuous rotation
Crane engine
6-cylinder four cycle diesel engine, manufactured by America Cummins, type QSL9-C305;
displacement :8.9L water-cooled, turbo charge, air cooling(air- air)
Rated power/rotational speed: 227kW (305HP) / 2000rpm;
Maximum torque/ rotational speed: 1505N.m /1400rpm
Type of starting equipment and voltage if applicable----- staring motor and 24V voltage
Type of generating equipment including---24V DC, negative ground, 2 batteries of 195AH
each.
fuel tank capacity------700L
altitude limitations-----≤9997′5″
cooling system refill capacity------44L
lubrication oil refill capacity-----23L
slope operation limitations-----30% of grade
Crane drive
Driving force, provided by diesel engine, is transmitted by transfer case to a dual variable
pump, a piston variable pump and a dual gear pump.
Crane control
CAN bus technology connecting engine, PLC controller and digital display;
All motions controlled independently by two 4-way control levers.
0066340-200-02Y.C
Winches
Used in hoisting mechanism and derricking mechanism
Slewing mechanism
Hydraulically powered by axial piston variable displacement pump and planetary reducer with
spring-loaded multi-disk brake;
The infinitely variable slewing speed from 0 to 1.0rpm by closed oil circuit.
Hoisting mechanism
available line pull------210kN(the six layer)
permissible line pull------147kN(the six layer)
available line speed-----109m/min(the six layer)
drum pitch diameter----2′1″ rope spooling capacity----1968′‐1″
Rear counterweight
187400 Ib, consisting of 10 counterweight plates 14600 Ib each and a 41900 Ib
counterweight base plate;
Fitted on the tail end of crane superstructure
Crane operator’s cab
Pressure-proof steel construction cab with safety glass;
With operator’s seat, operating and control instruments;
Swiveling sideways and tiltable backwards
Safety equipment
Angle indicator, load moment limiter, hoisting limit switch, overflow valves, support cylinder
locking device, derricking (luffing) limiter and so on
Electrical system
Single wire system; 24v DC; negative ground
The crane classification group is A1, and the classification group of working mechanism are:
traveling mechanism (M1), slewing mechanism (M2), hoisting mechanism (M3) and
derricking mechanism (M2).
Pumps
Type------ A8V0140LA1H2/63R1-NZG05F174
engine to pump speed ratio-----1.04
flow, L/min (gpm) at specified pressure, kPA (psi), and speed, rpm------2*285
maximum working pressure------42mpa
L/min
0066340-200-02Y.C
2.3.3 Overall dimensions
2.4 Technical data
2.4.1 Main technical parameter
a) Weight
Basic machine
187400 Ib
Rear counterweight
105800 Ib
Central counterweight
70600 Ib
Crawler carrier
2×55100 Ib
0066340-200-02Y.C
b) Speed
Mechanism
Hoisting winch 1
Speed
Rope diameter
360′9″ /min (maximum speed of single rope, the
Φ1.12″
360′9″/min (maximum speed of single rope, the 6th
Φ1.12″
6th rope layer)
Hoisting winch 2
rope layer)
Main boom derricking
winch
95′1″m/min (maximum speed of single rope, the
Φ1.12″
Luffing jib derricking
winch
150′10″/min (maximum speed of single rope, the
Φ1.12″
6th rope layer)
6th rope layer)
Slewing mechanism
0 - 1.0rpm
Gradeability
30%
2.4.2 Type of load hook and applicable rope reeving
Type of load hook
Maximum rope reeving
Weight of load hook (Ib)
573300 Ib
20
9300
352800 Ib /220500 Ib
12/8
6200
110250 Ib
4
3900
66150 Ib
2
2400
35280 Ib
1
2000
2.4.3 Hoisting rope reeving and specification of wire rope
2.4.3.1 Hoisting rope reeving table
1
Lifting
capacity
28665
2
8
Lifting
capacity
233730
61740
9
3
92610
4
15
Lifting
capacity
410130
260190
16
434385
10
286650
17
456435
121275
11
313110
18
478485
5
149940
12
337365
19
500535
6
178605
13
363825
20
573300
7
207270
14
388080
Reeving
Reeving
Reeving
Note:
1. If crane is working with hoisting rope reeving less than the value listed in the above
table, single hoisting rope load must be checked to make sure that the max.
permissible load capacity of single hoisting rope is not exceeded.
2. Maximum permissible load capacity of single rope is 33100 Ib.
0066340-200-02Y.C
2.4.3.2 Specification of wire rope
Description and
intended use
Hoisting rope for
winch1
Hoisting rope for winch
2
Derricking rope
Yes
Yes
No
Φ1.12″
Φ1.12″
Φ1.12″
Rope length
1574′4″
1574′4″
459′2″×2
Direction and type of
lay
Left-hand lang lay
Left-hand lang lay
Right-hand ordinary lay
Torsion-resistance or
not
Nominal rope
diameter
2.4.3.3 Use length of hoisting rope and derricking rope
When A-frame remains in its transport position on the superstructure, the shortest length
of derricking rope is about 65′7″;
When A-frame tilts forwards to maximum angle (i.e., the angle of A-frame to front
horizontal line reaches the minimum value), the longest length of derricking rope is about
705′2″
Crane operation with main boom: when main boom length is 114′9″ and the rope
reeving is 12, the longest possible hoisting rope is 1508′9″.
Crane operation with main boom and luffing jib: when main boom angle is 85°, main
boom length is 154′1″, luffing jib length is 88′6″ and the rope reeving is 5, the longest
possible hoisting rope is 1098′9″.
Crane operation with main boom and fixed jib: when main boom length is 252′6″, fixed
jib length is 39′4″ and the rope reeving is 3, the longest possible hoisting rope is 1197′2″.
0066340-200-02Y.C
2.4.4 Lifting height
Note: The main boom lifting height curve is drawn without considering boom deflection.
2.4.4.1 Lifting height on S&SL boom
Note:
1. The horizontal direction indicates working radius (in ft) and the vertical direction indicates
lifting height (in ft).
2. For S boom configuration, the heavy duty boom length varies from 65′7″~272′3″;
For SL boom configuration, the light duty boom length varies from 282′1″~311′8″.
0066340-200-02Y.C
2.4.4.2 Lifting height SF boom/fixed jib combination
Note:
1. The horizontal direction indicates working radius (in ft and the vertical direction
indicates lifting height (in ft).
2. For SF boom configuration, the main boom length varies from 95′1″~252′6″, the
fixed jib length varies from 34′9″~98′5″ and offset angle of fixed jib is 10° and 30°.
0066340-200-02Y.C
2.4.4.3 Lifting height on SFV boom/ heavy fixed jib combination
Note:
1. The horizontal direction indicates working radius (in ft) and the vertical direction
indicates lifting height (in ft).
2. For SFV boom configuration, the main boom length varies from 134′5″~252′6″ the
heavy fixed jib length is 19′8″, and offset angle of fixed jib is 14° and 20°.
0066340-200-02Y.C
2.4.4.4 Lifting height on SW boom/ luffing jib combination
Note:
1. The horizontal direction indicates working radius (in ft) and the vertical direction
indicates lifting height (in ft).
For SW boom configuration, the main boom length varies from 75′5″~203′4″
0066340-200-02Y.C
2. , and the luffing jib length varies from 68′10″~196′10″.
2.4.5 Lifting capacity charts
The valid lifting capacity charts for all machine configurations can be found in a special
volume.
Note:
1. The values in lifting capacity charts are applicable to 360° working range.
2. The value in lifting capacity charts is the rated total lifting capacity of crane,
which is the maximum permitted lifting capacity under various boom
configurations. It includes the weight of load hook, wire rope and other load
handling devices.
Rated total lifting
capacity =
Rated lifting
capacity
(Actual load)
+
(Weight of load hook,
wire rope and other load
handling devices)
3. The radius in lifting capacity charts is the horizontal distance from central axle of
slewing ring to centerline of hook when crane is loaded.
4. The rated total lifting capacity indicates the crane’s lifting capacity under
different boom configurations when it is operated on firm and flat ground.
Chapter 3
Safety Guidelines
0063640-200-03.CY
3.1 Operational planning
In addition to a perfectly working crane and a well-trained crew, operational planning is an
important precondition for safe and reliable crane operation.
The crane operator must obtain or receive the necessary information (familiarize himself with
the operating manual, basic knowledge about pneumatic, electrical and hydraulic drive, and
notes for safe operation as well as operating environment) before starting the crane operation,
in particular:
a) Clearly define the area of responsibility of all personnel concerned.
b) Type of crane operation and required working mode;
c) Distance between the lifting points and surrounding buildings;
d) Influence of communal facilities ( including the overhead high/low voltage lines and
underground gas pipes)
;
e) Space requirements at the work site
f)
Movement restrictions due to surrounding structures(e.g. is there another crane nearby in
working);
g) Number, weight, dimensions, material of load(s) to be lifted
h) Required lifting height and slewing radius
i)
Load-bearing capacity of soil or surface to be operated upon
j)
Height and widths of thoroughfares leading to the site;
k) Other factors affecting the site (e.g. weather, live lines, etc.);
l)
Communication means adopted between signalman and crane operator;
m) Take appropriate measures to keep people unconcerned and equipment away from the
working area;
n) Equipment modifications: the employer of the equipment shall adhere to the requirements
of 1926:1434
Based on the above information, the crane operator must assemble the equipment required to
operate the crane:
- Required working mode for crane operation
- Hook blocks/load hook (with or without hook blocks)
- Counterweight
0063640-200-03.CY
Caution:
1. A correct and complete operational planning is vital for safe and problem-free
operation of the machine. The operation planner must plan a safe and reliable
operational planning by obtaining and analyzing all necessary information about
the operation and considering all the factors that may impair safety of crane
operation.
2. If the crane operator does not possess all necessary and required information, it
may prove impossible to carry out the intended work and accidents may be the
result!
3.2 Safety—Technical Notes
3.2.1 Safety Instructions
3.2.1.1 Safety instructions for crane operator
The crane operator’s primary responsibility is to control, operate and adjust the crane in a
manner that is safe for both himself and others. Therefore the crane operator should meet
the following requirements.
a) The operator must be familiar with the operating manual for the crane, and know the
working principle, structure performance and the safety devices’ function, as well as
master the operation essentials and maintenance skills.
b) The operator should inspect brake, hook, wire rope and safety device before operating
the crane. Any irregularities detected during inspection should be removed
immediately.
c) The operator must focus his attention on his work during operation and is forbidden to
chat with others. Generally speaking, operator can only follow signal sent out by
appointed persons. For a stop signal, the operator should obey it at all times, no matter
who gives it. He should refuse to accept signal which violates operation regulations.
0063640-200-03.CY
Stop the crane immediately if somebody is found climbing the crane.
d) Operator who is in low spirits or poor healthy is not allowed to operate the crane.
e) Crane operator and slinger/banks man should be familiar with safety rules, signals and
symbols. Prohibit drinking and driving.
f)
Be qualified with the work in hearing, eyesight and reaction ability; be strong enough to
operate safely, and has the ability to estimate distance, height and clearance correctly.
g) Be familiar with the usage of fire extinguishing equipment and be well trained; know
how to survive under emergent conditions.
h) Make sure that only authorized personnel are allowed to operate the crane.
To make sure that the crane is kept in good working order, the crane operator should
perform the following checks before operating the crane:
a) Check the daily record of work to ensure that all regular inspections, maintenance and
repair work is performed.
b) Check the hoisting limiter, boom angle indicator, tilting-back support and other safety
equipment for functional work;
c) Check the load-bearing parts carefully, such as wire rope (hoisting rope, derricking
rope and sling etc.), boom, outriggers, hook and load handling devices;
d) Check if there are some bolts, nuts and pins lost, and the components are cracked or
damaged.
e) Ensure that no modification has been made to the crane without permission, e.g.,
increase or decrease in counterweight plate and improper repair of boom frame.
f)
Check fuel lines and hydraulic oil lines for leakage.
g) Check all control mechanisms for functional work after starting up the engine.
h) Check all control devices for functional work.
i)
Check the brakes. Test the braking performance by lifting a load away from the ground and
suspend it in the air for a moment.
j)
Check whether lubricating oil, grease or anti-freeze liquid is sufficient.
k) Check for contamination.
0063640-200-03.CY
The following improper operating errors, which are made again and again while operating,
should be avoided.
a) Slewing too quickly;
b) quick braking of the load;
c) diagonal pulling of the load to be lifted which is still in contact with the ground;
d) Loose wire rope formations;
e) overloading or improperly attaching the load;
f)
driving(or slewing) too fast with a load, or setting up and loading on an uneven surface;
g) diagonal pulling, breaking away stuck loads;
h) swinging of suspended load, crashing into bridges, roofs or high voltage wiring;
i)
Incorrect assembly or disassembly of booms
3.2.1.2 Safety instructions for the rigger
The rigger’s job is to hang or detach load from hook and to decide which hook or component to
be used in accordance with work plan. rigger also has the responsibility to guide operator’s safe
operation.
Qualifications for rigger:
a) With crane operation certificate;
b) Be qualified with the work in hearing, eyesight and reaction ability;
c) Be strong enough to carry hook or component;
d) Be able to estimate the load, balance the load and judge the distance, height and
clearance correctly;
e) Be trained in the skill of handling load;
f)
Be able to choose proper load handling device and components according to the loading
condition;
g) Be trained in hand signals for operation and familiar to use them;
h) Be able to safely use audio equipment (such as interphone) to send out oral order
exactly and clearly;
i)
Be capable of conducting the operation of crane to move the load safely;
j)
Make sure that only authorized personnel are allowed to carry out work.
0063640-200-03.CY
3.2.1.3 Safety instructions for the signalman
The main job of signalman is to assist crane operator to carry out safe operation. Potential
damage to property or personal injury could be avoided if the crane operator carries out the
crane movement following the signals given out by appointed signalman. However, only
one signalman may work with the crane operator at a time.
Qualifications for signalman:
a)
Familiar with the lifting task so as to cooperate with crane operator and other workers;
b) Make sure that only authorized personnel are allowed to carry out
work;
c) Be qualified with the work in hearing, eyesight and reaction;
d) Be able to estimate the distance, height and clearance correctly;
e) Be trained in hand signals for operating and familiar to use them;
f)
Use standard hand signals for crane operation. If necessary, use a
radio device to send out correct and clear order;
g) Be capable of conducting the operating of crane to move the load safely;
h) Position himself in a safe location from where he can see the whole process of
operation and be seen clearly by the crane operator.
Danger:
In order to assure yourself and other person’s interest, please operate crane in
accordance with specified regulations, and take precautions against possible
dangers caused by improper operation.
3.2.1.4 Points for attention for crane operating crew
a) Any unsafe operation must be corrected or any dangerous situations must be reported
to supervisor.
b) All the persons in vicinity of crane must observe the acoustic warning signals of the
machine so as to ensure himself and others safety.
c) All the worker must know about the content of task and working sequence;
d) Check whether dangerous situations occur during operation of the machine, and inform
crane operator and signalman of the unsafe factors such as high-voltage power line,
unauthorized persons, obstacles and poor ground conditions.
3.2.2 Selecting an operating site
It is very important to choose an appropriate location for crane operation in order to minimize
safety risks. The operating site should be selected so that:
a) crane movement can be carried out within the smallest possible radius;
0063640-200-03.CY
b) no obstacles hinder necessary movements;
c) the ground an the operating site is able to support expected loads;
d) Accessible areas within the swing radius of the rear of the rotating
superstructure of the crane, either permanently or temporarily mounted, shall
be barricaded in such a manner as to prevent an employee from being struck
or crushed by the crane
Danger:
The most essential requirement for safe crane operation is working on firm ground with the
capacity to support you loads.
3.2.3 Slopes and trenches
The crane may not be set up too close to slopes or trenches. A safety distance must always
be kept from them depending on the type of soil.
Note:
Safety distance is measured from the foot of the trench and is:
Soft or backfilled soil = 2× depth of trench (A2 = 2×T)
Hard or grown soil = 1×depth of trench (Al = 1×T)
Danger:
If a safe distance is not maintained, the slope or trench must be firmly filled. Otherwise,
there is a danger that the edge of the slope or trench will give away.
3.2.4 Permissible ground pressure
Soil type
A) back-filled, not naturally compacted ground
B) Natural soil, apparently undisturbed
10-1MPa
0 - 1
0063640-200-03.CY
1. mud, peat, marshy soil
0
3. non-cohesive, sufficiently compactly layered soil:
Fine to medium grained sand;
From coarse-grained sand to gravel
5
3.0
3. cohesive soil:
loamy;
soft;
stiff;
Semi-solid;
hard
0
4
0
0
4.0
4. rock with few fissures, in healthy, un-weathered
condition and in a favorable location:
In cohesive layer order
In massive or column-style shape
15
30
C) artificially compacted ground
5 - 15
1. asphalt;
3. concrete
concrete group B I;
Concrete group B II
50 - 250
350 - 550
Caution:If there is any doubt about the load-bearing capacity of the ground at the operating
site, soil test should be carried out, for example, with a penetrometer.
3.2.5 Checking safety measures
The safety condition of the crane should be checked thoroughly prior to operating the crane,
including:
a) Check whether the ground provides adequate load-bearing capacity.;
b) Check whether there is sufficient safety clearance to slopes and trenches;
c) Check whether the crane is adjusted to be horizontal;
d) Check whether there are live electrical wires within the working range of the crane.
e) Check whether there are obstacles which will hinder required crane operation.
working radius:
0063640-200-03.CY
Caution:
The crane operation belongs to dangerous operation; so much attention should be given to
the working condition of crane before and during crane operation.
3.2.6 Crane operation with a load
Before beginning any work, the crane operator must be convinced that the crane is in safe
operating condition. All safety devices, such as load moment limiter, hoist limiter switches,
brakes, etc., are in good working order.
a) The load moment limiter must be set according to the current crane configuration.
b) The load capacities as given in the load lifting capacity tables must be adhered to. The
loads given in the load lifting capacity tables must not be exceeded.
c) The crane operator must know the weight and dimensions of the load before operating
the crane.
d) Load handling devices, lifting equipment and tackle must be in accordance with specified
requirements.
e) It must be ensured that the weight of the hook block and the weight of the tackle are
subtracted from the load given in the lifting capacity table.
Example:
Maximum permissible load according to table
66150 Ib
Weight of the hook block
2359 Ib
Weight of the slinging rope
Actual useful load of the crane
In this case, the load to be lifted may no exceed 63702 Ib
88 Ib
63702 Ib
0063640-200-03.CY
3.2.6.1 Counterweight
The required counterweight should be installed prior to operation according to specified
requirements.
Danger:
If the counterweight is not installed according to the lifting capacity table, there is a danger
of the crane toppling over.
3.2.6.2 Hoisting gear, hoisting rope
The lifting capacity of the crane is a function of the tension force of the hoisting rope and
hoisting rope reeving. When working with a single cable, the crane can only lift as much of
a load as the hoisting gear is able to pull.
If the load to be lifted is heavier than the hoisting gear is capable of lifting, the hoisting rope
must be configured using block and tackle principles by appropriate reeving between the
pulley head on the boom and the hook block. Possible hoisting rope reeving is listed as
follows:
Hoisting rope reeving
reeving
Lifting load
reeving
lifting load
reeving
lifting load
1
28665
8
233730
15
410130
2
61740
9
260190
16
434385
3
92610
10
286650
17
456435
4
121275
11
313110
18
478485
5
149940
12
337365
19
500535
6
178605
13
363825
20
573300
7
207270
14
388080
Caution:
1. If crane is working with hoisting rope reeving less than the value listed in the above table,
single hoisting rope load must be checked to make sure that the max. permissible lifting
capacity of single hoisting rope is not exceeded.
2. Max. permissible lifting capacity of single hoisting rope is 33075 Ib
3. If the maximum tensile force is exceeded, there is the danger that the rope(s) may break or
that the hoisting gear and /or drive motor may be damaged.
0063640-200-03.CY
3.2.6.3 Crane operation
3.2.6.3.1 Operating conditions
a) All components of crane are in running-in state at the initial operating period. So, for the
first 100 operating hours, the working load should not be too great and the working speed
should not be too high. The maximum lifting load can not exceed 80% of its rated load.
And the maximum working speed is forbidden.
b) The ground on jobsite should be firm and flat and the gradient should not be greater than
5/1000. The complete vehicle should be level and the supporting ground should not give
away during operating. If the ground is soft, a steel plate should be placed under the track
shoe.
c) The permitted temperature range for crane’s operation is-20℃~40℃. Humidity should
not exceed 85%; however, high humidity up to 100% is only permitted for a short period
of time. The crane should be operated and supported on a ground lower than 1000m
above seal level.
0063640-200-03.CY
d) The maximum in-service wind speed should be not more than 9.8m/s during operation;
the maximum out-of-service wind speed should be no more than 21m/s when only main
boom is assembled, and no more than 15m/s when fly jib is assembled.
With the following table, the wind force and wind velocity can be estimated correctly:
Wind force beaufort
Wind force
Effects of the wind in the inland
Beaufort
description
m/s
0
Calm
0~0.2
1
Light air
0.4~1.4
Wind direction is shown only by observing the trail of
smoke, not by the wind sock
1.6~3
Wind can be felt on the face, the leaves rustle, wind
sock moves slightly
2
Light
breeze
No wind, smoke rises straight up
3
Gentle
breeze
3.4~5.3
Leaves and thin twigs move. Wind extends a small
breeze flag.
4
Moderate
breeze
5.5~7.8
Swirls up dust and loose paper, moves twigs and thin
branches
5
Fresh
breeze
8~10.6
Small deciduous trees begin to sway, foam forms at
sea.
6
Strong
breeze
10.8~13.7
Thicker branches move; telephone lines begin to
whistle, umbrellas are difficult to use
7
Stiff wind
13.9~17
8
Gale force
wind
17.2~20.6
9
Gale
20.8~24.5
10
Severe
gale
24.7~28.3
Entire trees swaying; difficult to walk into wind
Breaks twigs off trees, walking becomes difficult
Minor damage to property(chimney tops and roofing
tile are blown off)
Trees are uprooted, significant damage to property
0063640-200-03.CY
e) When crane is working near the high-voltage power line, the safe clearance between any
part of crane and overhead power line should comply with the following regulations:
Cutline:
The safe clearance from high-voltage power lines:
Operation near high-voltage power lines
Ft(m)/Note(l)
Up to 50
10/3.05
Over 50 to 200
15/4.60
Over 200 to 350
20/6.10
Over 350 to 500
25/7.62
Over 500 to 750
35/10.67
Over 750 to 1000
45/13.72
Over
1000
(as established by the utility owner/operator or registered professional
engineer who is a qualified person with respect
to electrical power transmission and distributiono)
Note: the volue that follows “to” is up to and includes that value ,for example over 50 to 200
means up to and including 200kv.
Opertion in transit with no load and boom or mast lowered
Ft(m)/Note(l)
Up to 0.75
4/1.22
Over 0.75 to 50
6/1.83
Over 50 to 345
10/3.05
Over 345 to 750
16/4.87
0063640-200-03.CY
Over 750 to 1000
20/6.10
Over 1000
(as established by the utility owner/operator or registered professional
engineer who is a qualified person with respect
to electrical power transmission and distributiono)
aa) Equipment or machinery, have been erected to prevent physical contact with the lines,
equipment or machines shall be operated proximate to power lines only in accordance with the
following:
bb) For lines rated 50 kV. or below, minimum clearance between the lines and any part of the
crane or load shall be 10 feet; Except where electrical distribution and transmission lines have
been deenergized and visibly grounded at point of work or where insulating barriers, not a part
of or an attachment to the
cc) For lines rated over 50 kV, minimum clearance between the lines and any part of the crane or
load shall be 10 feet plus 0.4 inch for each 1 kV. over 50 kV., or twice the length of the line
insulator, but never less than 10 feet;
dd) In transit with no load and boom lowered, the equipment clearance shall be a minimum of 4
feet for voltages less than 50 kV, and 10 feet for voltages over 50 kV, up to and including 345
kV., and 16 feet for voltages up to and including 750 kV.
ee) A person shall be designated to observe clearance of the equipment and give timely warning
for all operations where it is difficult for the operator to maintain the desired clearance by
visual means;
ff) Cage-type boom guards, insulating links, or proximity warning devices may be used on cranes,
but the use of such devices shall not alter the requirements of any other regulation of this part
even if such device is required by law or regulation;
gg) Any overhead wire shall be considered to be an energized line unless and until the person
owning such line or the electrical utility authorities indicate that it is not an energized line and
it has been visibly grounded
f)
Only the crane without fault is allowed to work.
0063640-200-03.CY
3.2.6.3.2 Instructions for Safety Operation
a) No person is allowed to stand under boom when crane is operated.
b) No person is allowed to stand on slewing table during operation.
c) It is forbidden to lift load over people.
d) It is forbidden to lift the load when someone is standing on it.
e) Overloading operation and lifting staggered load is prohibited. Never pull load
obliquely.
0063640-200-03.CY
f)
It is forbidden to lift load hidden in the ground or frozen on the ground.
g) The crane can travel with a load of 70% of the rated load. In this case, the ground
should be firm and its gradient should not be more than 5/1000. The driving speed
must be less than 0.5km/h. The boom frame must be located in the driving
direction.
h) If the crane is operated in the vicinity of transmission systems (e.g. transmitters),
strong electromagnetic field will be generated there, so measures should be taken
to protect the crane against high frequency interference and all workers who stand
on large metal plate should wear special isolating gloves and clothes to avoid
being burnt.
aa) Prior to work near transmitter towers where an electrical charge can be induced in the
equipment or materials being handled, the transmitter shall be de-energized or tests shall be
made to determine if electrical charge is induced on the crane. The following precautions
shall be taken when necessary to dissipate induced voltages:
bb) The equipment shall be provided with an electrical ground directly to the upper rotating
structure supporting the boom; and
0063640-200-03.CY
cc) Ground jumper cables shall be attached to materials being handled by boom equipment
when electrical charge is induced while working near energized transmitters. Crews shall be
provided with nonconductive poles having large alligator clips or other similar protection to
attach the ground cable to the load
dd) Combustible and flammable materials shall be removed from the immediate area prior to
operations
i)
The brake of hoist mechanism is not allowed to be adjusted when the crane is
lifting a load.
j)
Under any condition, there must be three windings of wire rope left on the hoisting
drum.
k)
When a load is suspending in the air, the operator is not allowed to leave the cab.
l)
Operation
and
gently.
jerkily and carry
abruptly.
should be carried out stably
Never operate control lever
out switchover operation
0063640-200-03.CY
m)
When actual load reaches 90% of the rated one, the load moment limiter will
sound an alarm, to which high attention should be given.
n)
Getting on and off the crane should be careful to avoid casualty.
o)
It is prohibited to make any modifications to the crane without permission;
otherwise you should take the consequences.
p) Stop the crane operation if one of the following conditions occurs:
1) The crane is overloaded or the weight of load is uncertain;;
2) Load’s binding or hanging is not good or load may fall due to imbalance;
0063640-200-03.CY
3) No protective mat is added between the edges of load and wire rope;
4) In case of poor visibility and /or darkness, it is difficult to identify load or conduct
signal;
5) There is defect or damage of configuration or components which will impair
safe operation, for example, the brake and safety equipment fail, or the wire
rope is damaged etc.
q)
Anyone is
hook, slings or load.
not permitted to climb on the load
0063640-200-03.CY
r)
Leave an ample space for stopping crane; otherwise persons nearby may be hurt
by crane counterweight due to narrow distance between counterweight and
surrounding building.
s)
Keep the windows of crane operator’s cab clean to ensure good visibility; stop
crane operation immediately in case of poor visibility; replace the broken window
as soon as possible.
t)
Persons may only access and leave the crane following permission from the
crane operator and only when the crane is at a complete standstill!
u)
Keep crane clean and dry, since slippery walkway, ladder, tools or loose parts
0063640-200-03.CY
may cause operator to fall down from crane.
v)
Do not lift the load which adheres to other objects forcibly. Otherwise, crane may
topple over, boom frame may buckle or objects may be damaged. Therefore, the
operator must ensure that the load is not in contact with other objects before
lifting.
w) Drive crane with great cautiousness, in working site or not. Observe the
conditions surrounding crane such as overhead power line, low-lying land, narrow
clearance, restriction to bridge and road, uneven ground and gradient of road. If
necessary, appoint a signalman to assist operator to move crane. Lock slewing
mechanism during traveling.
x) It is more dangerous that two cranes carry out lifting operations together.
Therefore, a careful calculation must be made before commencing the work, and
following import requirements for this type of operation must be observed.
1) The load is not casually attached to the crane. It must be calculated carefully
so that the actual lifting capacity of crane can not exceed the rated lifting
capacity.
2) Ensure that each lifting tackle can bear specified load weight which is
calculated during design.
3) The crane operator, signalman and other worker must evaluate the operational
planning together before operation.
4)
Ensure that crane can move properly in the whole process of operation.
y) When you leave the machine in an emergency, you are putting your lift at risk.
Therefore, you must take following measures prior to leaving the machine.
1) Detach the load from the hook and set it down on the ground; if necessary,
lower the boom frame;
2) Apply slewing brake or lock slewing mechanism;
3) Apply parking brake;
4) Lock traveling mechanism;
5) Cut off power supply or switch off engine;
z) Do not wear loose clothing, scarves, open jackets or open shirt sleeves, and do
not wear jewellery (rings, bracelets, earrings or similar). Otherwise, there is
serious danger of injury from being pulled into moving machine parts.
0063640-200-03.CY
aa) Do not stop crane near the bank which is possible to collapse or on low-lying
land that may be washed down by water.
bb) Take away the key when machine remains idle. In this way, the unauthorized
person can not start the machine without permission.
cc) Unqualified person is forbidden to repair crane and change parts.
3.2.6.3.3 Preparation for crane operation
Crane operator should perform the following checks before operating the crane:
a) Check the daily record of work to ensure that all regular inspections maintenance and
repair works are performed.
b) Check the hoisting limiter, boom angle indicator, tilting-back support and other safety
equipment for functional work.
c) Check if the load-bearing parts such as wire rope (hoisting rope, derricking rope and
sling etc.), boom, outriggers, hook and load handling devices are kept in good
working order.
d) Check if there are some bolts, nuts and pins lost, and the components are cracked or
damaged.
e) Ensure that no modification has been made to the crane without permission, e.g.,
increase or decrease in counterweight plate and improper repair of boom frame.
f) After starting up the engine, check if the values shown on instruments are normal.
g) Check fuel lines and hydraulic oil lines for leakage.
h) Check all control mechanisms for functional work.
i) Check brakes and clutch. Test the braking performance by lifting a load away from the
ground and suspend it in the air for a moment.
j) Keep communication between the operator and rigger.
0063640-200-03.CY
k) Estimate the weight and dimensions of load to be lifted in advance.
l) Crane operation can be carried out within minimum working radius. No obstacles
hinder the necessary movements. The ground at the operating site is able to support
expected loads.
m) Ensure that no obstacles are within working radius and operator can see the load
clearing from the cab. Check if the communication between operator and signalman
is kept smooth so as to ensure safe crane operation.
n) Determine the load-bearing capacity of ground to be operated upon. Ensure that
crane is supported properly and never operate the crane on the soft and uneven
surface or on the ground of high water content or covered with frozen soil. If crane is
set up close to trenches, reinforce the trenches to avoid landslide. If the ground does
not have adequate load-bearing capacity, the crane is liable to turnover. In this case,
crosstie, steel plates should be padded underneath the crawler to distribute load so
that the load-bearing capacity of the ground will not be exceeded; make sure that the
crane is leveled.
3.2.6.3.4 Notes for crane operation
a) Estimate the weight and dimensions of load to be lifted in advance.
b) Use load handling devices (wire rope or chain) correctly. Make the vertical line of
hook pass through center of gravity of load.
c) If any part of crawler crane or load handling devices come in contact with high-voltage
line, or emergent situation occurs, the operator should stop the vehicle at once.
d) The load capacities as given in the load lifting capacity tables must be adhered to.
The loads given in the load lifting capacity tables must not be exceeded. Driving(or
slewing) too fast with a load, or setting up and loading on an uneven surface, and
swinging of suspended load should be avoided.
e) Diagonal pulling of the load to be lifted which is still in contact with the ground is
prohibited.
f) It should be avoided that the load or auxiliary lifting device collides with structural
members of crawler crane.
g) If crane gets caught in a thunderstorm during operation, following measures should
be taken at once:
-- Stop work on the crane immediately
--always set down the load and boom frame on the ground.
--apply brake or lock winch and slewing gear
--switch off the crane engine and cut off the power of load moment limiter and limit
switch
0063640-200-03.CY
--ask all crane workers to leave away.
h) If the crane is struck by thunderbolt, following checks should be performed:
--check whether there are burnt or damaged components
--check the performance of electrical parts and load moment limiter
--check the associated components for functional work
i) If earthquake occurs when crane is operated, following measures should be taken
immediately:
-- Stop work on the crane immediately
--always set down the load and boom frame on the ground.
--apply brake or lock winch and slewing gear
--switch off the crane engine and cut off the power of load moment limiter and limit
switch
--ask all crane workers to leave away.
After earthquake, following checks should be performed prior to crane operation:
--check the performance of electrical parts and load moment limiter
--check the associated components for functional work
j) If any part of crawler crane or load handling device is in contact with high-voltage lines,
the best way to guarantee the personal safety of operator is to stay in operator’s cab
until the danger is obviated. If operator must leave the crane, he’d better jump rather
than climb down the cab.
k) The operator’s cab should be equipped with an emergency hammer which can be
used to smash the window in an emergency so that operator can run away from the
cab.
l) The load moment limiter, once be triggered, should be kept in that state until the crane
is not overloaded.
m) If the load moment limiter is not set to the actual configuration status of the crane, it
can not fulfill its function as a safety device.
n) Examine if the angle indicators and the strain gauges are in function.
o) The crane may topple over backwards if a load is suddenly freed since the tension
created in the boom can cause it to jerk back violently.
p) Make sure that the loads and working radius contained in the lifting capacity tables
are not exceeded.
q) When working in the vicinity of power cables, a sufficient safety clearance must be
maintained, if the cables are not isolated by electricity engineers or the hazardous
0063640-200-03.CY
area is not fenced off.
r) For all crane movements, the crane operator must always keep the load, as well as
the crane hook or loading equipment when the crane is not loaded, in his field of
vision. If this is not possible, the crane operator may only operate the crane according
to instructions given to him by a signalman. These instructions may be given in the
form of hand signals or over a two-way radio. Whatever method is used, precautions
must be taken to eliminate the risk of misunderstanding.
s) All employees shall be kept clear of loads about to be lifted and of suspended loads
Note:
If, despite all precautions having been taken, a flashover occurs, carry out the following
procedure:
1. Keep calm!
2. Do not leave the crane cab.
3. Warn those around the crane not to move and not touch the crane.
4. Move the crane away from the danger area.
Not adhering to the above points may lead to risk of accidents or damage!
3.2.6.3.5 Checks after operation
a) When crawler crane and auxiliary lifting device are in non-working condition, never
park the vehicle near the embankment liable to collapse or low-lying land subject to
be washed by water.
b) Set down the load on the ground, and if necessary low the boom frame to some
extend; lock the slewing gear and traveling gear and apply the brake.
c) Shut down the engine and cut off power.
d) Check if there is leakage in someplace and repair it if necessary.
e) Clean such components as movable parts and exposed part of the piston rod of
cylinder.
f) Check if bolts and nuts are fitted tightly. Any defects found should be eliminated at
once. It is prohibited to operate the crane with fault.
g) Record the operating conditions and abnormal symptoms.
h) Check if the quantity of tools and accessories meet specified requirements.
i) Lock the operator’s cab or safety devices.
j) Take precaution measures against storm or lightning strikes.
k) Take precaution measures against frostbite in winter.
0063640-200-03.CY
Caution:
To avoid engine from freezing in winter, drain all cooling water when park the vehicle, if no
anti-freeze is added into the cooling water.
3.2.7 Electromagnetic influences
Strong electromagnetic fields are likely to be present if the construction site is close to a
transmitter.
Caution:
These electromagnetic fields can pose direct or indirect danger to persons or objects, for
example:
1. Effect on human organs due to temperature increase.
2. Danger of burns or inflammation due to temperature increase.
3. Spark or electric arc formation.
In any case, before working with the crane near transmitters, contact Zoomlion representative.
In addition, consult a high frequency specialist.
l)
Every crane must be “totally” grounded. Check visually or with a simpler tester to ensure
that ladder, cab and cable pulleys are grounded.
m) All personnel working on the crane or with large metal objects must protect themselves
from burns by wearing non-conductive gloves and suitable clothing while working.
n)
If one feels an increase in temperature, there is no need to panic. Always work under
the assumption that the respective workpiece, structural steel member or support is
“hot”.
o)
The temperature of objects affected by high frequency radiation depends on their ‘size”.
Cranes, carriers and coverings, for example, are “hooter”.
p)
Contact with other crane loads is not permitted when operating the crane (arcing). Since
defects caused by burns considerable reduce rope carrying capacity, any such
occurrences must be reported immediately to the machinery supervisor so that the
ropes can be inspected.
q)
An insulator is required at all times between the crane load hook and tackle. It is strictly
prohibited to remove this insulator.
r)
The ropes may not be touched above the insulator. This is strictly prohibited!
s)
Crane with attached loads may not be touched by any unprotected parts of the body
after the load has been lifted or set down.
t)
Do not work with a bare upper torso or in short pants, this is prohibited.
u)
To minimize absorption of high frequency radiation, large loads should be transported
horizontally if possible.
v)
Loads must be grounded, or additional insulation used (rubber material between the
object and gloves) when manual work is required.
w) To avoid accidents, use a safety belt when working on components that are high off the
ground.
0063640-200-03.CY
x)
Handling explosive matter (such as refueling) may only be carried out at least 6 m away
from the place where sparks could form due to handling of larger metal parts. Use only
conductive rubber hoses to refuel.
y)
Any accidents and unexpected events must immediately be reported to the local
construction supervisor and the safety engineer.
3.2.8 Safety Signs
1) Warning: Suspended load
2) Warning: Dragging/entanglement
3) Danger: Crush hazard
4) Warning: Crushing/collisions
0063640-200-03.CY
5) Note: Lift point
6) Warning: Risk of falling
7) Danger: snagging/dragging
8) Danger: Risk of burn
9) Prohibited: No access for
unauthorized personnel
0063640-200-03.CY
10) Prohibited: Access prohibited
11) Warning: Keep off outriggers
12) Prohibited: Naked flames
13) Note: First aid kit
14) Note: Fire extinguisher
0063640-200-03.CY
15) No standing under the boom.
16) Be careful in the working radius.
As to the position of safety signs, please see following diagrams.
15
9
12
1
2
9
6
9
6
Safety signs position diagram 1
2
0063640-200-03.CY
15
13
9
2
9
6
9
6
2
Safety signs position diagram 2
9
Safety signs position diagram 3
13
0063640-200-03.CY
3
4
11
16
11
4
Safety signs position diagram 4
8
6
12
14
7
12
Safety signs position diagram 5
0063640-200-03.CY
Caution:
1. When the safety sign is damaged or illegible, please order it from appointed service
supplier.
2. It is forbidden to cover or take off safety signs casually.
3. If the safety sign is covered with dust, clean it in time.
4. The operator’s cab should be equipped with an emergency hammer which can be used
to smash the window in an emergency so that operator can run away from the cab.
0063640-200-03.CY
3.2.9 Hand Signals for Controlling Crane Operations
0063640-200-03.CY
0063640-200-03.CY
Caution:
1. We recommend using the hand signals illustrated above. However, users can decide
on their own hand signals depending on actual condition, as different countries and
regions may differ in the expression of hand signals.
2. Hand signals must first be discussed and mutually agreed upon and clearly executed.
Misunderstand of hand signals may lead to serious accidents.
3. In any case, national traffic regulations must always be observed when abroad.
Chapter 4
Crane operation
0066340-200-04Y.C
4.1 Operating and control instruments
4.1.1 Overview of crane operator’s cab
15
0
14
0
1
2
3
13
4
12
11
5
6
10
7
8
9
Overview of crane operator’s cab
0066340-200-04Y.C
Components in crane operator’s cab
No.
Description
Position and function
1
Fan
2
Interior light
3
Monitor
Display the images from the video camera near the slewing
table
4
Right control panel
The rocker switches, rotary switches and ignition starter
switch are fitted on the control panel. (For details, see
Section 4.1.4 and 4.5)
5
Digital display
system
Consists of display of load moment limiter and display of
control system
(For details, see Section 4.2)
6
Front windshield
wiper
At the bottom of front windshield
7
Accelerator pedal
Control the engine speed
8
Foot-operated
switch
9
Rearview mirror
At front left side of operator’s cab
10
Control box, left
Control the motions of hoisting winch 2, slewing mechanism
and left crawler. (For details, see Section 4.1.2 and 4.5)
11
Control box, right
Control the motions of hoisting winch 1, derricking
mechanism, right crawler and self-assembly & dismantling
mechanism. (For details, see Section 4.1.3 and 4.5)
12
Working floodlights
13
CD player
14
Roof windshield
wiper
15
Warning light
At the rear right side of operator’s cab
On the top of operator’s cab
Actuate the horn
Two working floodlights, front;
One working floodlight, rear
At the roof of operator’s cab
At the rear left side of operator’s cab
0066340-200-04Y.C
4.1.2 Left control box
19
20
18
17
16
21
25
22
23
24
26
Components of left control box
No.
Names of the components
Remarks
16
Emergency stop button
17
Left control lever
18
Deadman’s button
19
High-speed switch
20
“Swing free running” switch
21
Symbol “reel off H2”
H2 refers to hoisting winch 2
22
Symbol “spool up H2”
H2 refers to hoisting winch 2
23
Symbol “left crawler forwards”
24
Symbol “left crawler
backwards”
25
Symbol “slew to the left”
26
Symbol “slew to the right”
For details, please refer to section 4.4.1
Control the high speed of slewing movement. For
details, please refer to section 4.5.4.
For details, please refer to section 4.5.4.3
0066340-200-04Y.C
(1) The crane movements can be carried out only when deadman’s button is pressed.
(2) The crane movements can still be carried out before the control lever is returned to
neutral position with deadman’s button released. However, to perform the next
crane movement after returning the control lever to neutral position, the operator
must press deadman’s button first and then move the control lever. Otherwise, the
operation of control lever is invalid.
(3) In normal condition, stop the crane movements by returning the control lever to
neutral position.
(4) Make sure that the emergency stop button is triggered when needing to connect
the power or start up the engine again.
0066340-200-04Y.C
4.1.3 Right control box
30
29
27
28
31
33
35
37
38
32 34 36
Components of right control box
No.
Names of the
components
27
Right control lever
28
Deadman’s button
29
Switch
Remarks
Not assigned
Control the high speed of hoisting winch1, hoisting winch 2,
luffing jib derricking winch and travel gear. For details, please
refer to section 4.5.
30
High-speed switch
31
Symbol “extend
mounting cylinder on
A-frame”
Reserved
32
Symbol “retract
mounting cylinder on
A-frame”
Reserved
33
Symbol “reel off H1”
H1 refers to hoisting winch 1
34
Symbol “spool up
H1”
H1 refers to hoisting winch 1
35
Symbol “right crawler
forwards”
36
Symbol “right crawler
backwards”
0066340-200-04Y.C
37
Symbol “spool up
E/W1”
E refers to derricking winch, and W1 refers to luffing jib
derricking winch (spare)
38
Symbol “reel off
E/W1”
E refers to derricking winch, and W1 refers to luffing jib
derricking winch(spare)
(1) The crane movements can be carried out only when deadman’s button is pressed.
(2) The crane movements can still be carried out before the control lever is returned to
neutral position with deadman’s button released. However, to perform the next
crane movement after returning the control lever to neutral position, the operator
must press deadman’s button first and then move the control lever. Otherwise, the
operation of control lever is invalid.
(3) In normal condition, stop the crane movements by returning the control lever to
neutral position.
0066340-200-04Y.C
4.1.4 Control panel assy.
39
40
41
42
43
44
45
46
47
48
49
50
Rocker switches on the control panel
Description of the rocker switches
No.
Names of the
rocker switches
39
Master lighting
switch
40
“Working floodlight”
switch
41
“Cold-start on/off”
switch
Control the cold-start of the engine
42
Controller power
supply switch
Control the power supply of PLC controller and
LCD screen
The key
Remarks
1st position: The LED on the switches of control
panel lights up;
nd
2 position: master lighting switch
Control all the working floodlights on the crane
0066340-200-04Y.C
No.
Names of the
rocker switches
43
“Front windshield
wiper” switch
44
“Low-speed” switch
For details, please refer to section 4.5
45
“Automatic
lubrication system”
switch
Lubricate the superstructure lubricating points
automatically.
46
“Front windshield
washer” switch
47
“Oil cooling fan”
switch
The key
Remarks
Control the front windshield wiper
Control the front windshield washer
Pressing this switch can cool the hydraulic oil
48
“Engine shutdown”
switch
Pressing this switch can shut down the engine
Press the “engine shutdown” switch and hold it
for more than 30 seconds, the working hours of
the engine can be saved. In normal situation,
using the ignition key switch to stop the engine
is prohibited.
Ensure that this switch is not pressed down
before engine startup. Otherwise, the crane
cannot be started.
49
“SETUP” switch
For details, please refer to section 4.4
50
To carry out traveling movements, the operator
must first press the traveling switch and then
operate control lever!
Do not press this switch when crane winch is
operated.
“Travel” switch
(1) Put the master lighting switch
working floodlight switch
.
on the 2nd position before switching on the
0066340-200-04Y.C
(2) After putting the master lighting switch
on the 2nd position, the LED on the
rocker switches of control panel is still on.
(3) Press the “engine shutdown” switch and hold it for more than 30 seconds, the
working hours of the engine can be saved. In normal situation, using the ignition
key switch to stop the engine is prohibited.
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51
52
53
55
54
56
58
57
59
61
60
62
64
63
Right control panel
0066340-200-04Y.C
Components on right control panel
No.
Names of the
components
51
“H2 Control” Switch
52
“Manual/automatic
accelerator” switch
Remarks
Turn the switch to left, hoisting winch 2 (H2)will not work;
Turn the switch to right, hoisting winch 2(H2) can work.
When the switch is set in neutral position, the engine speed is
controlled by accelerator pedal.
When the switch is set in “manual” position, the engine speed
is controlled by Manual ACCEL adjuster.
When the switch is set in “automatic” position, the current
Manual ACCEL adjuster value is the maximum adjustable
speed of engine.
53
“H1Control” Switch
54
“Hoisting bypass”
switch
55
56
57
“Lowering bypass”
switch
Turn the switch to right, hoisting winch 1(H1) can work.
For details, please refer to section 4.4.
For details, please refer to section 4.4.
“Derricking bypass”
For details, please refer to section 4.4.
switch
“A-frame
erecting/lowering”
switch
58
Turn the switch to left, hoisting winch 1(H1) will not work;
“Tilt cab forwards
/backwards” switch
Turn the switch to left, A-frame will be erected;
Turn the switch to right, A-frame will be lowered.
Turn the switch to left, the cab will tilt forwards;
Turn the switch to right, the cab will tilt backwards.
When the switch is turned to “W1” position, move right control
lever to left and right to control the luffing jib derricking winch
(W1). This is only available for W1 winch. (For details, see
59
“W1 winch/Assembly”
switch
section 4.5.2.2.3.3.)
When the switch is turned to “Assembly” position, push right
control lever forwards and backwards to control the mounting
cylinder on A-frame. This is only used during assembly and
dismantling operation. (For details, see section 4.5.9.)
60
“Synchronization”
switch
“Synchronization” switch includes “Reeve sync” position and
“Mast +E sync” position.
“Reeve sync” For detailed description of “Mast +E sync”, For
details, please refer to section 4.5.3.
61
“Reeving winch”
Turn the switch to left, the reeving winch will be spooled up;
switch
Turn the switch to right, the reeving winch will be reeled off.
0066340-200-04Y.C
No.
Names of the
components
Remarks
start.
1. When the switch is placed in “off” position, the power
supply of the crane is turned off.
2. When the switch is placed in “power” position, the power
supply of the crane is turned on, including the control
system, auxiliary control system and engine electrical
control system.
3. When the switch is placed in “start” position, the starting
motor of the engine is turned on, thus starting the engine.
Releasing the switch after the crane starts up, the switch
will return to “power” position automatically.
64
“Manual ACCEL
adjuster” switch
1. In “manual accelerator mode”, the adjuster is used to
control the engine speed. Turn it clockwise to the required
speed.
2. In “auto accelerator mode”, the current value is the
maximum adjustable speed of engine.
(1) In cold weather, the engine will be preheated automatically after startup. Therefore,
the delay of engine startup in cold weather is a normal phenomenon.
(2) “Assembly” position of “W1 winch / Assembly” selective switch is only used for
assembling and dismantling.
(3) Only when the crane is fitted with luffing jib derricking winch (W1), can the
operator can turn the “W1 winch / Assembly” selective switch to “W1 winch”
position. Otherwise, there is a risk of danger!
(4) When the “Manual/automatic accelerator” switch is set in “manual” position
before starting the engine, turn “Manual ACCEL adjuster” to “MIN” position or
place “Manual/automatic accelerator” switch to the neutral position.
It’s dangerous to use “hoisting bypass” and “lowering bypass” switches, which can’t
be used in normal situation. Under special circumstances, and the user knows the
possible consequences, then he can operate it very carefully.
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4.2 Instruction for digital display system
65
66
Digital display system
No.
Description
65
Display of load
moment limiter
66
Display of control
system
Function
Display the current working condition of crane
Display the information about crane control system
4.2.1 Load moment limiter
As to detailed operation, refer to Load Moment Limiter Operating Manual.
4.2.2 Display of control system
It can display the working state of crawler crane in real time. When abnormal conditions occur,
the warning light will flash or a prompt will appear on the screen. The display can show the
working mode, engine speed, wind speed, voltage, water temperature, oil level, load and
pressure of pumps etc.
0066340-200-04Y.C
Main screen of display
The main screen is subdivided into five main areas.
a) Engine information
b) Alarm functions
c) Monitored additional functions
d) Pressure of crane control pumps
e) Function key line
Note: In view of legibility, Figures of display of control system given here are amplified.
However, when crane is working, the screen shown on the display is not as
large as the figure.
0066340-200-04Y.C
4.2.2.1 Engine information
67
68
69
70
71
Display of engine information
No.
Description
67
Engine speed and working time
68
Water temperature
69
Engine oil pressure
70
Fuel level
71
Engine load
Note:
The fuel leveland engine load are shown in percentage.
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4.2.2.2 Alarm functions
72
77
73
78
74
75
76
79
80
81
Display of alarm function
The limit ranges of the working state of crane are monitored. The following icons will flash
when the limits are reached.
No.
Description
72
Icon “Engine oil pressure”
73
Icon “Water temperature”
74
Icon “Preheating”
75
Icon “Air filter clog”
76
Icon “Oil inlet /return pipe
clog”
77
Icon “Upper limit switch on
H1”
78
Icon “Lower limit switch on
H1”
79
Icon “Upper limit switch on
H2”
80
Icon “Lower limit switch on
H2”
81
Icon “main boom,
85°”
Function
When engine oil pressure is too high, the icon
will flash.
When water temperature reaches the specified
value, the icon
will flash.
When engine is being preheated, the icon
will flash.
When air filter is clogged, the icon
will
flash.
When oil inlet pipe or oil return pipe is clogged,
the icon
will flash.
When load hook 1 comes into contact with the
hoisting limit switch weight during its upward
movement, the icon
will flash.
When there are only three windings of wire rope
left on H1, the icon
will flash.
When load hook 2 comes into contact with the
hoisting limit switch weight during its upward
movement, the icon
will flash.
When there are only three windings of wire rope
left on H2, the icon
will flash.
When main boom angle reaches 85o, the icon
will flash.
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4.2.2.3 Monitored additional functions
83
82
84
Display of monitored additional functions
No.
82
Description
Function
Crane inclination
Display the inclination of crane to the horizontal in longitudinal
and lateral direction
Note: The traveling direction of crane is taken as positive
direction.
Display the current wind speed at boom head detected by
anemometer
83
Wind speed
84
Voltage of machine
Display the voltage of machine battery
4.2.2.4 Pressure of crane control pumps
85
86
87
88
89
90
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Display of pressure of crane pumps
No.
Description
85
Pressure in main pump I circuit
86
Pressure in main pump II circuit
87
Pressure of A-frame erection cylinder (left)
88
Pressure in slewing pump circuit
89
Pressure in control pump circuit
90
Pressure of A-frame erection cylinder (right)
91
92
Display of pressure of tilting-back support cylinder for WA-frame 1
No.
Description
91
Pressure of tilting-back support cylinder for WA-frame 1 (left)
92
Pressure of tilting-back support cylinder for WA-frame 1 (right)
4.2.2.5 Function key line
93
94
95
96
97
98
99
100
Function key line
No.
Description
93
Key “main screen”
94
Key “IO”
95
Key “Parameter
adjustment”
96
Key “Fault diagnosis”
97
Key “working
conditions”
98
At present, this function is not set in the control system of
crane.
Pressing this key can switch to “Working conditions screen”.
Under this screen, the working conditions for main crane
movements can be checked.
Page up
Page down
99
100
Operation and function
Pressing this key in any other screen can switch to “main
screen” directly. The main screen is shown in Section 4.2.2.
Press this key to enter into “I/O screen”. In this screen, all the
input/output points of PLC can be checked for correction.
Adjust relevant parameters of main motions
Key “Enter”
Confirm the previous operation or save the modified
parameters.
Caution:
Never adjust the parameters without the permission of our technicians.
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4.3 Startup of crane
4.3.1 Adjustment of crane operator’s seat
a) Vertical adjustment of headrest
The height of headrest is adjusted manually.
b) Adjustment of armrest
The height of armrest can be adjusted by adjusting
knobs.
c) Horizontal adjustment of seat
-- Pull the lever upwards;
-- Move the seat to required position;
-- Release the lever.
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d) Adjustment of the height of seat
There are two levers to adjust the height of the seat. The front lever adjusts the height of
the front of the seat, and the rear lever adjusts the height of the rear of the seat.
-- Pull the lever upwards, the front of the
seat is raised up.
-- Pull the lever upwards, the rear of the
seat is raised up.
e) Adjustment of backrest
-- Press your back gently against the backrest;
-- Pull the lever upwards;
-- The backrest tilts backwards.
-- pull the lever downwards.
-- The backrest automatically tilts forwards.
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4.3.2 Checks before startup
Following checks should be performed before startup of engine.
a) Check oil filter and oil level
1) Engine oil level;
2) Oil level of hydraulic oil tank;
3) Oil filter on hydraulic oil tank.
b) Check coolant level
Add coolant to the rim of oil filler.
Danger:
Never check the coolant level before the engine is cooled down. Otherwise, you
may get scalded.
c) Check the general conditions of crane
Before starting up the crane, the operator must ensure that the following conditions are
fulfilled:
1) The crane is horizontally aligned;
2) The toothed gear of slewing ring must be clean and greased;
3) The air inlet of oil cooler is not blocked;
4) All cowlings and covers on the sides must be closed and locked;
5) No person or object is within the slewing radius of crane;
6) No ice or snow is on the wire rope, winding drum and limit switches;
7) There are no loose parts on the slewing table or on the boom;
8) The shutoff valve on the hydraulic oil tank should be opened;
9) The fixing pin for slewing table is pulled out.
Danger:
Before carrying out any boom movements, make sure that there are no loose parts
on the boom such as pin, retaining spring or ice. Otherwise, the falling parts may hit
the persons or other objects.
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4.3.3 Turn on power supply
Insert ignition key into ignition lock and turn it clockwise to the 1st position, then the power
supply is turned on.
Turn on power supply
a)
Digital display system
After the power supply is turned on, press the controller power supply switch
on the
right control panel, the LCD screen of load moment limiter and LCD screen of control
system are started.
Check the following indicators and warning icons:
Engine oil
pressure
Fuel level
1)
2)
Icon “Fuel level”;
3)
Icon “Air filter clog” (
4)
Inclinometer;
5)
Anemometer;
6)
Voltage;
);
Inclinometer,
anemometer, voltage
0066340-200-04Y.C
(1) Correctly set current work mode on load moment limiter, otherwise, operation
is not permitted to be carried out.
(2) Low engine oil pressure will impair the working efficiency of engine.
(3) Add diesel oil in time if the oil level is too low.
(4) If air filter is clogged, the icon “air filter clog”
will flash. At this moment,
clean or change air filter.
(5) The inclination range for the superstructure: the inclination should be less
than 1% in both lateral direction and longitudinal direction. If this range is
exceeded, the crane operator must adjust the crane to horizontal position
firstly.
(6) The maximum in-service wind speed should not exceed 9.8m/s.
(7) The maximum out-of-service wind speed should not exceed 21m/s when the
crane is only fitted with main boom;
The maximum out-of-service wind speed should not exceed 15m/s when the
crane is fitted with main boom and fixed jib.
If wind speed reaches or exceeds these values, the entire boom should be
lowered down.
(8) The battery master switch must be switched on to electrify the machine.
(9) To protect the battery, switch off the battery master switch if the crane will not
work for a long time.
b)
Right control panel
1)
Illumination
Press the “interior light” switch, the interior light in the cab will light up.
Turn the master lighting switch
to the 1st position or the 2nd position, the LED
on the switches of the control panel will light up;
2)
Turn on front windshield wiper and roof windshield wiper by pressing the front
windshield wiper switch
and roof windshield wiper switch respectively.
0066340-200-04Y.C
When front windshield needs to be washed, please press the “front windshield
washer” switch
3)
Fan
There is a fan fitted on the rear right side of the operator’s cab. Turn on the switch on
it, the fan will run.
4)
Horn
Check if the horn is working properly with foot-operated switch before work.
(1) Before switching on the working floodlight switch
switch
, put the master lighting
on the 2nd position.
(2) Warning light on boom head is a kind of solar light. The warning light is
charged during the day and will flash at night.
(3) The horn must be actuated before starting the engine to warn the person in the
vicinity of the crane.
(4) The horn can only be actuated before starting the engine and in emergencies.
4.3.4 Start engine
Insert the ignition key into the ignition lock and turn it clockwise to the 2nd position, then the
engine is started.
Start the engine
Start the engine
0066340-200-04Y.C
(1) When ambient temperature is higher than or equal to﹣10℃, the engine will be
preheated automatically before startup. Therefore, the delay of engine startup in
cold climate is a normal phenomenon.
(2) When the engine is being preheated, the icon
will flash. After the engine is
preheated, it will go out.
(3) When ambient temperature is lower than﹣10℃, the operator must actuate engine
cold-start device first and then start the engine. When engine cold-start device is
actuated, put the controller power (if there is) in (stop) position, the ignition key
switch in (power) position, the cold-start rocker switch
in the 2nd position.
After running the cold-start device for about ten minutes, start the engine.
What’s more, if the water temperature of the engine in cold climate is too low, start
the cold-start device to improve the water temperature, ensuring that the water
temperature of the engine is in normal range.
(4) The engine can not work with full load until the running temperature is reached.
4.4 Safety devices
The crane operator must check all safety devices for functional work before every crane
operation.
Operating crane with faulty safety devices is prohibited!
4.4.1 Emergency stop button
As soon as this emergency stop button is pressed,
– the electrical control system is switched off and the diesel engine shuts down;
– All crane movements stop immediately.
The emergency shut-down button must only be used in case of emergency and not as
a normal procedure for shutting down the diesel engine!
If an emergency stop is triggered while a load is being lifted, there may be a risk of
accident owing to swinging of load.
0066340-200-04Y.C
4.4.2 Battery master switch
Position of the battery master switch
Battery master switch
The battery master switch is put in the rear right side of the slewing table, near the battery,
which is described above. When the crane doesn’t work at night or for a long time, the battery
master switch should be put in “OFF” position to prevent the battery from discharging.
4.4.3 Load moment limiter
The load moment limiter switches off all crane movements that increase the load moment if
the permissible load moment is exceeded. Only crane movements that reduce load moment
can be carried out. Although the crane is equipped with load moment limiter, the operator
can’t escape the responsibility of unsafe operation. Before lifting a load, he must know the
approximate weight of the load and decide if the crane is in a position to carry out this job with
the help of load capacity chart.
Before operating the crane, the load moment limiter must be adjusted to the current
setup condition according to the lifting capacity chart. Only this way can it be able to
fulfill its protective task. If the crane operator does not observe this safety regulation,
there is a great danger of toppling or destroying the crane, despite the load moment
limiter is working normally. The load moment limiter can not monitor and control all
possible operating conditions; this is still primarily the responsibility of the operator.
4.4.3.1 The moment percentage between 100%-110%
If the moment percentage is between 100%-110%, it means that the crane overloads by
100%-110%, the crane movements “spool up hoisting winch 1 or 2” , “spool up derricking
winch” and “reel off derricking winch” are limited. The tricolor light sends out yellow
early-warning and red warning continuously. The buzzer sounds continuously. The icon
will be shown on the display.
0066340-200-04Y.C
The following operation can bypass the limited crane movements temporarily.
“Setup”switch
1.
When the control lever is in neutral position, if press “Setup” switch and then
release it, the cut-off movements “spool up hoisting winch 1 or 2” and “reel off
derricking winch” will be bypassed. The movements will be slower, the tricolor
light will send out yellow warning continuously, and the buzzer will sound,
meanwhile the icon
2.
“Derricking bypass” switch
will be shown on the display.
When the control lever is in neutral position, if press “Setup” switch and then
release it, and turn the “derricking bypass” switch to the right as shown in the
above figure, the cut-off movements “spool up hoisting winch 1 or 2”, “spool up
derricking winch” and “reel off derricking winch” will be bypassed. The
movements will be slower, the tricolor light will send out yellow and red warning
continuously, and the buzzer sounds, meanwhile the icon
is shown on the
display.
4.4.3.2 The moment percentage more than 110%
If the moment percentage is more than 110%, it means that the crane overloads by 110%, the
crane movements “spool up hoisting winch 1 or 2” , “spool up derricking winch” and “reel off
derricking winch” are limited. The tricolor light sends out yellow early-warning and red warning
continuously. The buzzer sounds continuously. The icon
will be shown on the display.
4.4.3.3 Unspecified rated load
If the load moment limiter enters the unspecified rated load work range, the crane movements
“spool up hoisting winch 1 and 2” and “reel off derricking winch” are limited. The tricolor light
will send out yellow early warning and red warning continuously. The buzzer will sound.
0066340-200-04Y.C
The following operation can bypass the limited crane movements temporarily.
When the control lever is in neutral position, if press “Setup” switch and then release it,
the cut-off movements “spool up hoisting winch 1 or 2” and “reel off derricking winch”
will be bypassed. The movement will be carried out at normal speed, the tricolor light
will send out yellow warning, and the buzzer will sound, meanwhile the icons
and
are shown on the display.
(1) “Bypass” means when overload appears and the movement is restricted, the
operator get the permission to operate in the direction of danger temporarily
through switch, but it doesn’t mean that it excludes overload.
(2) Only when the control lever is in neutral position, can the “Setup” switch be
operated, otherwise, it will be invalid.
(3) Pressing “Setup” switch for the first time works, press it again, the control lever
returns to neutral position for more than 10 seconds or the engine stops, the lever
will be invalid.
(1) When the control lever is in neutral position and the engine is still on, turning
“safety bypass” switch right can bypass the overload safety device. Only operate
when professional supervisor is present and with special care.
(2) If bypassing the overload safety device, there will be no protective device to
prevent overloading, which will increase the chance of accident!
(3) “Safety bypass” works if turn it for the first time. Turn it again, the engine stops or
the working time is more than 30 minutes, it will be invalid.
(4) The movement will be slower after the “safety bypass” releases the safety
restriction.
(5) The icon
shows on the display when the “safety bypass” switch works.
(6) The “safety bypass” switch is placed in electrical control box for slewing table.
(7) The “safety bypass” switch can only be used by professionals and can’t be used
as device for normal operation.
0066340-200-04Y.C
It’s very dangerous to use “safety bypass” switch, which is not allowed to use in
normal circumstances. Only in special condition and the operator knows the possible
consequences, the operation is allowed and with special care.
4.4.4 Boom angle indicator
Boom angle indicator is fitted on the lower rear end of main boom pivot section (i.e. on the
right side of the crane operator’s cab). In this way, the operator, even in crane operator’s cab,
can clearly read boom angle shown on the indicator.
Boom angle indicator
4.4.5 Derrick limiter
It is used to detect main boom angle and in real time according to the data collected by angle
sensors. Once detected angle exceeds safe angle range, an alarm will be sent out and
dangerous movements will be switched off so as to ensure safe crane operation.
a)
Crane operation with main boom
When the main boom angle is 80°, the derricking speed will be slower and the buzzer
will give an alarm.
When the main boom angle is 83°, the crane movement “raise main boom” will be cut
off automatically and the buzzer will give an alarm.
b)
Crane operation with main boom and fixed jib
The requirements for main boom angle under this boom configuration are the same as
that under “Main boom” configuration. The fixed jib can be fitted in the angle of either 10°
or 30° to main boom.
0066340-200-04Y.C
c)
For SW boom configuration
1)
When the main boom is raised to 80° position, the main boom derricking speed will
be slower.
2)
When the main boom is raised to 85° position, the system will cut off hoisting
movements automatically and gives an alarm.
3)
When the main boom is lowered to 65° position, the system will cut off lowering
movements and gives an alarm. After switching to “assembly mode” or press “Setup”
switch, the main boom will be lowered down.
4)
When the angle between the main boom and luffing boom is less than 85°, main
boom derrick winch will be spooled up, and luffing jib lowering will be stopped
automatically in “assembly mode” and “working mode”.
5)
When the upper angle between main boom and luffing jib is more than 10° and less
than 15°, the luffing jib will move slowly.
6)
When the upper angle between main boom and luffing jib is 10°, the system will cut
off luffing jib raising movements and give an alarm.
7)
When the luffing jib angle is less than 15°, the luffing jib lowering movements will be
stopped automatically. After switching to “assembly mode” or press “Setup” switch,
the luffing jib can still be lowered down.
Under this boom configuration with S-boom angle of 85°: when W-luffing jib angle
exceeds 60°, the luffing jib with a load should not be raised/lowered at high speed.
And the load should be the min. lifting capacity under this boom configuration;
otherwise the luffing jib is liable to overturning. Before the load is detached from
the load hook, lower the luffing jib to a position(less than 60°). In other words,
lower the luffing fly jib to 60° by the pulling force of load.
0066340-200-04Y.C
4.4.6 Lowering limiter
Lowering limiter
In order to prevent wire rope from being wound in the opposite direction after it is unwound
completely, the lowering limit switches fitted on winch 1 and 2 are triggered when there are
only 3 windings of wire rope left on the drums. Under this condition, the buzzer on the control
panel will sound, the tricolor light will send out yellow early warning and red warning
continuously, and the icons
icon
or
on the main screen of display will flash. The
will be shown on the display. At this time, the movement of “reel off winch” is
switched off, and only the movement of ‘spool up winch” can be carried out.
The following operation can bypass the limited crane movements temporarily.
“Lowering bypass” switch
Turn the “lowering bypass” switch to the right as described above, the cut-off movement “reel
of hoisting winch 1 or 2” will be bypassed, the tricolor light will send out yellow early warning,
the buzzer will sound continuously, and the icon
time.
is shown on the display at the same
0066340-200-04Y.C
(1) “Bypass” means when lowering appears and the movement is restricted, the
operator get the permission to operate in the direction of danger temporarily
through switch, but it doesn’t mean that it excludes lowering.
(2) The bypass of lowering limiter must be guided by a professional. He must contact
with the crane operator directly and monitor the residual length of the wire rope all
the time. Great care is needed to operate the crane.
If the lowering limiter is bypassed, there will have no protective device to prevent wire
over-lowering, which will increase the chance of accident!
4.4.7 Hoisting limiter
Hoisting limiter
If the load hook comes into contact with the hoisting limit switch weight during its upward
movement, the hoisting limit switch is triggered, the buzzer on the control panel sounds, and
the crane movement “Spool up hoisting winch 1 and 2” “reel off derricking winch” are switched
off. The tricolor light sends out yellow early warning and red warning continuously. The icon
or
on the display starts to flash. The icon
will be shown on the display.
The following operation can bypass the limited crane movements temporarily.
0066340-200-04Y.C
“Hoisting bypass” switch
Turn the “hoisting bypass” switch right, as described above, which will bypass the
cut-off movement “spool up hoisting winch H1 or H2”. The tricolor light sends out
yellow warning, and the buzzer sounds, meanwhile showing the icon
.
1)
“Bypass” means when hoisting appears and the movement is restricted, the
operator get the permission to operate in the direction of danger temporarily
through switch, but it doesn’t mean that it excludes hoisting.
2)
The bypass of hoisting limiter must be guided by a professional. He must contact
with the crane operator directly and monitor the distance between the load hook
and boom end all the time. Great care is needed to operate the crane.
If the hoisting limiter is bypassed, there will be no protective device to prevent wire
hoisting, which will increase the chance of accident!
4.4.8 Support cylinder locking device
When the high pressure oil pipe, which is connected to support cylinder, is damaged, the
bidirectional hydraulic lock fitted in oil circuit can prevent pressure oil in the two chambers of
support cylinder from flowing outside so as to avoid cylinder retracting or extending, and thus
guaranteeing the safety of assembly and dismantling of the crawler crane.
4.4.9 Overflow valve
The overflow valve in hydraulic system can restrain the pressure in the circuit from rising
irregularly, thus protecting such hydraulic elements as hydraulic oil pump and hydraulic motor
against damage and preventing the hydraulic system from being overloaded.
0066340-200-04Y.C
4.4.10 Anemometer
The anemometer fitted on the boom or jib head can detect the wind speed in real time.
When the in-service wind speed exceeds 9.8m/s, the crane operation should be stopped
immediately.
When the out-of-service wind speed for “Main boom” configuration exceeds 21m/s, the entire
boom should be placed on the ground.
When the out-of-service wind speed for “Main boom with fixed jib” configuration exceeds
15m/s, the entire boom should be placed on the ground.
The operator should constantly observe the wind speed displayed on the screen.
0066340-200-04Y.C
4.5 Crane operation
a)
1)
2)
The crane is horizontally aligned with enough bearing capacity of the
ground
3)
b)
4)
The hook bloc
5)
All safety devices are set in accordance with the load capacity charts;
6)
No person and object are within danger zone.
1)
Always operate the control lever slowly and carefully. This can not only
ensure longer service life of crane, but also help to avoid accidents.
2)
During all crane movements, make sure there are neither obstacles nor
persons in the danger zone.
3)
Before every crane operation, at least an acoustic signal should be
given.
Checks during crane operation
If the crane has been worked for a long time, switch on “Oil cooling fan” switch
cool down hydraulic oil automatically.
When the engine is running, the
1)
Icon “Engine oil pressure”
2)
Icon “Water temperature”
3)
Icon “Air filter clog”
4)
Icon “Oil inlet/return pipe clog”
5)
Icon “Upper limit switch on H1”
6)
Icon “Lower limit switch on H1”
to
0066340-200-04Y.C
7)
Icon “Upper limit switch on H2”
8)
Icon “Lower limit switch on H2”
9)
Icon “Main boom, 85o”
(1) If one of the above icons flashes during crane operation, stop the operation
immediately and shut down the engine at once. Check the corresponding
device and eliminate the fault.
(2) If the icon “Engine oil pressure”
does not go out after engine starts or
during crane operation, the engine should be shut down at once. If this
operation is not done, the engine will be damaged caused by insufficient oil
pressure.
(3) In order to see the positions of press-keys on the right control panel and the
position of boom clearly when the crane works at night, the crane operator
must turn on the LED on the keys of control panel, the working light on the
slewing table by placing master lighting switch
then pressing “Working light on/off” switch
to the 2nd position, and
.
(4) During operation, always check the indicators on the display of load moment
limiter. When carrying out crane movement, the operator must see the
changing load condition and changing forces. The overloading condition
should be recognized early, and the crane movement should be slowed down
accordingly.
0066340-200-04Y.C
c)
The valid area for control lever movement
Valid area for single control lever movement
When operating single movement by control lever, the valid area in front and rear
direction of the control lever is -20°- 20°, the valid area in left and right direction is
-20°- 20°,which is described as above in the grid.
Front
Left
Right
Back
Valid area for single control lever compound movement
When do a compound movement using a single control lever, the valid area for control
lever movement is 20°- 70°,which is described in the above grid. The valid movement
range for A,B,C,D areas is 50°.
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d)
Setting configuration
For the specific methods to set configuration, please refer to load moment limiter
instructions.
Set the corresponding configuration in the load moment limiter according to actual
situation. Since the configuration will affect the control system on winch. The
configuration must be set properly to avoid danger and accident.
e)
“Speed setting” and the use of micro-move switch
Speed switch can be divided into four shifts: slow, normal, middle and high. For details,
please refer to section 4.5.1~4.5.4.
The switch
setting speed
Speed set
Function
Slow speed
when need to load in fixed position and position exactly,
press the key, the system will design proper speed to
work no matter how big the opening of the control lever,
loading in fixed position and positioning exactly. The
work range: hoisting winch 1, hoisting winch 2 and
luffing jib derricking winch and main boom derricking
winch.
Normal speed
The middle position of the switch means the automatic
working speed of the system
Middle speed
When the hoisting winch needs a speed higher than
“slow speed” shift, use middle speed.
Rocker
switch
Rotating switch
Left control lever
“high speed”
switch
Right control
lever “high
speed” switch
High speed
The hoisting movement, luffing jib derricking movement
and traveling movement will be performed in high
speed.
High speed
Slew in high speed
High speed
Raise the hoisting winch and travel in high speed
1)
The automatic working speed for slewing mechinism is low speed. After pressing
left control lever “high speed” switch, the slewing mechinism will work in full
speed.
2)
The high-speed switch is only used when the crane is working without load or with
light load and the hoisting winch is operated alone.
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4.5.1 Operation of traveling mechanism
4.5.1.1 Component parts of traveling mechanism
The traveling mechanism comprises drive sprocket, driven sprocket, track-carrier roller, track
roller and track pad, crawler carrier as well as traveling reducer. Both right crawler carrier and
left crawler carrier are fitted with an independent traveling reducer. The hydraulic oil in
traveling motor is supplied by superstructure main pump through main valve and centre
revolving joint.
Drive
sprocket
Track-carrier
roller
Track pad
Track
roller
Driven
sprocket
Traveling mechanism
4.5.1.2 Operation of traveling mechanism
The traveling movements are controlled by left and right control levers. The movements “left
crawler forwards” and “left crawler backwards” are controlled by left control lever, and the
movements “right crawler forwards” and “right crawler backwards” are controlled by right
control lever. In this way, crane can carry out such movements as traveling straight
ahead/backwards, steering during traveling and turning on spot.
Note:
Before carrying out the traveling movement, the operator must first press the
traveling switch
, and then operate the control lever.
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Left crawler forwards
Left control lever
Left crawler backwards
Right crawler forwards
Right control lever
Right crawler backwards
Operation of left and right crawler traveling
Instructions for traveling movements
Description
Left control lever
Right control lever
Operation
Movement
Push forwards
Left crawler forwards
Push backwards
Left crawler backwards
Return to neutral position
Left crawler stops moving
Push forwards
Right crawler forwards
Push backwards
Right crawler backwards
Return to neutral position
Right crawler stops moving
0066340-200-04Y.C
1)
Before carrying out traveling movement, the operator must first press
traveling switch
2)
When operate the control lever, first press the deadman’s button, then
press the control lever. Otherwise, the operation is invalid.
3)
The crane movements can still be carried out before the control lever is
returned to neutral position with deadman’s button released. However, to
perform the next crane movement after returning the control lever to
neutral position, the operator must press deadman’s button first and then
move the control lever. Otherwise, the operation of control lever is invalid.
In normal operation, stop the crane movements by returning the control
lever to neutral position.
4)
a)
, and then operate the control lever.
Traveling on level road
Traveling straight ahead: Push both control levers forwards at the same time
Traveling straight backwards: Push both control levers backwards at the same time
Turning with a crawler
Turning to left: Push right control lever forwards
Turning to right: Push left control lever forwards
Turning to left with a crawler
Turning to right with a crawler
Note:
When crane is traveling with a crawler, the operator had better change into
low-speed shift.
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Differential steering:
Steering to right: Push left control lever heavily and push right control lever slightly to
make the speed of left crawler higher than that of right crawler
Steering to left: Push right control lever heavily and push left control lever slightly to
make the speed of right crawler higher than that of left crawler
Differential steering
Turning on the spot:
Turning to right: push right control lever backwards heavily, then right crawler will turn to
left; push left control lever forwards heavily, then left crawler will turn to right.
Turning to left: Push left control lever backwards heavily, then left crawler will turn to
right; push right control lever forwards heavily, then right crawler will turn to left.
Turning on the spot
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Note:
1. The high speed is prohibited when the crane is turning.
2. When there is a need to stop traveling or steering, turn the control lever to
neutral (zero) position, the traveling brake will be activated automatically.
3. When crane is traveling with a load, it can only travel forwards with boom
located straight ahead.
4. When crawler crane is traveling for a long distance, ensure that the traveling
motor is behind the slewing table.
b)
Traveling on slope
Make crawler crane travel forwards, and place the slewing control lever in neutral (zero)
position. When crawler crane is traveling uphill, the engine speed must be within medium
speed range and the boom length must be reduced as possible as you can. When
crawler crane is traveling on a slope with maximum permissible gradient, it can only be
fitted with basic boom.
Turning on the slope
If crawler crane needs to turn on the slope when it is traveling downhill, some treatments
should be taken to the undulations to form a gentle slope curve (see following diagram),
which can prevent crane’s center of gravity from deviating and load from concentrating
on a section of crawler when crawler crane is traveling over
Remove the undulation
Gentle slope
Slope treating diagram
Note:
1. When crawler crane is traveling from the horizontal ground to the slope, if its
center of gravity deviates forwards, the crane should be stopped to adjust the
center of gravity.
2. When crawler crane is traveling on a slope with rated gradient, it is impossible to
obtain a special mass parameter according to ground condition. Therefore, in
order to assure safety, the counterweight and boom should be dismantled from
crane during traveling.
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Traveling with suspended load:
The crane can travel with suspended load, providing that the following precautions are
taken:
c)
a)
The ground surface must be flat and level (no gradient);
b)
The subsoil must be capable of bearing crane’s maximum service weight
and the weight of suspended load;
c)
The crane can travel with a load of 70% of the rated load. In this case, the
ground should be firm and its gradient should not exceed 5/1000. The
boom frame must be located in the driving direction;
d)
Jerky crane movements must be avoided;
e)
The suspended load must be lashed to prevent it from swinging;
f)
Steering of crawler is forbidden.
Fast travelling
High-speed
switch
右手柄高速开关
Right
control lever
右手柄
Turn the Speed Set switch “High Speed” position or press the high-speed switch
of right control lever, which is described as above. Then operate left and right
control levers to move crane at higher speed.
1)
Before carrying out traveling movement, the operator must first press
traveling switch
, and then operate the control lever.
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2)
Only when deadman’s button is pressed, can the operation of control lever is
valid.
3)
The crane movements can still be carried out before the control lever is
returned to neutral position with deadman’s button released. However, to
perform the next crane movement after returning the control lever to neutral
position, the operator must press deadman’s button first and then move the
control lever. Otherwise, the operation of control lever is invalid.
4)
In normal operation, stop the crane movements by returning the control lever
to neutral position.
5)
The high-speed switch is only used when the crane is traveling straight
without a load.
4.5.2 Operation of crane winches
Note:
1. Set correct boom configuration prior to operating crane winches.
2. Switch off traveling switch
.
4.5.2.1 Hoisting mechanism
a)
Components of hoisting mechanism
Hoisting mechanism consists of hydraulic motor, winch reducer, brake, lowering limiter,
hoisting limiter and wire rope as well as load hook 1 and 2. The speed of hoisting
movement can be changed by adjusting the inclination angle of control lever. The angle
can vary from - 5 to -25 or from 5 to 25. The bigger the inclination angle is, the quicker
the hoisting speed is.
b)
Operation of hoisting winch
The crane is fitted with two hoisting winches: hoisting winch 1 and hoisting winch 2. Even
though the structure of hoisting winch 1 is the same as that of hoisting winch 2, their
positions and functions are different.
Hoisting winch 1 is required for crane operation with main boom, and hoisting winch 2 is
required for crane operation with main boom and fixed jib, crane operation with main
boom with luffing jib, or crane operation with tip boom.
The control lever for hoisting winch 1 is fitted at the right side of operator’s seat, and the
control lever for hoisting winch 2 is at the left side of operator’s seat.
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Operation of hoisting winch 1:
Push right control lever backwards: spool up hoisting winch 1;
Push right control lever forwards: reel off hoisting winch 1.
Reel off hoisting winch 1
Right control lever
Spool up hoisting winch 1
Operation of hoisting winch 1
Instructions for the movements of hoisting winch 1
Description
Right control lever
Operation
Movement
Push forwards
Reel off hoisting winch 1 to
lower the load hook
Push backwards
Spool up hoisting winch 1 to lift
the load hook
Return to neutral position
Hoisting winch 1 stops working
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Operation of hoisting winch 2:
Push left control lever backwards: spool up hoisting winch 2;
Push left control lever forwards: reel off hoisting winch 2.
Reel off hoisting winch 2
Left control lever
Spool up hoisting winch 2
Operation of hoisting winch 2
Instructions for the movements of hoisting winch 2
Description
Left control lever
Operation
Movement
Push forwards
Reel off hoisting winch 2 to
lower the load hook
Push backwards
Spool up hoisting winch 2 to lift
the load hook
Return to neutral position
Hoisting winch 2 stops working
Note:
1. Before operating the winch, the operator must first choose correct boom
configuration by turning boom configuration switch to required position. As to the
functions of winch 1 and 2, they are determined by selected boom configuration.
2. When spooling up or reeling off hoisting rope, keep watching the winch to make
sure that there is slack wire rope on the winch.
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c)
High-speed operation of hoisting winches
High-speed switch
Right
lever
control
High-speed operation of hoisting winches
Turn “SpeedSet” switch to “high-speed” position or press “high-speed switch on right
control lever”, which is described above. Then operate right control lever or left control
lever to lift and lower load hook at higher speed.
Turn “SpeedSet” switch to “Medium-speed” position, then operate right control lever or
left control lever to lift and lower load hook at middle speed.
(1) Choose proper rope reeving in accordance with boom length.
(2) When the load swings due to winding wire rope, the load should be put down
and be loaded again after complete unlocking of wire rope.
(3) Under any conditions, there must be at least three windings of wire rope left on
the winding drum.
(4) When a load is lifted away from the ground, it should first be suspended in the
air for a moment. Do not lift the load until the operator confirms that there is no
safety hazard. Do not derrick and telescope the boom if the load is still in
contact with the ground.
(5) Do not change the control lever between “lift hook” and “lower hook” jerkily.
The operator must return the control lever to neutral position and ensure that
the winding drum has stopped before changing control lever from “lift hook”
to “lower hook”. Otherwise, the winch components will be damaged.
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(6) If main boom is extended under “Main boom” configuration, the lifting height
of crane will increase accordingly, which will therefore make the wire rope not
long enough. Such problem can be solved by changing the rope reeving of
wire rope. Before changing the rope reeving, fit a hoisting limit switch weight.
When the crane is overloaded, or wire rope on hoisting winch 1 or 2 is
excessively wound /unwound, the dangerous motions will be switched off
automatically and an alarm will be given out
(7) After the system sounds the alarm, only movements towards safe directions
are permitted. If some movements towards dangerous directions are required,
please refer to instructions in section 4.4.
(8) The high-speed switch is only used when the crane is working without load or
with light load and the hoisting winch is operated alone.
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4.5.2.2 Derricking mechanism
4.5.2.2.1 Component parts of derricking mechanism
Through changing the length of wire rope reeved between derricking pulley blocks (including
derricking crown block and derricking traveling block), the derricking mechanism, via
derricking winch, can adjust boom angle so as to change the working radius. In different boom
configurations, different winches are selected.
Crane operation with main boom and crane operation with main boom and fixed jib
Main boom angle can be adjusted by changing the length of wire rope reeved between
derricking pulley blocks, which consist of derricking crown block at the tail end of slewing table
and derricking traveling block on the top of A-frame.
Anchoring rods
Boom
Tilting-back support cylinders of main boom
A-frame
Derricking traveling block
Wire rope
Main boom derricking winch
Derricking crown block
Derricking mechanism
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Crane operation with main boom with luffing jib
Luffing jib angle can be adjusted by changing the length of wire rope reeved between luffing
pulley blocks, which are comprised of pulley blocks respectively located on the top of
WA-frames 1 and 2.
Luffing pulley blocks
Derricking mechanism
Note:
1. Before operating derricking mechanism, the operator must first choose correct
boom configuration by turning boom configuration switch to required position. As
to the different derricking methods, they are determined by selected boom
configuration.
2. Switch off traveling switch
prior to operating crane winches.
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4.5.2.2.2 Operation of derricking mechanism in different boom configurations
4.5.2.2.2.1 Crane operation with main boom
Main boom angle can vary from 0 to 83, and main boom can be raised and lowered via main
boom derricking winch.
Crane operation with main boom
Reel off main boom derricking winch
Right control lever
Spool up main boom derricking winch
Operation of main boom derricking winch
Instructions for the movements of main boom derricking winch
Description
Right control lever
Operation
Movement
Move to left
Spool up main boom derricking winch to raise main
boom
Move to right
Reel off main boom derricking winch to lower main
boom
Return to neutral
position
Main boom derricking winch stops working
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4.5.2.2.2.2 Crane operation with main boom and fixed jib
The fixed jib can be mounted in the angle of either 10 or 30 to main boom. Once the angle is
set, it can not be changed during operation.
The main boom can be raised and lowered via main boom derricking winch.
Crane operation with main boom with fixed jib
Reel off main boom derricking winch
Right control lever
Spool up main boom derricking winch
Operation of main boom derricking winch
Instructions for the movements of main boom derricking winch
Description
Right control lever
Operation
Movement
Move to left
Spool up main boom derricking winch to raise main
boom
Move to right
Reel off main boom derricking winch to lower main
boom
Return to neutral
position
Main boom derricking winch stops working
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4.5.2.2.3.3 Crane operation with main boom with luffing jib
Under this boom configuration, main boom can be fixed at 65, 75 or 85 position via main
boom derricking winch, while luffing jib can be raised or lowered via hoisting winch 1 or luffing
jib derricking winch.
Crane operation with main boom with luffing jib
Note:
1. When luffing jib derricking winch is not fitted,
- raise and lower main boom via main boom derricking winch;
-raise and lower luffing jib via hoisting winch 1.
2. When luffing jib derricking winch is fitted,
- raise and lower main boom via main boom derricking winch;
-raise and lower luffing jib via luffing jib derricking winch.
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a)
Raise/lower boom
“W1 winch/Assembly” switch
Reel off main boom derricking winch
Right control lever
Spool up main boom derricking winch
Operation of main boom derricking winch
Place the “W1 winch/Assembly” switch in neutral position, and then move right control
lever to left and right to control the main boom derricking winch, see the above figure.
Instructions for the movements of main boom derricking winch
Description
Right control lever
Operation
Movement
Move to left
Spool up main boom derricking winch to raise main
boom
Move to right
Reel off main boom derricking winch to lower main
boom
Return to neutral
position
Main boom derricking winch stops working
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Note:
Under crane operation with main boom with luffing jib, main boom must be fixed at
65, 75 or 85 position.
b)
Raise/lower luffing jib
1)
Use hoisting winch 1 to raise/lower luffing jib
“W1 winch/Assembly” switch
Reel off winch 1
Right control lever
Spool up winch 1
Raise/lower luffing jib via hoisting winch 1
Place the “W1 winch/Assembly” switch in neutral position, and then use hoisting winch 1
(H1) to raise and lower the luffing jib by moving right control lever forwards and
backwards. At this time, the overwiding signal for H1 is shielded.
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Instructions for the movements of hoisting winch 1
Description
Right control lever
Operation
Movement
Push forwards
Reel off hoisting winch 1 to lower luffing jib
Push backwards
Spool up hoisting winch 1 to raise luffing jib
Return to neutral
position
Hoisting winch 1 stops working
High-speed switch
Right control lever
Turn “SpeedSet” switch to “high-speed” position or press “high-speed switch on right
control lever”, which is described above. Then push right lever forwards or backwards to
control luffing jib derrick at higher speed.
Note:
1. Switch off traveling switch
prior to operating winches.
2. Only use luffing jib derricking winch high-speed gear when operating the
luffing jib alone. Otherwise, it’s prohibited to use.
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2)
Use luffing jib derricking winch to raise/lower luffing jib
“W1 winch/Assembly” switch
Neutral position
Reel off luffing jib derricking winch
Right control lever
Spool up luffing jib derricking winch
Raise/lower luffing jib via luffing jib derricking winch
Turn the “W1 winch / Assembly” switch to “W1 winch” position, and then move right
control lever to left and right to control luffing jib derricking winch.
Instructions for the movements of luffing jib derricking winch
Description
Right control lever
Operation
Movement
Move to left
Spool up luffing jib derricking winch to raise luffing jib
Move to right
Reel off luffing jib derricking winch to lower luffing jib
Return to neutral
position
Luffing jib derricking winch stops working
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Turn “SpeedSet” switch to “high-speed” position or press “high-speed switch on right
control lever”, Then push right lever to left or right to control luffing jib derrick at higher
speed.
Note:
1. The derricking operation must be carried out stably. Otherwise, a great impact
will be made on the crane with a load.
2. Only use luffing jib derricking winch high-speed gear when operating the
luffing jib alone. Otherwise, it’s prohibited to use.
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4.5.3 Operation of synchronizing A-frame and main boom derricking winch and
synchronizing reeving winch and working winch
(1) The functions of synchronizing A-frame and derricking winch only works for
erecting the A-frame.
(2) Reeving winch synchronizing isn’t suitable for main boom derricking winch.
4.5.3.1 A-frame and main boom derricking winch synchronization
“Synchronisation” switch
“A-frame retracting and erecting “switch
Procedure for this operation:
(1) Turn “synchronizing” switch on the right control panel to “Mast (A-frame) + E sync”
position, as described above.
(2) Turn “A-frame erecting/lowering” switch to the left “Erecting” position, as described
above.
(3) Then the A-frame is erected, while the main boom derricking winch is reeled off
synchronously and automatically;
(4) The movements “reel off main boom derricking winch” and “erect A-frame’ will be carried
out at the matched speed. And the movements can be stopped at any time according to
actual conditions.
4.5.3.2 Operation of reeving winch
(1) Prerequisite
An assistant is present to guide the hoisting rope.

Complete the assembly operation on a stable area! If it is unavoidable that the rope
must be hand-guided over the boom to rope pulleys in boom head, proceed with
great caution when walking on the boom.

The person guiding the rope will slip on the boom if the crane is not operated
properly. There is a great danger of a serious accident!
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
After the A-frame reaching the required position, turn the synchronisation switch to
neutral position.
(2) Operation of reeving winch
1)
Reel off reeving winch. The rope of reeving winch is reeved in accordance with the
reeving diagrams, however in reverse direction with hoisting rope between the rope
pulleys in the boom head and the hook block.
Turn the reeving winch switch to the right on right control panel– reel off reeving
winch.
2)
Attach the rope end point of reeving winch to hoisting rope for winch 1 (or winch 2) with
rope lock.
3)
The hoisting winch 1 (or 2) is reeled off, while the reeving winch is spooled up at the
same time.
Turn the reeving winch switch to left, then the reeving winch is spooled up.
4)
1.
Reel off hoisting winch 1 (or 2) when spooling up the reeving winch.
2.
The speed of spooling up reeving winch should be higher than the speed
of reeling off hoisting winch 1 (or 2).
Release the hoisting rope from the rope lock after the rope of hoisting winch 1 (or 2)
is reeved between the load hook and boom head.
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(1) When the assistant guides the hoisting rope to the rope pulley on the
boom head, the crane operator must operate the reeving winch. This
procedure must be done in such a manner that the rope does not slacken
up on the winding drum.
(2) Reeving can be done manually or with the help of a reeving winch.
If the reeving winch is used, the rope on it must first be reeved in reverse
direction between the hook block and the rope pulleys on boom head and
then connected with the hoisting rope of winch 1 (or winch 2).
(3) Reeving winch and hoisting winch synchronisation
Procedure for this operation: (taking hoisting winch 1 as working winch)
1)
Turn “synchronization switch” to the left “Reeve SYNC” gear, which is described as
above;
2)
Push right control lever forwards and backwards, the reeving winch and hoisting
winch 1 will carry out synchronous movements, namely, reeling off hoisting winch 1
and spooling up reeving winch, or spooling up hoisting winch 1 and reeling off
reeving winch.( Push left control lever forwards and backwards, the reeving winch
and hoisting winch 2 will carry out synchronous movements. namely reeling off
hoisting winch 2 and spooling up reeving winch, or spooling up hoisting winch 2 and
reeling off reeving winch)
3)
After hoisting rope is reeved well, return the “synchronization” switch to neutral
position, and remove the rope lock connecting the reeving rope and hoisting rope.
Finally wind the reeving rope onto the reeving winch.
(1) The operation mentioned above must be carried out by at least tow persons.
(2) After the hositing rope is reeved correctly between rope pulleys, the
“synchronization” switch must be returned to neutral position.
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4.5.4 Operation of slewing mechanism
4.5.4.1 Component parts of slewing mechanism
The slewing mechanism consists of hydraulic motor, planetary gear reducer, brake, drive gear
and slewing ring, etc. The slewing speed can be adjusted by changing the inclination angle
of control lever.
An independent piston variable pump is applied to hydraulic system to supply oil, which can
adjust slewing speed accurately.
4.5.4.2 Operation of slewing mechanism
Note:
1. The speed range for slewing movement must be set according to the load
capacity charts.
2. Operating with high slewing speed will cause an increased risk of accidents!
Before initiating any slewing movements, the operator must make sure that there
are no persons or obstacles within slewing radius. Otherwise, there is an
increased risk of accidents. Before carry out slewing movement, an acoustic
signal should be given.
Slew to right
Left control lever
Slew to left
Operation of slewing mechanism
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Instructions for the movements of slewing mechanism
Description
Left control lever
Operation
Movement
Move to left
Superstructure slews to left
Move to right
Superstructure slews to right
Return to neutral
position
Stop slewing
High-speed
switch of left
control lever
Left control
lever
Note:
1. The automatic speed of slewing mechanism is low speed. After pressing the
high-speed switch of left control lever, the slewing mechanism can work at full
speed.
2. Longer boom - slower slewing speed;
3. Heavier load - slower slewing speed;
4.5.4.3 Swing free running
If the load hook is not positioned vertically over the load’s center of gravity before lifting
operation, the operator can press the button on the left control lever to activate swing free
running mode. At this moment, the side force on the boom can be reduced, and the boom and
superstructure, under the effect of external fore, are pulled to the position where the load hook
is vertical to the load’s center of gravity. In this way, pulling the load obliquely can be avoided
and the equipment can be protected against damage.
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“Swing free running” button
Left control lever
Operation of swing free running
Press the button on the left control lever, the movement “Swing free running” will be carried
out.
After hoisting rope is vertical, the movement “Swing free running” stops.
Note:
1. When carrying out the movement “Swing free running”, operate the control lever
to lift the hook at the same time. In this way, the side force will be produced on
the wire rope to make load hook vertical to the boom.
2. Before each swing of the superstructure the crane operator must personally
make sure that there are no obstacles in the crane slewing area and no person
is in the danger zone. Give a short warning signal (horn) before starting a crane
movement.
3. When slewing with a load, initiate the slewing movement very carefully. It is
prohibited to stop slewing movement or change slewing direction jerkily.
4. Longer boom - slower slewing speed;
5. Heavier load - slower slewing speed;
6. It is not permitted to slew the superstructure on the trailer.
7. In order to ensure safe operation, the customer should check slewing ring bolts
with 1800N.m tightening torque after initial 100 operating hours. Then check and
tighten them after 300 operating hours. After that, do the checks every 500
operating hours.
8. When operator has to leave the machine in traveling or transport condition,
never rely solely on the slewing brake to lock the slewing mechanism. Even
though the slewing brake is applied, the superstructure may still slew, because it
0066340-200-04Y.C
is not a positioning lock.
9. Activating slewing brake switch to lock slewing mechanism abruptly should be
avoided, since it may cause damage to the superstructure.
4.5.5 Simultaneous operation
No
Simultaneous operation
Operation
1
Slewing mechanism and Winch
1
Left control lever(left and right)+ right control
lever(forwards and backwards)
2
Slewing mechanism and
derricking mechanism
Left control lever(left and right)+ right control
lever(left and right)
3
Slewing mechanism and winch
2
Operate the left control lever in 20°~70°
range
4
Winch 1 and derricking
mechanism
Operate the right control lever in 20°~70°
range
5
Winch 2 and derricking
mechanism
Left control lever(forwards and backwards)+
right control lever(left and right)
6
Winch 2 + wich1 (luffing jib)
Left control lever(forwards and backwards)+
right control lever(forwards and backwards)
7
8
9
10
Slewing mechanism + winch 1
(luffing jib)
Winch 1+ luffing jib derricking
winch
Winch 2+ luffing jib derricking
Left control lever(left and right)+ right control
lever(forwards and backwards)
Operate the right control lever in 20°- 70°
range
winch
Left control lever(forwards and backwards) +
right control lever(left and right)
Winch 1+ luffing jib derricking
winch
Left control lever(left and right)+ right control
lever(left and right)
4.5.6 Operation of movements of crane operator’s cab
Operator’s cab movement-controlling mechanism consists of operator’s cab, swivel arm of
operator’s cab, fixing pin spindle of swivel arm, operator’s cab tilting cylinder.
The operator’s cab, an independent cabin, can make relative movement to the basic machine.
It can not only tilt forwards or backwards, but also swivel sideways. Under working condition,
the cab can not be swiveled out, but can be tilted forwards and/or backwards. Only when the
crane transfers from transport position to working position, can the cab be swiveled out.
0066340-200-04Y.C
Swivel
arm
operator’s cab
Operator’s cab
of
Operator’s cab tilting
cylinder
Operator’s cab movement-controlling mechanism
4.5.6.1 Swiveling the operator’s cab sideways
To reduce the transport width of the basic machine on the low-loader, the operator’s cab must
be swiveled out of the side working position to the centre of slewing table.
Fixing pin spindle of
swivel arm
Slewing
table
Traveling direction
Operator’s cab in transport position
Before swiveling the cab from transport position to working position, the operator must swivel
the swivel arm of cab 90 ° manually and then secure it with pin spindle.
The procedure for swiveling cab to the working position:

Pull out the fixing pin spindle of swivel arm.

Swivel the swivel arm of operator’s cab 90 ° manually.

Insert fixing pin spindle to secure the swivel arm after cab is in the working position.
0066340-200-04Y.C
Operator’s cab in working position
Note:
1. Swiveling the operator’s cab to the transport condition is carried out in reverse
order.
2. Do not operate any other devices when swiveling the operator’s cab.
3. Close the door before swiveling the operator’s cab.
4. Take off the interior light on the roof of cab before swiveling the operator’s cab.
The cab should not collide with tilting-back support cylinders of main boom when
it is swiveled out.
4.5.6.2 Tilting the operator’s cab forwards/backwards
In order to enlarge the view of crane operator, the cab can tilt forwards or backwards using
tilting cylinder.
When tilting cylinder is extended completely, the cab is in horizontal position;
When tilting cylinder is retracted, the cab will tilt backwards to a maximum of 20°.
This function can be achieved by operating “Tilt cab forwards/backwards” switch in operator’s
cab, which can make cab stop and maintain at any position within the range of 0°- 20°.
0066340-200-04Y.C
a)
Tilting operator’s cab backwards
When cab is horizontal, turn the “tilt cab forwards/backwards” switch to the left, then the
cab will tilt backwards. After it tilts to proper position, turn the switch to neutral position.
Operation of tilting cab backwards
Turn the “tilt cab forwards/backwards” switch on the right control panel to the left, the cab
will tilt backwards;
Turn the “tilt cab forwards/backwards” switch on the right control panel to the neutral
position, the cab will stop tilting backwards.
b)
Tilting operator’s cab forwards
When operator’s cab is tilted backwards, turn the “tilt cab forwards/backwards” switch to
the right, then the cab will tilt forwards. After it tilts to proper position, turn the switch to
neutral position.
Turn the “tilt cab forwards/backwards” switch on the right control panel to the right, the
cab will tilt forwards;
Turn the “tilt cab forwards/backwards” switch on the right control panel to the neutral
position, the cab will stop tilting forwards.
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4.5.7 Auxiliary remote control box
The auxiliary remote control box, located on the right side of slewing table, is mainly used for
self-assembly & dismantling operation. The functions of switches on it are shown in following
figure.
101
102
103
104
105
106
107
108
Auxiliary remote control box
Instructions for switches on the auxiliary remote control box
NO.
101
102
103
104
105
Name of switch
Operation
Function
Counterweight left lifting
Push up
Extend left counterweight cylinder
cylinder switch
Push down
Retract left counterweight cylinder
Right counterweight
Push up
Right counterweight cylinder extends
control switch
Push down
Right counterweight cylinder retracts
Counterweight bolting
Push up
Extend bolting cylinder
cylinder switch
Push down
Retract bolting cylinder
A-frame erecting/lowering
Push up
Erect A-frame
switch
Push down
Lower A-frame
Emergency stop switch
Its function is the same as that of emergency shut-down
button on the right control panel.
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106
107
108
Undercarriage control
Only when this switch is turned on, can the support cylinder
switch
control levers be operated. (For details, see Section 4.5.8)
Pivot section bolting
Push up
Extend pivot section bolting cylinder
cylinder switch
Push down
Retract pivot section bolting cylinder
Push up
Spool up reeving winch
Push down
Reel off reeving winch
Reeving winch switch
Its function is the same as that of “Reeving winch” rotary
switch on the right control panel.
Note:
As soon as the emergency stop switch is pressed, the power supply of machine is
cut off and the engine shuts down!
4.5.8 Undercarriage remote control box
109
110
111
113
114
115
112
116
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Description of switches on the undercarriage remote control box
No.
Description
109
Changeover switch, FL support cylinder / left crawler carrier extension cylinder
110
Changeover switch, RL support cylinder / right crawler carrier extension cylinder
111
"FR support cylinder” switch
112
“RR support cylinder” switch
113
Emergency stop button
114
“Engine on/off” switch
115
Changeover switch, undercarriage auxiliary device / horn
116
“Cylinder extending/retracting” switch
Note:
1. As soon as the emergency stop button is pressed, the power supply of machine is
cut off and the engine shuts down!
2. Before carrying out the following operation, the undercarriage auxiliary device
switch should be switched on. Otherwise, no movements are performed.
Operation of support cylinders and crawler carrier bolting cylinders
Place the switch 109 in “FL support cylinder” position, and then push the
Extend
Front left
support
cylinder
toggle-switch 116 to “Extend” position. (Note: the switch 116 is a self-return
switch. Release it after the cylinder is extended to prescribed position.)
Place the switch 109 in “FL support cylinder” position, and then push the
Retract
toggle-switch 116 to “Retract” position. (Note: the switch 116 is a
self-return switch. Release it after the cylinder is extended to prescribed
position.)
Place the switch 110 in “RL support cylinder” position, and then push the
Extend
Rear left
support
cylinder
toggle-switch 116 to “Extend” position. (Note: the switch 116 is a self-return
switch. Release it after the cylinder is extended to prescribed position.)
Place the switch 110 in “RL support cylinder” position, and then push the
Retract
toggle-switch 116 to “Retract” position. (Note: the switch 116 is a
self-return switch. Release it after the cylinder is retracted to prescribed
position.)
Front
right
support
Place the switch 111 in “FR support cylinder” position, and then push the
Extend
toggle-switch 116 to “Extend” position. (Note: the switch 116 is a self-return
switch. Release it after the cylinder is extended to prescribed position.)
0066340-200-04Y.C
cylinder
Place the switch 111 in “FR support cylinder” position, and then push the
Retract
toggle-switch 116 to “Retract” position. (Note: the switch 116 is a
self-return switch. Release it after the cylinder is retracted to prescribed
position.)
Place the switch 112 in “RR support cylinder” position, and then push the
Extend
switch. Release it after the cylinder is extended to prescribed position.)
Rear right
support
cylinder
toggle-switch 116 to “Extend” position. (Note: the switch 116 is a self-return
Place the switch 112 in “RR support cylinder” position, and then push the
Retract
toggle-switch 116 to “Retract” position. (Note: the switch 116 is a
self-return switch. Release it after the cylinder is retracted to prescribed
position.)
Place the switches 109, 110, 111 and 112 in “FL support cylinder”, “RL
support cylinder”, “FR support cylinder” and “RR support cylinder”
Extend
positions, and then push the toggle-switch 116 to “Extend” position to
extend four cylinders simultaneously. (Note: the switch 116 is a self-return
All
switch. Release it after the cylinder is retracted to prescribed position.)
support
Place the switches 109, 110, 111 and 112 in “FL support cylinder”, “RL
cylinders
support cylinder”, “FR support cylinder” and “RR support cylinder”
Retract
positions, and then push the toggle-switch 116 to “Retract” position to
retract four cylinders simultaneously. (Note: the switch 116 is a self-return
switch. Release it after the cylinder is retracted to prescribed position.)
Place the switch 109 in “Left crawler carrier extension cylinder” position,
Left
crawler
carrier
extension
cylinder
Extend
and then push the toggle-switch 116 to “Extend” position. (Note: the switch
116 is a self-return switch. Release it after the cylinder is extended to
prescribed position.)
Place the switch 109 in “Left crawler carrier extension cylinder” position,
Retract
and then push the toggle-switch 116 to “Retract” position. (Note: the switch
116 is a self-return switch. Release it after the cylinder is retracted to
prescribed position.)
Place the switch 110 in “Right crawler carrier extension cylinder” position,
Right
Extend
crawler
116 is a self-return switch. Release it after the cylinder is extended to
prescribed position.)
carrier
Place the switch 110 in “Right crawler carrier extension cylinder” position,
extension
cylinder
and then push the toggle-switch 116 to “Extend” position. (Note: the switch
Retract
and then push the toggle-switch 116 to “Retract” position. (Note: the switch
116 is a self-return switch. Release it after the cylinder is retracted to
prescribed position.)
0066340-200-04Y.C
4.5.9 Operation of A-frame erection cylinder and mounting cylinder on A-frame
a) Operation of A-frame erection cylinder
A-frame can be erected by operating the “A-frame erecting/lowering” switch in operator’s
cab, or the “A-frame erecting/lowering” switch on auxiliary remote control box. (For
details, see Section 4.5.7)
Turn the “A-frame erecting/lowering” switch on right control panel to the left, A-frame
erection cylinder will be extended.
Turn the “A-frame erecting/lowering” switch on right control panel to the right, A-frame
erection cylinder will be retracted.
The above mainly introduces the operation of A-frame erection cylinder. As to the
operation of A-frame during self-assembly & dismantling, refer to section 5.2.2.
b) Operation of mounting cylinder on A-frame
Turn “W1 Winch/Assembly” switch on the right control panel to “Assembly” position, as
described above.
Push right control lever forwards, the mounting cylinder will be extended to low the load;
Push right control lever backwards, the mounting cylinder will be retracted to lift the load.
0066340-200-04Y.C
Extend mounting cylinder
Right control lever
Retract mounting cylinder
Operation of mounting cylinder
When operating self-assembly & dismantling mechanism, turn the “W1 winch /
Assembly” switch to right.
4.5.10 Emergency control box
117
118
119
120
121
122
123
124
0066340-200-04Y.C
Description of switches on emergency control box
No.
Names of the switches
117
Reserved
118
“Hoisting winch 1 (H1)” switch
Operation
Push it upward, spool up H1 to lift main load hook;
Push it downward, reel off H1 to lower main load hook;
Push it upward, spool up H2 to lift auxiliary load hook;
119
“Hoisting winch 2 (H2)” switch
Push it downward, reel off H2 to lower auxiliary load
hook;
120
“Main pump” switch
121
Emergency stop button
Push it upward, main pump 1 is selected;
Push it downward, main pump 2 is selected.
Cut off the power of emergency control box
Push it upward, spool up E to raise main boom (or
lower derrick boom when crane is operated with
122
“Main boom derricking winch
(E)” switch
derrick boom and suspended ballast);
Push it downward, reel off E to lower main boom (or
raise derrick boom when crane is operated with
derrick boom and suspended ballast);
123
124
“Luffing jib derricking winch
(W1)” switch
“Slewing mechanism” switch
Push it upward, spool up W1 to raise luffing jib;
Push it downward, reel off W1 to lower luffing jib;
Push it upward, slew the superstructure to the left;
Push it downward, slew the superstructure to the right;
The emergency control box is used only when the control system malfunctions.
Before operating the emergency control box, plug its 24-pin plug into the 24-hole socket
(X109) inside the electrical control box, which is near the slewing table.
(1) The emergency control box must only be used in an emergency to make crane do
safe motions.
(2) When control system is working normally, the emergency control box is not used
generally. It must be put in the waterproof toolbox, and the electrical connection
between emergency control box and electrical control box is disconnected.
0066340-200-04Y.C
4.6 Rope reeving
Select proper load hook and rope reeving in accordance with operational planning and different
boom configurations.
Type of load hook
Maximum rope reeving
Weight of load hook (Ib)
573300 Ib
20
9300
352800 Ib /220500 Ib
12/8
6200
110250 Ib
4
3900
66150 Ib
2
2400
35280 Ib
1
2000
573300 Ib load hook
352800 Ib /220500 Ib load hook
0066340-200-04Y.C
110250 Ib load hook
66150 Ib load hook
4.6.1 Heavy duty boom (S)
4.6.1.1 Hoisting rope guidance and reeving
573300 Ib load hook
35280 Ib load hook
0066340-200-04Y.C
0066340-200-04Y.C
352800 Ib /220500 Ib load hook
0066340-200-04Y.C
0066340-200-04Y.C
160/100t load hook
Winch 1 (1.3)
160/100t load hook
Winch 1 (1.3)
Winch 1 (1.3)
0066340-200-04Y.C
160/100t load hook
Winch 1 (1.3)
160/100t load hook
Winch 1 (1.3)
0066340-200-04Y.C
110250 Ib load hook
50t load hook
Winch 1 (1.3)
50t load hook
Winch 1 (1.3)
50t load hook
Winch 1 (1.3)
0066340-200-04Y.C
66150 Ib load hook
35280 Ib load hook
0066340-200-04Y.C
4.6.1.2 Main boom with tip boom
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4.6.2 Light duty boom (SL)
4.6.2.1 Hoisting rope guidance and reeving
0066340-200-04Y.C
4.6.2.1 Hoisting rope guidance for tip boom
0066340-200-04Y.C
4.6.3 Fixed jib on heavy duty boom (SF)
0066340-200-04Y.C
4.6.4 Luffing jib on heavy duty boom
4.6.4.1 Hoisting rope guidance and reeving
0066340-200-04Y.C
0066340-200-04Y.C
0066340-200-04Y.C
4.6.4.2 Hoisting rope guidance for tip boom on the luffing jib
4.6.5 Main boom derricking rope guidance and reeving
Derricking pulley
Derricking pulley in A-frame
in A-frame
To balance beam
To balance
beam
Derricking pulley at the tail
end of slewing table
Derricking
pulley
at the tail end of
Main boom derricking winch
slewing table
Main
boom
derricking winch
0066340-200-04Y.C
4.6.6 luffing jib derricking rope guidance and reeving
WA-frame 1
WA-frame 2
Hoisting winch 1
Chapter 5
Assembly and
dismantling
0066340-200-05Y.C
5.1 Safety-technical notes
5.1.1 Notes on assembly
a) Make sure that the crane complies with operating requirements. Then check the
position of A-frame, anchoring rods, WA-frame 1, WA-frame 2 and sequence of boom
intermediate sections one by one according to combination mode of boom length.
b) The hoisting rope must be reeved between the rope pulley on the main boom head and
load hook in accordance with the corresponding hoisting rope reevings specified in
Rope Reeving in chapter 4.
c)
Counterweight plates must be fitted according to load capacity chart.
d) For assembly work on the crane, a safety assembly scaffolding/ working platform
should be used. Improvisations are prohibited. Otherwise, there is a danger of falling
down.
e) Remove obstacles away from the ground on the site before assembling and
dismantling. In addition, the ground on the site should be cordoned off to prevent
access by unauthorized person.
f)
Assembly of the boom must be done over the front or rear of the undercarriage of the
machine; attention must be given to choose flat and solid ground to ensure proper
support of the crane.;
g) The fly jib should be assembled in accordance with the maximum permissible boom
length, and the wire rope should be installed strictly according to the hoisting rope
reevings.
h) Each dismantled part should not only satisfy the requirement of load-bearing capacity
under operating conditions, but also meet the art technology requirement of
self-assembling /dismantling operation which must be carried out strictly in accordance
with design requirement since the self-assembling /dismantling operation is a
complicated lifting process.
i)
Lattice components which are not in contact with the ground
assembly/disassembly must be supported by appropriate and stable objects.
during
j)
Make sure that no one is standing beneath the lattice boom when the lattice boom is
pinned or unpinned.
k)
Following certain disassembly principles and methods, QUY260 crawler crane can be
divided into several parts for transportation. Main parts include undercarriage centre
section, slewing table, A-frame and luffing pulley blocks, whose gross weight should be
controlled within 105840Ib. The slewing table and undercarriage centre section should
be placed in the same direction, and operator’s cab should be swung in 90°. Crawler
carrier should be transported as a whole part. Boom system can be dismembered into
boom sections and fly jib can be placed in main boom and secured with two chains
during transportation. If lattice components are not secured, the inside lattice
components will slide out and fall down which may cause severe accident.
0066340-200-05Y.C
l)
For SW boom configuration:
Only when the angle of luffing jib to main boom reaches 100°(main boom angle is
larger than 65°) and the luffing jib is not attached with a load hook, can it be raised up;
to lay down the luffing jib, make sure that the angle between the main boom and luffing
jib is equal to or larger than 10° when the tilting-back supports of luffing jib are yet not
dismantled.
5.1.2 Checking safety measures
a) Clearly define the duty and area of responsibility of all personnel concerned.
b) Check whether the crane is adjusted to be horizontal.
c) Check whether there is sufficient safety clearance to slopes and trenches.
d) Check whether there are any live wires within the operating range of the crane and make
sure that any parts of the crane are not in contact with the live-wire when crane
movement is carried out.
e) Checks that appropriate operating site has been selected so that the crane movements
can be performed within maximum and minimum working radius.
f)
Check whether there are obstacles which will hinder required crane operations.
g) Check whether the ground provides adequate load-bearing capacity.
h) Know clearly about the type of crane operation and working mode.
i)
Check the distance between the lifting points and surrounding buildings;
j)
Check influence of communal facilities(including the overhead high/low voltage lines
and underground gas pipes;
k) Check movement restrictions due to surrounding structures(e.g. is there another crane
nearby in working);
l)
Check number, weight, dimensions, material of load(s) to be lifted;
m) Check required lifting height and slewing radius;
n) Check heights and widths of thoroughfares leading to the site.
o)
Communication means must be agreed upon by both the signalman and crane
operator;
p)
Take appropriate measures to keep people unconcerned and equipment away from the
working range;
Note:
To master the actual condition of lifting operation accurately and ensure safe operation,
the safety measures mentioned above should checked and a proper operational planning
should be carried out.
0066340-200-05Y.C
5.1.3 Inspection of wire rope, load hook, rope pulley and anchoring rods
5.1.3.1 Checking the wire ropes
The ropes must be checked by an expert before assembly and checks must be
performed at regular intervals in order to detect possible damage or wear and tear at an
early stage.
The ropes must be removed immediately if any of the following damage is detected:
a) Breakage of a strand;
b) Wire breaks;
c) reduction in the rope diameter by more than 10% of the nominal size
d) Rope deformation.
The replacement rope must comply with the original rope specifications, including length,
diameter and strength rating. The cam-type limit switch must be readjusted if a new
hoisting rope is used!
Damaged rope pulley should be repaired or changed prior to replacing wire rope;
otherwise, new wire rope will be damaged.
The inspection and maintenance of wire rope is detailed in Chapter 7.
5.1.3.1.1 A small piece of rope is cut and clipped to the dead end. This method is good for regular
rope and is approved by ASME sTANDARD B30.5. Distance S
" " should be approximately
3xrope diameter or 75mm (3in),whichever is less,please see the warning in Clause E5 for its
use.
5.1.3.2 Checking load hook
a) Check the hook for distortions; e.g., at the hook jaw;
b) Inspect all bolts and screws, and ensure all cotter pins are complete.
0066340-200-05Y.C
c) Check that the rotary connection of hook can move easily, and the clearance is not
too large;
d) Check the easy rotation of the hook: rotate the hook by hand. If it is stiff, it indicates
that the bearing has been damaged;
e) Check the safety catch for completeness and functional work;
f)
Check the hook for corrosion and wear.
5.1.3.3 Checking rope pulleys
a) Check rope pulley all around for damage and cracks.
b) If rope pulleys have been hit during crane operation (for example on buildings) or if
they were subjected to other stress factors, they must be then extensively checked
for damage or cracks.
c)
Check for wear on the rope groove. Replace the pulley if the bottom of the rope
pulley has been worn down more than 1/4 of the rope diameter.
d) If any damage or cracks are found, then the rope pulley must be replaced
immediately. If this is not observed, there is great danger of causing a serious
accident!
e) Check rope pulley for tight fit and shakes; Loose and shaken rope pulley indicates
that the bearing and bearing bush is damaged.
5.1.3.4 Checking anchoring rods
a) The anchoring rods should be secured well on boom frame during
transportation;
b) The anchoring rods, if removed from boom frame for transportation, must be
re-assembled according to anchoring rods configuration;
c) Check the anchoring rods for cracks, wear and corrosion;
d) The anchoring rods should be checked regularly. For the items to be checked,
please refer to the Section 7.6 “Inspection and maintenance of anchoring rods” in
Chapter 7.
0066340-200-05Y.C
5.1.4 Connecting or disconnecting the hydraulic lines with quick-release couplings
When hydraulic lines are connected or disconnected using quick-release couplings please
ensure that the coupling procedure is being performed correctly.
Requirements for a proper connection:
a) Depressurize hydraulic system before connecting and disconnecting (switch off the
engine and wait for about 5 minutes).
b) Coupling parts (cathode end and anode end) are plugged into each other and
screwed together using the hand-tightened nut.
c) Turn the hand-tightened nut over the O-ring until a firm and tight fit is attained.
d) The hydraulic couplings may only be tightened or unscrewed by hand rather than by
tools which may cause damage to couplings.
Danger: Improperly connected couplings may lead to a loss of pressure or sudden leaking,
thereby causing accidents.
5.1.5 Setting-up and taking-down
Before setting up and taking down the boom system, ensure that the following prerequisites
are met:
a) The crane is properly supported and level;
b)
The counterweight plates have been attached in accordance with the load capacity
chart.
c)
All limit switches has been correctly fitted and are fully operational;
d) The main boom and fly jib have been attached in accordance with the boom
configurations and operating instructions.
e) All pinned connections have been secured;
f)
The hoisting rope has been correctly placed in the rope pulleys and prevented from
jumping out (from rope groove) using rope retaining pins.
g) There are no loose parts on main boom or fly jib.
h) In winter, the main boom, fly jib and associated components (limit switches, rope drums,
warming lamp, anemometer etc.) must be kept free of ice and snow.
Danger:
Incorrectly fitted or faulty limit switches and falling parts (pins, retaining pins, ice etc.) can
cause injury.
0066340-200-05Y.C
5.2 A-frame
The A-frame erecting mechanism consists of A-frame, erection cylinder and auxiliary
hydraulic system, etc. it is mainly used for the assembly, dismantling or conversion of the
machine on the site. Erect the A-frame by the erection cylinder to the upper tilt point at
approximately 110° (the angle of A-frame to the front horizontal line is 70°). When A-frame
tilts forwards under its own weight, the main boom derricking winch is simultaneously
operated in a lowering direction until A-frame reaches 165° (the angle of A-frame to the front
horizontal line is 15°). Under this condition, the A-frame erecting mechanism can be used to
connect anchoring rods and used as a mounting crane.
The function of A-frame erecting mechanism:
a)
Serving as a mounting crane
— After the A-frame is tilts forwards to a required position, the boom sections, and
0066340-200-05Y.C
crawler carriers and individual counterweight plate can be lifted by the mounting
cylinder on A-frame. in the process of self assembly & dismantling, the A-frame
erecting mechanism serves as a mounting crane, whose maximum lifting capacity
is 55125Ib in 16′4″working range;
b) Serving as a component of derricking mechanism
— The derricking mechanism of the crane is composed of A-frame and the boom frame,
the A-frame is therefore an integral part of the derricking mechanism.
5.2.1 Connecting the hydraulic lines to mounting cylinder on A-frame
The hydraulic lines to mounting cylinder are connected as follows:
a) The quick-release coupling is a hydraulic connector consisting of a cathode end
(internal thread) and an anode end (external thread).
b) To connect the hydraulic lines, the operator just need to plug the anode end of
quick-release coupling into the cathode end of it.
c) To distinguish between the two quick-release couplings of the same type, on the
mounting plate are often installed a cathode end of one coupling and an anode end of
the other coupling.
Two quick-release couplings are fitted on the left arm of A-frame(see following diagram)
Position of quick-releasing coupling in A-frame:
Mounting balance valve
installation position of quick-release coupling
Hydraulic lines connecting diagram:
Quick-release coupling
0066340-200-05Y.C
Anode end of quick-release coupling
Cathode end of quick-release coupling
Plug the anode end of quick-release coupling to its cathode end.
Caution:
When hydraulic lines are connected and disconnected using quick-release couplings,
please ensure that the coupling procedure is being performed correctly.
Requirements for a proper connection:
1. Depressurize hydraulic system before connecting and disconnecting. Turn off engine and
wait for 5 minutes.
2. Coupling parts (cathode end and anode end) are plugged into each other and screwed
together using the hand-tightened nut.
3. Turn the hand-tightened nut over the O-ring until a firm and tight fit is attained.
4. The couplings may only be tightened by hand rather than by tools which will cause
damage to coupling.
5. It is strongly recommended that a quick-release coupling with a diameter larger than 1
inch should be tightened by spanner.
Fit together the protective covers of the hydraulic couplings and hydraulic connectors.
Danger:
Improperly connected couplings may lead to a loss of pressure or sudden leaking, thereby
causing accidents.
0066340-200-05Y.C
5.2.2 Operation of A-frame
5.2.2.1 A-frame movement control
A-frame can be erected or lowered by operating the “A-frame erecting/lowering” switch
(57) in the operator’s cab.
Erect A-frame
Neutral
Lower A-frame
Turn the switch (57) on the right control panel (4) to the left——erect A-frame
Turn the switch (57) on the right control panel (4) to the right——lower A-frame
A-frame movement can also be controlled by operating the “A-frame erecting/lowering”
switch on the auxiliary remote control box.
“A-frame (mast) erecting/lowering” switch
Push the “A-frame erecting/lowering” switch up ----erect A-frame
Push the “A-frame erecting/lowering” switch down----lower A-frame
0066340-200-05Y.C
Caution:
1. The control lever code and control panel code appeared in this chapter are detailed in section
4.1 “Control and operating instruments” of chapter 4 “Crane Operation”
2. The operation mentioned above should be performed by two persons. One worker gives
guidance (watch the A-frame, erection cylinder and rope guiding condition on the derricking
winch), while another worker operates.
5.2.2.2 Erecting A-frame
Note: before operation, make sure that derricking rope is reeved between derricking pulley
block on A-frame and that on slewing table and sit well in the derricking pulley block.
a) Turn switch (57) in operator’s cab to the left or push up “A-frame erecting/lowering”
switch on the auxiliary remote control box, the erection cylinder will extend to erect
A-frame from 0°position upwards until the derricking rope between the slewing table
and the derricking pulley block is tensioned, and then move the right control lever (27)
to the right to reel off the derricking winch.
b) After A-frame is erected to 110° position, return the switch (57) or “A-frame
erecting/lowering” switch on the auxiliary remote control box to neutral position, and
then the erection cylinder will stop movement. At this time, A-frame tilts forwards under
its own weight, and the derricking winch is reeled off simultaneously.
Neutral--stop
Right- reel off derricking winch
Right control lever
Left-spool up derricking winch
c) When A-frame tilts forwards under its own weight to 165° limit position, return the right
control lever(27) to neutral position to stop the movement of “reel off the derricking
winch ”
0066340-200-05Y.C
Caution:
1.
A-frame movement limit should not be exceeded; otherwise, the crane is likely to topple
over.
2.
A-frame position can be adjusted within its movement limit depending on different
working requirements.
3.
No slack must be allowed to develop in derricking rope when A-frame is in motion.
5.2.2.3 Lowering A-frame
a) Move the right control lever (27) to the left to spool up the derricking winch, and the
A-frame will be raised backwards.
b) After A-frame is raised by the derricking rope to 110° position, turn the switch (54) in
operator’s cab to the right or push down “A-frame erecting/lowering” switch on the
auxiliary remote control box, the erection cylinder will retract, and A-frame will also
retract.
c) When the erection cylinder and A-frame return to original or required position, return the
switch (57) in operator’s cab or “A-frame erecting/lowering” switch on the auxiliary
remote control box to neutral position, and then the erection cylinder will spot motion. At
the same time, move the right control lever (27) to neutral position to stop the
movement of “spool up the derricking winch”.
Caution:
1.
No person may stand underneath A-frame as long as A-frame is moving; otherwise there is a
risk of injury.
2.
No slack must be allowed to develop in derricking rope when A-frame is in motion.
0066340-200-05Y.C
5.3 Attaching the crawler carriers
5.3.1 Unloading of basic machine
5.3.1.1 Checks before operation
a) Jobsite
1) The ground on the jobsite must be firm and flat. If necessary, steal plate should be
padded.
2) It should be large enough for trailer traveling and auxiliary hoist operation.
b) Operating procedure and safety regulations
All operators should be familiar with operating procedure and safety regulations and
clear about their areas of responsibility before operation.
c) Checks before operation
Check the basic machine before operation.
5.3.1.2 Unloading the basic machine
a) After the basic machine reaches the jobsite, remove related fixing devices and the
package.
Basic machine in transport position
b) Swivel the operator’s cab from transport position to working position and then secure it
with “fixing pin for swivel arms”
Fixing pin for
swivel arm
Slewing table
Forward
direction
Operator’s cab in transport position
operator’s cab in working position
0066340-200-05Y.C
c) Raise the A-frame by erection cylinder to 110° position.
d) To support the basic machine
- swivel the folding brackets out into the support position
- pull out the fixing screw for support plates on the undercarriage centre section
- detach the support plates and assemble it under the support cylinder
e) Use bonded wooden plates or steel plates to underlay all support plates.
- Before operate the support cylinders and crawler carrier bolting cylinders, turn on
“undercarriage auxiliary control switch” in the auxiliary remote control box (see
Section 4.5.7), and then operate the undercarriage control levers.
- Each support cylinders and crawler carrier bolting cylinders can not only be controlled
0066340-200-05Y.C
independently but also operated simultaneously.
- Select a support cylinder to be operated by the undercarriage selective control lever,
and then extend the support cylinder by operating the cylinder telescoping control
lever.
Note: in the assembling process, the maximum force support cylinder can bear is
63945 Ib.
Caution:
1. In no circumstance, can the extending of support cylinders be carried out by one person. At
least two assistants are available to support the basic machine. One assistant operates the
control levers while another assistant watches the position of support cylinders and see
whether the crawler carrier bolting cylinder is extended to specified position.
2. When the support cylinders are operated, the engine should run at low-middle speed (about
1000-1500rpm).
3. The support cylinders should be extended on firm and even ground. During operation, pay
attention to the level state of basic machine.
0066340-200-05Y.C
f) Drive the low-loader away.
0066340-200-05Y.C
5.3.2 Attaching the first crawler carrier
a) Tilt the A-frame forwards according to the Section 5.2 “ Operation of A-frame”
b) Turn “self-assembly& dismantling” switch on the right control panel to right and push the
right control lever (27) forwards, and then the mounting cylinder on A-frame will be
extended. Connect the mounting cylinder to crawler carrier with assembling chain.
Caution:
Hang the twin hook on the loose end of the attachment in the holes of the floor plate
underneath to prevent the crawler carrier from hanging down during mounting of the crawler
carrier.
c) Push the right control lever (27) backwards to retract the mounting cylinder to lift the
first crawler carrier from the transport vehicle.
Slowly raise A-frame and adjust the mounting cylinder to align the crawler carrier
exactly on the bolting points on the undercarriage centre section. Carefully and
sensitively position the crawler carrier by the undercarriage centre section and upper
limit plate of crawler carrier.
0066340-200-05Y.C
Turn on “undercarriage auxiliary control” switch on the auxiliary remote control box,
and then extend the crawler carrier bolting cylinders with appropriate control lever. In
this way, the first crawler carrier is attached on the undercarriage centre section by the
bolting cylinders.
Positioned by the upper limit plate of crawler carrier and undercarriage centre section
Overhang beam
of undercarriage
centre section
Upper limit plate of crawler
carrier
Bolting
cylinder
Caution:
Bring the transport vehicle with the first crawler carrier as close as possible to the basic
machine to make sure that the distance between the centre of crawler carrier and the
rotation axis of the upper carriage is smaller than or equal to 5m.
Note: the slewing radius of hook attached to the mounting cylinder on A-frame must be
smaller than or equal to 5m.
0066340-200-05Y.C
5.3.3 Attaching the second crawler carrier
a) Slew the superstructure to a position where the second crawler carrier can be attached.
The assembly sequence for the second crawler carrier is essentially the same as for the
first crawler carrier.
b) After the second crawler carrier is attached, it must be lowered on the ground by
retracting the support cylinders. c) Detach the support plates from support cylinders and fixed them on undercarriage
centre section.
d) Retract the support cylinders completely. Swivel inwards the folding brackets and
secure them with locking pins. e) Swivel in the locking plate on folding bracket and secure it with locking pin.
f)
Establish hydraulic connection to both crawler carriers via quick-release couplings.
Caution:
1.
The slewing radius of hook attached to mounting cylinder on A-frame must be no more
than 16′4″; otherwise the basic machine may turn over.
2.
When mounting the crawler carrier, nobody is permitted to stand in the working radius.
3.
Crawler carrier bolting cylinders which are used to connect the crawler carriers to
undercarriage centre section should be greased.
0066340-200-05Y.C
5.3.4 Connecting the hydraulic lines to the crawler carrier
There are 8 hydraulic lines in total led out from the left and right sides of undercarriage
centre section, which are respectively connected to the left and right crawler carrier. Take
the hydraulic connection to the left crawler carrier for example:
Connect hydraulic lines to two crawler carriers via quick-release couplings:
The quick-release coupling is a hydraulic connector consisting of a cathode end (internal
thread) and an anode end (external thread). Plug the anode end of a quick-release coupling
to the cathode end of it, the hydraulic connection can then be established.
To distinguish between the two quick-release couplings of the same type, a cathode end of
one coupling and an anode end of the other coupling are often installed on the mounting
plate.
Hydraulic lines connecting diagram:
Quick-release coupling
Anode end of quick-release coupling
Cathode end of quick-release coupling
0066340-200-05Y.C
Plug the anode end of quick-release coupling to its cathode end.
Position of mounting plate for quick-release coupling:
Mounting
plate
for
quick-release coupling
Fit together the protective covers of the hydraulic couplings and hydraulic connectors.
Note:
When hydraulic lines are connected and disconnected using quick-release couplings,
please ensure that the coupling procedure is being performed correctly.
Requirements for a proper connection:
1. Depressurize hydraulic system before connecting and disconnecting. Turn off engine and
wait for 5 minutes.
2. Coupling parts (cathode end and anode end) are plugged into each other and screwed
together using the hand-tightened nut.
3. Turn the hand-tightened nut over the O-ring until a firm and tight fit is attained.
4. The couplings may only be tightened by hand rather than by tools which will cause
damage to coupling.
Danger:
Improperly connected couplings may lead to a loss of pressure or sudden leaking, thereby
causing accidents.
0066340-200-05Y.C
5.4 Attaching the central counterweight
Central counterweight plate (weight: 14600Ib ×2)
The central counterweight consists of two central counterweight plates, which are located at
the front and rear of the undercarriage between the crawler carriers. After the basic machine
is fitted with the left and right crawler carriers, lift the first counterweight plate from transport
vehicle and lay it on the supports on the inside of crawler carriers after rotating the
superstructure to the front of crane. The second counterweight plate is installed at the rear
end of crane in the same way (for the operation of superstructure, A-frame and mounting
cylinder, please refer to Section 5.3 “attaching the crawler carriers”).
Schematic diagram for fitting Central counterweight plate
0066340-200-05Y.C
Central counterweight
Central counterweight fitting position
5.5 Assembling the rear counterweight
The rear counterweight, weighing 187400Ib in total, consists of 10 counterweight plates of
14600Ib each and a counterweight base plate of 41900Ib. The stacks of individual
counterweight plates must always be stacked up symmetrically on both sides of
superstructure tail-end.
Counterweight base plate(41900Ib.×1)
Counterweight plates (14600Ib×10)
0066340-200-05Y.C
Procedure for mounting the rear counterweight:
Lift the counterweight base plate and lay it on a flat ground, and then lift the individual
counterweight plate one by one from the transport vehicle and stack them on the base
plate by aligning them over the fixing position (two circular prominences) at the two
sides of base plate. Fix the counterweight locking chain and secure it (the locking
chain passes through the center of counterweight).
0066340-200-05Y.C
b)
Push up the “left and right counterweight control” switches on the auxiliary remote control
box, the left and right counterweight cylinders will extend to lift the counterweight.
Tail-end of slewing
table
E
D
C
B
A
F
F
A.Counterweight base plate
C. Counterweight lifting cylinder
B. counterweight plate
D. Counterweight assembly chain
E. counterweight locking chain (through the center of counterweight)
F. counterweight bolting cylinder
c) If the counterweight is not level during the lifting process, adjust one counterweight
cylinder by the “counterweight left/right lifting cylinder” switch to make the counterweight
to be level. And then extend or retract the two counterweight cylinders simultaneously;
d) Turn on the “counterweight bolting cylinder” switch on the auxiliary remote control box to
extend the counterweight bolting cylinder to required position and secure the bolting
cylinder with retaining spring. After that, retract the counterweight cylinders.
0066340-200-05Y.C
e) The dismantling of counterweight plates is carried out in the reverse order to assembling.
Caution:
1.
When stacking the counterweight plate on top of one another, align the upper
counterweight plate over the circular prominences at the two sides of the lower
counterweight plate and secure well.
2.
In any condition, the assembling and dismantling of counterweight plates should be
carried out by more than two persons. A person is not permitted to perform this
operation. When extending or retracting the counterweight cylinders, make sure that the
counterweight base plate is level and synchronous at any time. When inclination
situation occurs, the operator should synchronize them immediately through controlling
the movement of one cylinder.
3.
In the process of self assembly& dismantling, A-frame can only be used to lift one
counterweight plate at a time.
0066340-200-05Y.C
5.6 Available boom configurations for Crawler Crane QUY260
G10
G22
G12
G25
G15
G29
G15
G15
G15
G15
G15
G15
G15
G15
G15
G15
G15
G14
G14
G13
G13
G11
G11
G70
G17
G70
G17
S---Heavy duty boom
SL---light duty boom
0066340-200-05Y.C
G32
G74
G34
G74
G41
G37
G75
G37
G31
G12
G75
G12
G15
G15
G15
G15
G15
G15
G15
G15
G15
G15
G15
G15
G13
G13
G11
G11
G70
G17
SF---Fixed jib on heavy duty boom
G1
G70
SFV---Heavy fixed jib on heavy duty boom
0066340-200-05Y.C
G20
G22
G25
G25
G25A
G24
G24
G23
G27
G21
G71
G28
G12
G72
G15
G15
G15
G15
G14
G11
G70
G17
SW---luffing jib on heavy duty boom
0066340-200-05Y.C
Description of part number of boom configuration
Length (ft)
Weight (Ib)
Part number
Description
G10
Tip boom on main boom
head
G11
Main boom pivot section
(32′9″)
6659.1
G12
Main boom head
(32′9″)
7452.9
G13
Main boom intermediate
section
(9′10″)
1587.6
G14
Main boom intermediate
section
(19′8″)
2646.0
G15
Main boom intermediate
section
(29′6″)
3924.9
G17
A-frame
G20
Tip boom on luffing jib head
G21
Luffing jib pivot section
(29′6″)
2315.3
G22
Luffing jib head
(29′6″)
2425.5
G23
Luffing jib intermediate
section
(9′10″)
705.6
G24
Luffing jib intermediate
section
(19′8″)
1323.0
G25A
Luffing jib intermediate
section
(29′6″)
1764.0
G25
Luffing jib intermediate
section
(29′6″)
1323.0
G27
WA-frame 1
3351.6
G28
WA-frame 2
3836.7
441.0
6923.7
0066340-200-05Y.C
Part number
Description
Length (ft)
Weight (Ib)
G29
Reducing section
(13′1″)
1808.1
G31
Fixed jib pivot section
(19′8″)
1036.4
G32
Fixed jib head
(19′8″)
1367.1
G33
Fixed jib intermediate
section
573.3
G37
FA-frame
1653.8
G70
Titling-back support of main
boom
573.3
G71
Tilting-back support of
lufffing jib
176.4
G72
Rear tilting-back support of
luffing jib
154.4
G74
Front tilting-back support of
fixed jib
132.3
G75
Rear tilting-back support of
fixed jib
66.2
Danger:
1.
Any other boom configurations and anchoring rods combination that have not been
stipulated in the operating manual are prohibited.
2.
When attaching boom sections, make sure that the intermediate sections are assembled to
their specified positions; otherwise there is a risk of accidents.
0066340-200-05Y.C
5.7 Boom configuration
5.7.1 Heavy duty boom (S)
5.7.1.1 Component of heavy duty boom
The heavy duty boom, whose length varies from 65′7″~272′3″, comprises basic boom
and an optional number of main boom intermediate sections. The basic boom is 65′7″
long, including main boom pivot section (G11), main boom head (G12), tip boom (G10).
There are three types of main boom intermediate section: 9′10″ main boom intermediate
section (G13), 19′8″ main boom intermediate section (G14) and 29′6″ main boom
intermediate section (G15).
the longest heavy duty boom of 83m, overview:
G10
G12
G15
G15
G15
G15
G15
G15
G14
G13
G11
G17
G70
0066340-200-05Y.C
Main boom pivot section—G11
Main boom head—G12
(9′10″)main boom intermediate section—G13
(19′8″) boom main intermediate section—G14
(29′6″ ) main boom intermediate boom section—G15
0066340-200-05Y.C
When different main boom length is required, crane operator only needs to disconnect
main boom pivot section from main boom head, and then install main boom intermediate
sections between them. In this way, main boom can be assembled to required length.
Main boom assembly table
Main boom
length (ft)
assembly sequence of
main boom sections
Main boom
length (ft)
assembly sequence of main boom
sections
(65′7″)
G11+G12
(173′10″)
G11+G14+3×G15+ G12
(75′5″)
G11+G13+G12
(183′8″)
G11+4×G15+ G12
(85′3″)
G11+G14+ G12
(193′6″)
G11+G13+4×G15+ G12
(95′1″)
G11+G15+ G12
(203′4″)
G11+G14+4×G15+ G12
(104′11″)
G11+ G13+G15+ G12
(213′2″)
G11+5×G15+ G12
(114′9″)
G11+ G14+G15+ G12
(223′0″)
G11+G13+5×G15+ G12
(124′7″)
G11+2×G15+ G12
(232′10″)
G11+G14+5×G15+ G12
(134′5″)
G11+G13+2×G15+ G12
(242′8″)
G11+6×G15+ G12
(144′3″)
G11+G14+2×G15+ G12
(252′6″)
G11+G13+6×G15+ G12
(154′1″)
G11+3×G15+ G12
(262′4″)
G11+G14+6×G15+ G12
(164′0″)
G11+G13+3×G15+ G12
(272′2″)
G11+G13+G14+6×G15+ G12
Principle for assembling main boom: when connecting main boom intermediate sections,
always bolt the shorter intermediate sections first.
Danger:
1. Pin different boom sections strictly in accordance with main boom assembly table.
2. The operator should not stand inside the boom or beneath it when the boom sections are
pinned.
5.7.1.2 Connecting the hydraulic lines to luffing winch(if luffing winch is used)
Connect the hydraulic lines to A-frame via quick-release coupling.
Connect the hydraulic lines to luffing winch:
There is a mounting plate for quick-release coupling at the front left side of slewing table. It is
used to establish hydraulic connection to luffing winch. The coupling procedure of hydraulic
lines is shown in following figure.
Hydraulic lines connecting diagram:
Quick-release coupling
0066340-200-05Y.C
Anode end of quick-release coupling
Cathode end of quick-release coupling
The quick-release coupling is a hydraulic connector consisting of a cathode end (internal
thread) and an anode end (external thread).
To connect the hydraulic lines, the operator just needs to plug the anode end of quick-release
coupling into the cathode end of it.
To distinguish between the two quick-release couplings of the same type, on the mounting
plate are often installed a cathode end of one coupling and an anode end of the other
coupling.
The mounting plate for quick-release coupling is installed on the left side of boarding (see
following fig.) on the mounting plate are fixed five ends of five quick-release couplings, and
the rest five ends are fixed on the left side plate of bottom section of A-frame.
0066340-200-05Y.C
Quick-release coupling
Mounting plate for quick-release
coupling
Fit together the protective covers of the hydraulic couplings and hydraulic connectors.
Caution:
When hydraulic lines are connected and disconnected using quick-release couplings, please
ensure that the coupling procedure is being performed correctly.
Requirements for a correct connection:
1.
Depressurize hydraulic system before connecting and disconnecting. Turn off engine and wait
for 5 minutes.
2.
Coupling parts (cathode end and anode end) are plugged into each other and screwed
together using the hand-tightened nut.
3. Turn the hand-tightened nut over the O-ring until a firm and tight fit is attained.
4.
The couplings may only be tightened by hand rather than by tools which will cause damage to
coupling.
0066340-200-05Y.C
Danger:
Improperly connected couplings may lead to a loss of pressure or sudden leaking, thereby causing
accidents.
5.7.1.3 Combination of anchoring rods of heavy duty boom
Each kind of boom is assigned to anchoring rods of specific length, and the anchoring rods
should be connected strictly in accordance with the given method.
Now, we will illustrate the connection method of anchoring rods of different main boom, for
example basic boom of 65′7″.
0066340-200-05Y.C
0066340-200-05Y.C
Component parts of main boom anchoring rods
Part
Description
Illustration
No.
1
Pin spindle
2
Cotter pin
ISO1234-1997(0.4″×3.8″)
Anchoring rod
3
connected to main
boom
4
Pin spindle
5
Retaining pin
Single-anchoring
6
rod
7
Pin spindle
Double-anchoring
8
rod
0066340-200-05Y.C
Single-anchoring
9
rod
Double-anchoring
10
rod
11
Coupling link
12
Pin spindle
Double-anchoring
13
rod
14
15
Reducing piece
Cotter Pin
ISO1234-1997(0.48″×4.8″)
0066340-200-05Y.C
16
Pin spindle
Double reducing
17
piece
Single-anchoring
18
rod
19
Coupling link
20
Cotter Pin
ISO1234-1997(0.4″×4.8″)
21
Pin spindle
0066340-200-05Y.C
22
anchoring rod
connected to
A-frame
23
Cotter Pin
ISO1234-1997 (0.32″×2.4″)
24
Pin spindle
Note:
The part number of main boom anchoring rods given in Section 5.7.1.3 “combination of main
boom anchoring rods” is consistent with that in the above table, so the component parts of
anchoring rods can be found by referring to the part number.
Principle for determining the length of main boom anchoring rods:
When basic boom is 65′7″ long, the length of main boom anchoring rods is 56′1″;
When main boom length increases by 9′10″, a 0′11″-long double anchoring rod(8) and a
8′10″-long single anchoring rod(9) should be added accordingly.
When main boom length increases by 19′8″, a 0′11″-long double anchoring(8) rod and a
18′8″-long single anchoring rod(6) should be added accordingly.
When main boom length increases by 29′6″, two 0′11″-long double anchoring rods(8) and a
8′10″-long single anchoring rod(9) as well as a 18′8″-long single anchoring rod(6)should be added
accordingly.
The width of main boom anchoring rods is 2.6″, and the diameter of pin spindle is φ2″.
Combination of main boom anchoring rods is shown in following diagram:
0066340-200-05Y.C
Connecting diagram of main boom anchoring rods
41m
38m
35m
32m
29m
26m
23m
20m
0066340-200-05Y.C
Connecting diagram of main boom anchoring rods
0066340-200-05Y.C
5.7.2 Light duty boom ( SL)
5.7.2.1Components of light duty boom
The light duty boom, whose length varies from 282′1″~311′8″, comprises main boom
sections, 13′1″ reducing section (G29) and luffing jib sections. And main boom sections
consist of main boom pivot section (G11) and an optional number of main boom
intermediate sections 9′10″ (G13), 19′8″(G14) and 29′6″ (G15) in length. Luffing jib
sections contain luffing jib head (G22) and an optional number of luffing jib intermediate
sections 9′10″(G23), 19′8″( (G24) and 29′6″ (G25) in length.
the longest light duty boom of
311′7″(, overview:
G22
G25
G29
G15
G15
G15
G15
G15
G15
G14
G13
G11
G17
G70
0066340-200-05Y.C
13′1″ reducing section (G29)
luffing jib pivot section(G21)
Luffing Jib head (G22)
(9′10″) luffing jib intermediate section (G23)
(19′8″ )luffing jib intermediate section (G24)
0066340-200-05Y.C
(29′6″) luffing jib intermediate section (G25)
When different main boom length is required, crane operator only needs to disconnect
pivot section from main boom head, and then install intermediate sections between them.
In this way, the main boom can be assembled to required length.
Assembly table of light duty boom sections
Boom
length(ft)
Assembly sequence of boom
sections
Boom
length (ft)
Assembly sequence of boom
sections
(282′0″)
G11+
G13+G14+6×G15+G29+G22
(301′9″)
G11+
G13+G14+6×G15+G29+G24+G22
(291′11″)
G11+
G13+G14+6×G15+G29+G23+G22
(311′7″)
G11+
G13+G14+6×G15+G29+G25+G22
Principle for assembling boom sections: when connecting boom intermediate sections,always bolt
the shorter intermediate sections first.
For this boom configurations, the first 239′5″ long boom is composed of main boom sections, and
the rest boom is either composed of 13′1″ reducing section (G29) and luffing jib head (G22), or
13′1″ reducing section (G29), lufffing jib head (G22) together with a luffing jib intermediate
section (i.e. G23, G24 or G25). See the table above.
5.7.2.2 Components of anchoring rods of light duty boom
Anchoring rods of light duty boom consists of anchoring rods of heavy duty boom and light
anchoring rods.
Anchoring rods of heavy duty boom
The length of anchoring rods of heavy duty boom used in this boom configuration is always 231′2″
. Different lengths of anchoring rods of light duty boom can be available by adjusting the length of
light anchoring rods according to the length of light duty boom.
0066340-200-05Y.C
To A-frame
To41m
light
anchoring rods
38m
Anchoring rods of heavy duty boom (it length is 231′2″)
35m
32m
Caution:
32m
38m
35m
32m
For 29m
part number of main boom anchoring rods, please see Section 5.7.1.3 “Combination of
29m
anchoring rods of heavy duty boom”
29m
26m
23m
20m
26m
23m
20m
26m
23m
20m
0066340-200-05Y.C
b)
light anchoring rods
Another component part of anchoring rods of light duty boom is the light anchoring rods. The
anchoring rods shown in the following figure is the light anchoring rods assigned to 282′0″ light duty
boom
To anchoring
rods of heavy
duty boom
To luffing
head
jib
0066340-200-05Y.C
Component parts of light anchoring rods
Part
No.
Description
1
Pin spindle
2
Retaining pin
3
Double-anchoring
rod
4
Coupling link
5
Single-anchoring
rod
6
Cotter pin
illustration
ISO1234-1997 (0.4″×3.8″)
7
Coupling link
0066340-200-05Y.C
8
Double-anchoring
rod
9
Pin spindle
10
Single-anchoring
rod
17
Double-anchoring
rod
19
Single-anchoring
rod
20
Single-anchoring
rod
21
Double-anchoring
rod
0066340-200-05Y.C
Note:
The part number of anchoring rods given in Section 5.7.2.2——b “light anchoring rods” are
consistent with those in the above table, so the component parts of anchoring rod can be found by
referring to the part number.
Combination of light anchoring rods:
Combination of light anchoring rods
Length of light
duty boom (ft)
Length of light
anchoring rods (ft)
(311′7″)
(69′2″)
LA=3+4+5+7+8+10+17+19+17+20+17+20+21
(301′9″)
(59′4″)
LB=3+4+5+7+8+10+17+19+17+20+21
(291′11″)
(49′6″)
LC=3+4+5+7+8+10+17+20+17+19+21
(282′0″)
(39′8″)
LD=3+4+5+7+8+10+17+19+21
5.7.2.2.3
Combination of light anchoring rods(between anchoring
rods of heavy duty boom and luffing jib head)
Total length of anchoring rods of light duty boom
Possible total length of anchoring rods of light duty boom
Total length
of anchoring
rods of light
duty boom
(ft)
Length(L) of
anchoring
rods of heavy
duty boom
(311′7″)
(300′5″)
(231′2″)
(69′2″)
L+LA
(301′9″)
(290′7″)
(231′2″)
(59′4″)
L+LB
Length of
light duty
boom (ft)
Length of light
anchoring rods(ft)
(ft)
Combination of
anchoring rods of light
duty boom
(between A-frame and
luffing jib head)
0066340-200-05Y.C
(291′11″)
(280′9″)
(231′2″)
(49′6″)
L+LC
(282′0″)
(270′11″)
(231′2″)
(39′8″)
L+LD
5.7.2.3 Intermediate tensioners on the main boom
The fitting of intermediate tensioners is obligatory for SL boom configuration. The
installation positions of intermediate tensioners for different main boom length have been
shown in the following figures:
Installation position of intermediate tensioners for 282′0″ long light duty boom (SL boom)
Tensioning rope
282′0″ long light duty boom
Part 17 of light anchoring
rods—Double-anchoring rod
Part 10 of light anchoring
rods—single-anchoring
rod
Connecting position between
tensioning
rope
and
light
anchoring rods
13′1″ reducing section
To luffing jib
head
To anchoring rods of heavy
duty boom
Combination of light anchoring rods of
282′0″
light duty boom
Note:
For the parts number of light anchoring rods given in the above table, please refer to
Section 5.7.2.2-b “light anchoring rods”
0066340-200-05Y.C
Installation position of intermediate tensioners for 291′11″ long light duty boom
291′11″ long light duty boom
Tensioning rope
Part 10 of light anchoring
rods—single-anchoring rod
Part 17 of light anchoring
rods—Double-anchoring rod
13′1″reducing section
Connecting position between
tensioning rope and light
anchoring rods
To luffing
jib head
To anchoring rods of
heavy duty boom
Combination of light anchoring rods of 291′11″ light duty boom
Note:
For the parts number of light anchoring rods given in the above table, please refer to Section
5.7.2.2-b “light anchoring rods”.
0066340-200-05Y.C
Installation position of intermediate tensioners for 301′9″ long light duty boom
301′9″ long light duty boom
Part 10 of light anchoring
rods—single-anchoring rod
Tensioning rope
Part 17 of light anchoring
rods—Double-anchoring rod
13′1″ reducing section
Connecting position between
tensioning rope and light
anchoring rods
To anchoring rods of
heavy duty boom
To luffing
jib head
Combination of light anchoring rods of 301′9″ light duty boom
Note:
For the parts number of light anchoring rods given in the above table, please refer to Section
5.7.2.2-b “light anchoring rods”.
0066340-200-05Y.C
Installation position of intermediate tensioners for
311′7″
Part 10 of light anchoring
rods—single-anchoring
rod
311′7″ long light duty boom
long light duty boom
Tensioning rope
Part 17 of light anchoring
rods—Double-anchoring rod
13′1″ reducing section
Connecting position between
tensioning rope and light
anchoring rods
To anchoring rods of
heavy duty boom
To luffing
jib head
Combination of light anchoring rods of
311′7″ light duty boom
Note:
For the parts number of light anchoring rods given in the above table, please refer to Section
5.7.2.2-b “light anchoring rods”.
0066340-200-05Y.C
Intermediate tensioners for light duty boom with different length:
Intermediate tensioners for 282′0″ and 291′11″ long light duty boom
To anchoring rods
To13′1″reducing section
Intermediate tensioners for 301′9″ and 311′7″ long light duty boom
To anchoring rods
To13′1″ reducing section
Component parts of intermediate tensioners
Component parts of intermediate tensioners
Part
No.
Description
1
Double-anchoring
rod
Illustration
0066340-200-05Y.C
2
Pin spindle
3
Single-anchoring
rod
4
Single-anchoring
rod
5
Double-anchoring
rod
6
Pin spindle
7
Retaining pin
Note:
Part numbers of intermediate tensioners given in Section 5.7.2.3 “intermediate tensioners on
the main boom” are consistent with those in the above table, so the component parts of
intermediate tensioners can be found by referring to the part numbers when assembling.
0066340-200-05Y.C
5.7.3 Fixed jib on heavy duty boom (SF)
5.7.3.1 Components of SF boom
SF boom comprises main boom (S) and fixed jib (F). The main boom length varies from
95′1″~252′6″ and the fixed jib length varies from 34′9″~98′5″. The fixed jib consists of
fixed jib pivot section (G31), fixed jib head (G32) and an optional number of fixed jib
intermediate section 6m in length (G34). The fixed jib can be assembled in the angle of
10° or 30° to main boom. When different fixed jib length is required, operator only needs to
disconnect fixed jib pivot section from fixed jib head, and then install fixed jib intermediate
sections between them. In this way, the fixed jib can be assembled to required length.
Main boom sections in this boom configuration are pinned together in the same way as
that in S boom configuration.
252′6″ long main boom with 59′0″ fixed jib, overview:
G32
G74
G34
G37
G31
G75
G12
G15
G15
G15
G15
G15
G15
G13
G11
G17
G70
0066340-200-05Y.C
Fixed jib pivot section—G31
19′8″
fixed jib intermediate section—G33
Fixed jib head—G32
FA-frame —G37
Rear tilting-back support of fixed jib—G75
4′7″~7′4″
Front tilting-back support of fixed jib—G74
10′2″~12′9″
0066340-200-05Y.C
Combination of fixed jib sections:
Assembly table of fixed jib sections
Fixed jib length (ft)
assembly sequence of
fixed jib sections
Fixed jib length (ft)
assembly sequence of
fixed jib sections
(39′4″)
G31+G32
(78′8″)
G31+2×G34+G32
(59′0″)
G31+G34+G32
(98′4″)
G31+3×G34+G32
5.7.3.2 Components of anchoring rods of SF boom
The anchoring rods of SF boom comprises main boom anchoring rods, fixed jib front
anchoring rods and fixed jib rear anchoring rods. For the combination of main boom
anchoring rods, see Section 5.7.1.3. And the combination of fixed jib anchoring rods has
been given as follows.
a
Fixed jib front anchoring rods
When the fixed jib length is 39′4″, the fixed jib front anchoring rods is composed by the following
component parts.
0066340-200-05Y.C
0066340-200-05Y.C
Component parts of fixed jib front anchoring rods
Part
No.
Description
1
Double
anchoring rod
2
Pin spindle
3
Retaining pin
4
5
Reducing
doubleanchoring rod
Reducing
singleanchoring rod
illustration
0066340-200-05Y.C
6
Single
anchoring rod
7
Double
anchoring rod
8
Cotter pin
ISO1234-1997 (0.4″×3.6″)
9
Pin spindle
Note:
The part numbers of anchoring rods given in Section 5.7.3.2——a “ Fixed jib front anchoring
rods” are consistent with those in the above table, so the component parts of anchoring rods
can be found by referring to the part numbers when assembling.
The width of fixed jib front anchoring rods is 1.8″, and the diameter of pin spindle is φ1.6″. When
fixed jib is 39′4″ long, the corresponding front anchoring rods is 49′0″ long. When fixed jib length
increases by 19′8″, a 10.8″-long double anchoring rod (part 1) and a 17′9″-long single anchoring rod
(part 6) should be added accordingly.
0066340-200-05Y.C
Combination of fixed jib front anchoring rods is shown in the following table
Combination of front anchoring rods of fixed jib
Fixed jib
length (ft)
length of
fixed jib
front
anchoring
rods (ft)
(39′4″)
(47′8″)
1+4+5+1+(6+1)+6+7
(59′0″)
(66′5″)
1+4+5+1+2×(6+1)+6+7
(78′8″)
(85′2″)
1+4+5+1+3×(6+1)+6+7
(98′4″)
(103′11″)
1+4+5+1+4×(6+1)+6+7
Combination of fixed jib front anchoring rods (between FA-frame to
fixed jib)
12m
18m
24m
30m
b) Fixed jib rear anchoring rods
The width of fixed jib rear anchoring rods is 1.8″, and the diameter of pin spindle isφ1.6″.
Since the fixed jib can be mounted in the angle of either 10o or 30o to main boom, the fixed jib
rear anchoring rods can be combined in two ways.
The following figure shows the combination of rear anchoring rods when fixed jib is mounted in
the angle of 30o to main boom.
0066340-200-05Y.C
B
To FA-frame
A view
To main boom
A
C
D
C
B
D
0066340-200-05Y.C
Component parts of fixed jib rear anchoring rods
Part
No.
Description
1
sleeve
2
Cotter pin
illustration
ISO1234-1997(0.16″×1.2″)
3
Nut
ISO4032-1999(M20-8)
4
Bolt
ISO4014-1999(M20×8″-8.8)
5
Anchoring rod
6
Single-anchoring
rod
7
Double-anchoring
rod
0066340-200-05Y.C
8
Pin spindle
9
Retaining pin
10
Single-anchoring
rod
11
Coupling link
12
Double-anchoring
rod
13
Reducing piece
0066340-200-05Y.C
14
Pin spindle
15
Cotter pin
ISO1234-1997(0.4″×3.6″)
16
Reducing
double-anchoring
rod
17
Single-anchoring
rod
18
Single-anchoring
rod
Note:
The part numbers of anchoring rods given in Section 5.7.3.2——b “Fixed jib rear anchoring
rods” are consistent with those in the above table, so the component parts of anchoring rods
can be found by referring to the part numbers when assembling.
0066340-200-05Y.C
Combination of fixed jib rear anchoring rods is shown in the following table
Combination of fixed jib rear anchoring rods
Fixed jib
angle to
main
boom
Length of
fixed jib
rear
anchoring
rods(ft)
30°
(42′8″)
7+16+13+12+11+7+10+7+18+7+17+5
10°
(35′7″)
7+16+13+12+11+7+10+7+18+5
Combination of fixed jib rear anchoring rods (between main boom to
FA-frame )
0066340-200-05Y.C
5.7.4 Heavy fixed jib on heavy duty boom (SFV)
5.7.4.1 Components of SFV boom
SFV boom comprises main boom (S) and heavy fixed jib (FV). The main boom length
varies from 134′5″~252′7″, and the heavy fixed jib length is 19′8″. The heavy fixed jib can
be assembled in the angle of 14° or 20° to main boom. When different main boom length is
required, operator only needs to disconnect main boom pivot section from main boom head,
and then install main boom intermediate sections between them. In this way, the main
boom can be assembled to required length.
Main boom sections in this boom configuration are pinned together in the same way as that
in S boom configuration.
252′7″ long main boom with 19′8″ heavy fixed jib, overview:
G74
G41
G37
G75
G12
G15
G15
G15
G15
G15
G15
G13
G11
G17
G70
0066340-200-05Y.C
Heavy fixed jib——G41
5.7.4.2 Components of anchoring rods of SFV boom
The anchoring rods of SFV boom comprises main boom anchoring rods, heavy fixed jib
front anchoring rods and heavy fixed jib rear anchoring rods. For the combination of main
boom(heavy) anchoring rods, see Section 5.7.1.3. And the combination of heavy fixed jib
anchoring rods has been given as follows.
a) Heavy fixed jib front anchoring rods
The heavy fixed jib front anchoring rods is composed by the following component parts, and
its length is unvaried.
0066340-200-05Y.C
A view
To heavy fixed jib
A
To FA-frame
B
C
0066340-200-05Y.C
Component parts of heavy fixed jib front anchoring rods
Part
No.
Description
1
Pin spindle
2
Retaining pin
3
Double anchoring
rod
4
Single anchoring
rod
5
Double anchoring
rod
illustration
0066340-200-05Y.C
Reducing single
anchoring rod
6
7
Pin spindle
8
Cotter pin
ISO1234-1997(0.4″×3.6″)
9
Reducing doubleanchoring rod
10
Pin spindle
Note:
The part numbers of anchoring rods given in Section 5.7.4.2——a “ Heavy fixed jib front
anchoring rods” are consistent with those in the above table, so the component parts of
anchoring rods can be found by referring to the part numbers when assembling.
0066340-200-05Y.C
b) Heavy fixed jib rear anchoring rods
The width of heavy fixed jib rear anchoring rods is 1.8″, and the diameter of pin spindle is φ1.6″..
Since the heavy fixed jib can be mounted in the angle of either 14o or 20o to main boom, the
heavy fixed jib rear anchoring rods can be combined in two ways.
The following figure shows the combination of rear anchoring rods when heavy fixed jib is
mounted in the angle of 20o to main boom.
0066340-200-05Y.C
B
To main boom
A
C
D
C
B
D
To FA-frame
A view
0066340-200-05Y.C
Component parts of heavy fixed jib rear anchoring rods
Part
No.
Description
1
sleeve
2
Cotter pin
illustration
ISO1234-1997(0.16″×1.2″)
3
Nut
ISO4032-1999(M20-8)
4
Bolt
ISO4014-1999(M20×8″-8.8)
5
Anchoring rod
6
Single-anchoring
rod
7
Double-anchoring
rod
0066340-200-05Y.C
8
Pin spindle
9
Retaining pin
10
Single-anchoring
rod
11
Coupling link
12
Double-anchoring
rod
13
Reducing piece
14
Pin spindle
0066340-200-05Y.C
15
Cotter pin
ISO1234-1997(0.4″×3.6″)
Reducing double
anchoring rod
16
Note:
The part numbers of anchoring rods given in Section 5.7.4.2——b “heavy fixed jib rear
anchoring rods” are consistent with those in the above table, so the component parts of
anchoring rods can be found by referring to the part numbers when assembling.
Combination of heavy fixed jib rear anchoring rods is shown in the following table
Combination of heavy fixed jib rear anchoring rods
Heavy fixed
jib angle to
main boom
Length of
heavy fixed jib
Combination of heavy fixed jib rear anchoring rods (between main
rear anchoring
boom to FA-frame)
rods (ft)
20°
(42′8″)
7+16+13+12+11+7+10+7+10+7+6+5
14°
(35′7″)
7+16+13+12+11+7+10+7+10+5
0066340-200-05Y.C
5.7.5 Luffing jib on heavy duty boom (SW)
5.7.5.1 Components of luffing jib
The luffing jib, whose length varies from 68′10″~196′10″, comprises luffing jib pivot section
(G21), luffing jib head (G22) and an optional number of luffing jib intermediate sections 9′10″
(G23), 19′8″ (G24) and 29′6″ (G25, G25A) in length.
203′4″ long main boom with 196′10″ luffing jib, overview:
0066340-200-05Y.C
0066340-200-05Y.C
Luffing jib pivot section (G21)
Luffing jib head (G22)
(9′10″) luffing jib intermediate section (G23)
(19′8″ )luffing jib intermediate section (G24)
(29′6″ )luffing jib intermediate section (G25,G25A)
0066340-200-05Y.C
WA-frame 2 (G28)
WA-frame 1 (G27)
Tilting-back support of luffing jib (G71)
9′1″~8′8″
Tilting-back support of WA-frame 2 (G72)
10′9″~12′5″
Tiling-back support accumulator cylinder for WA-frame 1(G73)
6′2″~8′8″
0066340-200-05Y.C
When different luffing jib length is required, operator only needs to disconnect luffing jib pivot
section from luffing jib head, and then install luffing jib intermediate sections between them. In this
way, the luffing jib can be assembled to required length.
Combination of luffing jib sections:
Combination of luffing jib sections
Luffing jib
length(ft)
assembly sequence of
luffing jib sections
Luffing jib
length(ft)
assembly sequence of luffing jib
sections
(59′0″)
G21+G22
(137′9″)
G21+G24+2×G25+G22
(68′10″)
G21+G23+G22
(147′7″)
G21+3×G25+G22
(78′8″)
G21+G24+G22
(157′5″)
G21+G23+3×G25+G22
(88′6″)
G21+G25+G22
(167′3″)
G21+G24+3×G25+G22
(98′5″)
G21+G23+G25+G22
(177′1″)
G21+G23+G24+3×G25+G22
(108′3″)
G21+G24+G25+G22
(187′0″)
G21+3×G25+G24+G24+G22
(118′1″)
G21+2×G25+G22
(196′10″)
G21+G23+G24+G24+3×G25+G22
(127′11″)
G21+G23+2×G25+G22
Principle for assembling luffing jib sections: when connecting jib intermediate sections,always
bolt the shorter intermediate sections first.
5.7.5.2 Components of luffing jib anchoring rods
The luffing jib anchoring rods comprises luffing jib front anchoring rods and luffing jib rear
anchoring rods. Their lengths are respectively determined by the length of luffing jib and length of
main boom. The width of luffing jib front anchoring rods is 2″, and the diameter of pin spindle is
φ1.8″.
a) Luffing jib front anchoring rods
When main boom is 75′5″ long, and the luffing jib is 68′10″ long, the combination of the
luffing jib front anchoring rods is shown in the following figure.
0066340-200-05Y.C
0066340-200-05Y.C
Component parts of luffing jib front anchoring rods
Part No.
Description
1
Cotter pin
illustration
ISO1234-1997(0.24″×3.2″)
2
Pin spindle
3
Anchoring rod
4
Pin spindle
5
Coupling link
6
Cotter pin
ISO1234-1997(0.4″×3.6″)
7
Pin spindle
8
Double-anchoring
rod
0066340-200-05Y.C
9
Reducing piece
(single)
10
Cotter pin
ISO1234-1997(0.4″×4.8″)
11
Pin spindle
12
Reducing piece
(double)
13
Single anchoring
rod
14
Coupling link
15
Pin spindle
16
Retaining pin
0066340-200-05Y.C
17
Double-anchoring
rod
18
Single anchoring
rod
19
Single anchoring
rod
20
Single anchoring
rod
21
Double-anchoring
rod
22
Single anchoring
rod
23
Double-anchoring
rod
0066340-200-05Y.C
24
Single anchoring
rod
25
Double-anchoring
rod
26
Single anchoring
rod
Note:
The part numbers of anchoring rods given in Section 5.7.5.2—a “luffing jib front anchoring
rods” are consistent with those in the above table, so the component parts of anchoring rods
can be found by referring to the part number when assembling.
Combination of luffing jib front anchoring rods:
Connecting diagram of luffing jib front anchoring rods
0066340-200-05Y.C
Connecting diagram of luffing jib front anchoring rods
0066340-200-05Y.C
0066340-200-05Y.C
b) Luffing jib rear anchoring rods
When main boom is 75′5″ long, and the luffing jib is 68′10″ long, the combination of the luffing jib
rear anchoring rods is shown in the following figure.
0066340-200-05Y.C
Component parts of luffing jib rear anchoring rods
Part No.
Description
1
Retaining pin
2
Double
anchoring rod
3
Pin spindle
4
Coupling link
5
Cotter pin
illustration
ISO1234-1997(0.4″×3.6″)
6
Pin spindle
0066340-200-05Y.C
7
Single
anchoring rod
8
Reducing
piece(single)
9
Pin spindle
10
Cotter pin
ISO1234-1997(0.4″×4.8″)
11
Reducing
piece(double)
12
Single
anchoring rod
0066340-200-05Y.C
13
14
Coupling link
Single
anchoring rod
15
Single
anchoring rod
16
Single
anchoring rod
17
Double
anchoring rod
0066340-200-05Y.C
Note:
The part numbers of anchoring rods given in Section 5.7.5.2—b “ luffing jib rear anchoring
rods” are consistent with those in the above table, so the component parts of anchoring rods
can be found by referring to the part numbers when assembling.
0066340-200-05Y.C
Combination of luffing jib rear anchoring rods:
Connecting diagram of luffing jib rear anchoring rods
0066340-200-05Y.C
Connecting diagram of luffing jib rear anchoring rods
0066340-200-05Y.C
5.8 Assembly and dismantling of heavy duty boom(S)
Note:
Before assembly or dismantling, set the “Boom configuration” switch to “main boom”
position.
5.8.1 Preparations for assembly
a) Choose appropriate boom combination and relevant anchoring rods combination
according to operational planning and load capacity chart;
b) Choose appropriate load hook and rope reeving for load to be lifted;
c) Assemble required counterweight plates;
d) Make sure that an auxiliary crane is available and operating personnel get full prepared
and qualified for operation;
e) Change the “operating mode” into “assembly mode”.
Caution:
1. After the “operating mode” is changed to “assembly mode”, all safety devices built in the
crane will be deactivated, the assembly, dismantling of the machine must be therefore
carried out with utmost care.
2. For assembly work on the crane, a safety assembly working platform must be used.
Improvisations are prohibited. Otherwise, there is a danger of falling down.
3. Any other boom configurations and anchoring rods combination that have not been
stipulated in the operating manual are prohibited.
4. Always bolt on the shorter intermediate sections first!
5. If the main boom head is lifted by an auxiliary crane, at least two pieces of lifting chain with a
breaking force≥33100Ib should be used.
6. Do not stand on the lattice boom when it is assembled.
7. Do not stand beneath the boom when it is being pinned or unpinned!
8. The use of squared timbers or pad block to support the chord in the middle position or web
members is prohibited; otherwise the boom sections will be damaged.
0066340-200-05Y.C
5.8.2 Assembling main boom
After unloading the basic machine, unload each boom section from the transport vehicle via
mounting cylinder on A-frame, and then attach such boom components as main boom head,
main boom intermediate sections according to actual working requirement.
5.8.2.1 Pinning on main boom pivot section
a) After unloading the main boom pivot section from the transport vehicle, connect it to the
mounting cylinder on A-frame with two lifting chains.
b) -
Derrick the A-frame up or down to proper position by moving the right control
lever(27) to left or right
-
turn the “self assembly& dismantling” switch (55) on the right control panel to the right
-
adjust the mounting cylinder on A-frame by pushing the right control lever(27)
forwards or backwards;
c) Align the main boom pivot section with connecting points on slewing table.
0066340-200-05Y.C
A
A
pivot section bolting cylinder
d) Activate the “pivot section bolting cylinder” switch on auxiliary remote control box to
extend the pivot section bolting cylinder, and then fit the locking plate. In this way, the
main boom pivot section is pinned on.
e) Remove the lifting chains from the pivot section.
0066340-200-05Y.C
5.8.2.2 Attaching main boom sections
a) Preassemble main boom sections according to Section 5.7.1“heavy duty boom”. For
detailed operation, refer to following methods:
— Pin main boom intermediate sections of 3m, 6m or 9m to each other in the following
sequence:
1. Position two intermediate sections to be pinned in such a way that the connection
holes in one intermediate section are precisely aligned with those in the other
intermediate section (see following figure).
2. Join them with double tapered pins (1) and secure on both sides with retaining
springs (2).
3. Join the other connecting holes in the same way.
— Pin main boom head to the assembled intermediate sections in the following
sequence:
1. Position the assembled intermediate section in such a way that the upper
connecting holes in it are aligned with those in the main boom head.
2. Join the upper connecting holes with double tapered pins (3) and secure with
retaining springs (2)
3. Join the lower connecting holes in the same way.
0066340-200-05Y.C
Connecting parts of main boom section
Part
No.
Description
1
Double tapered
pin
2
Retaining spring
3
Double tapered
pin
illustration
0066340-200-05Y.C
b) Attaching the preassembled main boom to main boom pivot section.
1. Slowly drive the basic machine with main boom pivot section attached up to the
preassembled main boom.
2. Adjust the A-frame position by moving the right control lever (27) left or right to
make the upper connecting holes in adjacent main boom intermediate section
are aligned with the connecting holes in pivot section.
3. Join the upper connecting holes with double tapered pins (1) and secure
properly on both sides with retaining springs (2).
4. Adjust the mounting cylinder on A-frame until the lower connection holes in pivot
section are aligned with those in adjacent main boom intermediate section.
5. Join the lower connecting holes with double tapered pins (1) and secure on both
sides with retaining springs (2).
6. Disconnect the main boom pivot section from mounting cylinder on A-frame by
removing the lifting chain.
0066340-200-05Y.C
Connecting parts of pivot section
Part
No.
Description
1
Double tapered
pin
2
Retaining spring
illustration
Warning:
1. It is prohibited to put hand or fingers into the connecting hole during installation.
2. While the connecting pin is being removed, no person is allowed to stand beneath or in
the boom.
3. It is prohibited to climb up the boom, and stand or walk on the boom.
4. Utilize a ladder or other similar tools to carry out assembly operation.
0066340-200-05Y.C
5.8.2.3 Assembling main boom anchoring rods and reeving in rope
a) Assembling main boom anchoring rods:
Connect the anchoring rods on A-frame and on main boom pivot section together, and
then attach anchoring rods of main boom intermediate section and anchoring rods of
main boom head to each other by pin spindles and secure them with retaining pins. (The
arrangement and combination of main boom anchoring rods are specified in Section
5.7.1.3).
b) Reeving hoisting winch 1 in:
1)
Move the right control lever(27) to the left to wind the derricking rope until the main
boom head is raised to a proper position a littler higher than the load hook, and then
position the load hook directly under the main boom head.
2)
Turn the switch (60) to right or push down the “reeving winch” on the remote control
box to unwind the rope of reeving winch until it approach the load hook. Reeve the
rope of reeving winch in the reverse direction between the load hook and the rope
pulleys on main boom head and then pull it to tail-end of main boom (for the details,
please refer to Section 4.5.3.3 “Operation of reeving winch”).
3)
Push the right control lever (27) forwards to unwind hoisting rope for winch 1 until it
reaches the tail-end of main boom. Attach rope end point of reeving winch to hoisting
rope for winch 1 with rope lock (see following figure).
4)
Turn the switch (60) to left or push the “reeving winch” on the remote control box up
to wind the rope of reeving winch, simultaneously unwind the hoisting rope for winch
1. Guided by the rope of reeving winch, the hoisting rope for winch 1 will then reeve
between the rope pulley and load hook. After that, stop operation on winch 1 and
reeving winch, detach the rope lock. Finally, spool up the reeve winch to wind the
rope end point onto the reeving winch.
0066340-200-05Y.C
Rope pulleysⅠ
Rope pulleysⅡ
Load hook (rope pulleys Ⅲ )
Hoisting rope reeving method for 260t load hook, for example, will be detailed here:
-- According to the method stipulated in Section 4.6.1.1 “hoisting rope reeving for winch 1”,
reeve the rope of reeving rope in the reverse direction between rope pulleys III and rope
pulleys II on main boom head and then through the rope pulleys I.
-- Attach rope end point of reeving winch to hoisting rope for winch 1 with rope lock.
-- Wind the rope of reeving winch and simultaneously unwind the hoisting rope for winch 1.
Guided by the rope of reeving winch, the hoisting rope for winch 1 will then reeve in desired
direction between the rope pulleys and load hook (see following figures.).
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Rope reeving plans (the hoisting rope is led by rope of reeving winch):
573300 Ib load hook
(rope reeving: 20)
Attach the two ropes together
Rope pulleysⅠ
Hoisting winch 1
Rope pulleys Ⅱ
Rope pulleys Ⅲ
Reeving winch
573300 Ib load hook
(rope reeving: 18)
Attach the two ropes together
Rope pulleysⅠ
Hoisting winch 1
Rope pulleys Ⅱ
Rope pulleys Ⅲ
Reeving winch
573300 Ib load hook(rope reeving: 16)
Attach the two ropes together
Hoisting winch 1
Rope pulleysⅠ
Rope pulleys Ⅱ
Rope pulleys Ⅲ
Reeving winch
Winch 1
573300 Ib load hook(rope reeving:14)
0066340-200-05Y.C
Attach the two ropes together
Rope pulleysⅠ
Hoisting winch 1
Rope pulleys Ⅱ
Rope pulleys Ⅲ
Reeving winch
Winch 1
573300 Ib load hook(rope reeving:12)
Attach the two ropes together
Hoisting winch 1
Rope pulleysⅠ
Rope pulleys Ⅱ
Rope pulleys Ⅲ
Reeving winch
Caution:
1. Working personnel who guides the wire rope should take great care to prevent against falling
down when walking on the boom frame; otherwise, serious accident may occur.
2. The rope unwinding speed from winch 1 must be faster than rope-winding speed on reeving
winch.
0066340-200-05Y.C
5.8.3 Connect electrics to main boom
5.8.3.1 Electrical line connections
Note:
The following figure shows the connected electrical parts on main boom. Before erecting the
boom, make sure that all electrical lines are connected and safety measures are checked.
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Layout of electrical parts on main boom
Part No.
Description
Installation position
X15
Socket ,10 hole
At the front of slewing table
X16
Socket ,10 hole
At the front of slewing table
201
Angle sensor
main boom pivot section
202
Cable drum 1
main boom pivot section(if luffing jib is used)
203
Cable drum 2
main boom pivot section
204
Main boom tension force
sensor
anchoring rod of A-frame
205
Luffing winch
Main boom pivot section(optional)
206
anemometer
Main boom head
207
Warning lamp(2)
Main boom head
208
Main boom junction box
Main boom head
209
Control box for Load Moment
Limit on luffing jib
Main boom head(if luffing jib is used)
210
Cable drum 3
Main boom head(if luffing jib or fixed jib is used)
211
Hoisting limit switch weight
Connected with hoisting rope on main boom head
212
Hoisting limit switch
Boom head, connected with hoisting limit switch
weight
a) Connecting electrics to main boom pivot section
Insert the cable plug of X15 on main boom pivot section into the X15 socket at the front of
slewing table. If a luffing winch is fitted on the main boom, insert the cable plug of X16
into the X16 socket at the front of slewing table.
b) Connecting electrics to main boom head
Unplug the cable plug of cable drum 2, pull the cable plug along the main boom and then
insert it into the “lead to junction box” socket on main boom junction box. Establish the
0066340-200-05Y.C
electrical connections from the junction box on the main boom head to associated
components respectively.
Description of main boom junction box:
The main boom junction box, installed on main boom head, has 9 input and output
sockets in total, including:
— “lead to junction box” sockets (12-hole) on the left side, which is used to establish a
connection to main boom cable drum 2
— “to cable drum” socket (12-hole) on the right side, not-assigned
0066340-200-05Y.C
Other sockets at the bottom of the junction box, from the left to right, are respectively:
— “Warning lamp” socket (2-hole), which is used to establish a connection to warning
lamp on main boom head;
— “Warning lamp” socket (2-hole), which is used to establish a connection to warning
lamp on main boom head
— “Hoisting limit switch for H1” socket (3-pin), which is used to a establish connection to
hoisting limit switch for H 1 connected to main boom head;
— “Hoisting limit switch for H2” socket (5-pin), not-assigned
— “Anemometer” socket (4-pin), used to establish a connection to anemometer on main
boom head;
—“Tilting-back support of luffing jib” socket (2-pin), not-assigned
—“Hoisting limit switch for H3” socket (3-pin), not-assigned.
Establish electrical connections:
— Insert the two cable plugs of main boom warming lamps (2) into the two “warning lamp”
sockets respectively in the junction box
— insert the cable plug of hoisting limiter for H1 into the “hoisting limit switch for H1” socket in
the junction box.
— insert the cable plug of hoisting limiter for H2 into the” hoisting limit switch for H2” socket in
the junction box.
— insert the cable plug of anemometer into the “anemometer” socket in the junction box
Caution:
Cable plug which is not used should be protected by seal cover.
c) Electrical connection to Load Moment Limiter
See the Installation Guide& User’s Manual for Load Moment Limiter.
5.8.3.2 Checks before erecting the boom
a) Check warning lamp on main boom head
Set the Master Lighting Switch 39 (see Section 4.1.4) to the second position, and press
“warning lamp on/off” switch 41 at the same time, check that the warning lamp lights up..
b) Check the anemometer
Rotate the vane of anemometer to check whether the wind velocity shown on the display in
the operator’s cab is normal.
0066340-200-05Y.C
c) Check hoisting limit switch for H 1
Support and hold the hoisting limit switch weight for H1 to ensure that the switch is
triggered, and then check that the Icon “upper limit switch on H1” on the screen will flash
and the buzzer will sound.
d) Check hoisting limit switch for H2(when the tip boom is used)
Support and hold the hoisting limit switch weight for H2 to ensure that the switch is
triggered, and then check that the Icon “upper limit switch on H2” on the screen will flash
and the buzzer will sound.
5.8.4 Erecting main boom
5.8.4.1 Requirements for erecting main boom
a) The crane is properly supported and level;
b) The required counterweight plates have been attached;
c) Select appropriate boom configurations according to the load to be lifted and the
load capacity charts; ensure that boom sections have been connected and secured;
d) All limit switches has been correctly fitted and are fully operational;
e) All pinned connections have been secured;
f)
The hoisting rope has been correctly placed in the rope pulleys and prevented from
jumping out (from rope groove) using rope guard tube;
g) No person is present in the danger zone;
h) There are no loose parts on main boom;
i)
In winter, the main boom, fixed jib and associated components (limit switches, rope
drums, warning light, anemometer etc.) must be kept free of ice and snow.
Danger:
Incorrectly fitted or faulty limit switches and falling parts (pins, retaining pins, ice etc.)
can cause injury.
5.8.4.2 Erecting main boom
a) Move the right control lever (27) to the left to spool derricking winch up, and the main
boom anchoring rods will be tensioned gradually.
Note: During the erecting process, to prevent the load hook from being dragged on the
ground, while moving the right control lever (27) in 45° direction, press the
“simultaneously operation ” button(29)at the same time until main boom reaches 30°
position. When the main boom reaches 30° position, the “assembly mode” will
automatically be changed into “operating mode”. Then return the right control lever (27) to
0066340-200-05Y.C
neutral position.
b) Continue to move the right control lever (27) to left until the main boom is erected to
required position.
Caution:
1. The main boom angle can be changed between 0° to 85°. When main boom is
raised to 80°, acoustic warning will be given out, but main boom can still be
derricked up. And when main boom is raised to 83°, the movement of derricking
boom up will be switched off automatically along with warning being sent out, but
the main boom can still be derricked up by pressing the “bypass key button”(54).
However, when main boom is raised to 85° position, the movement of derricking
0066340-200-05Y.C
boom up will be switched off automatically along with warning being sent out.
Under this condition, even though “bypass key button” is pressed, the main boom
can not be raised any further.
2. Always monitor the wire rope in process of erecting main boom to make sure that
the wire rope is kept in the rope groove all the time.
3. The boom-raising movement should be performed slowly and stably. And during
the operation, the crane operator must observe the data shown on the display,
while other workers must observe the surrounding areas for potential dangers.
4. Standing beneath the boom frame is prohibited.
5. Working radius stipulated in the Load Capacity Charts should be adhered to, even
if no load is attached on the load hook! Non-observance of it is likely to cause the
crane turnover.
5.8.5 lowering and disassembling the main boom
5.8.5.1 Lowering main boom
a) Move the right control lever (27) to the right to reel derricking winch off, and then the
main boom will be lowered gradually. When the main boom is lowered to 30° position,
return the control lever (27) to neutral position.
b) Push the right control lever(27) forwards to reel off hoisting winch 1 to lower stably the
load hook on the ground;
c) Move the right control lever (27) to the right until the main boom head comes into contact
with the ground. Return the right control lever (27) to neutral position.
Caution:
1. In the process of lowering main boom, the hoisting winch 1 must be reeled off to
avoid the hook’s collision with the pulley head.
2. Standing within danger area of crane during operation is prohibited.
3. The boom-lowering movement should be performed slowly and stably. And during the
operation, the crane operator must observe the data shown on the display, while
other workers must observe the surrounding areas for potential dangers.
4. To prevent the crane from overturning, the counterweight must be removed prior to
the dismantling of main boom pivot section.
0066340-200-05Y.C
5.8.5.2 Dismantling boom sections and anchoring rods
a) After the anchoring rods are lowered down on the anchoring rod supports on the
relevant boom sections, remove the pin spindles from anchoring rods, and then
secure them on anchoring rod supports with pin spindles for transportation.
b) Separate boom sections using self-assembly system or an auxiliary crane.
c) Lower A-frame down on the slewing table.
Note:
1. Dismantling is carried out in the reverse order to assembly.
2. Warnings and safety precautions for assembly should be followed during assembly
operation.
5.9 Assembly and dismantling of main boom with luffing jib(SW)
Caution:
1. Before operation, turn the “Boom configuration” switch to “luffing jib” position.
2. The luffing jib can be derricked up or down by hoisting winch 1 or luffing winch.:
By hoisting winch 1: push the right control lever (27) forwards or backwards- derrick the jib
down or up.
By luffing winch: move the right control lever(27) to left or right- derricking the jib up or
down.
Only when the “Boom configuration” switch is turned to “main boom” position, can the main
boom be derricked up or down by pushing the right control lever (27) forwards or backwards.
In other words, if the crane operator wants to derrick main boom or luffing jib up/down, he
should first turn the “Boom configuration” switch to “main boom” or “luffing jib” position.
5.9.1 Preparations for assembling luffing jib
a) Choose appropriate boom combination and relevant anchoring rods combination
according to operational planning and boom configuration.
b) Choose the correct load hook and rope reevings for the load to be lifted;
c) The main boom is installed;
d) The required counterweight plates have been assembled;
e) The safe load indicator system of Load Moment Limiter is set according to the data given
0066340-200-05Y.C
in the load capacity charts;
f)
Make sure that an auxiliary crane is available and operating personnel get full prepared
and qualified for operation;
g) Change the “operating mode” to “assembly mode”.
Caution:
1. After the “operating mode” is changed to “assembly mode”, all safety device built in the
crane will be deactivated, the assembly, dismantling of the machine should therefore be
carried out with utmost care.
2. For assembly work on the crane, a safety assembly working platform should be used.
Improvisations are prohibited. Otherwise, there is a danger of falling down.
3. Any other boom configurations and anchoring rod combination that have not been
stipulated in the operating manual are prohibited.
4. Always bolt on the shorter intermediate sections first!
5. If the main boom head is lifted by an auxiliary crane, at least two pieces of lifting chain
with a breaking force≥15t should be used.
6. Do not stand on the lattice boom when it is assembled.
7. The use of squared timbers or pad block to support the chord in the middle position or
web members is prohibited; otherwise the boom sections will be damage.
8. Do not stand beneath the boom when it is being pinned or unpinned!
5.9.2 Assembling main boom with luffing jib
During transportation, the luffing jib pivot section (G21), WA-frame 1 (G27) and WA-frame 2
(G28) as well as tilting-back support accumulator cylinder (G73) of WA-frame 1 are
assembled together. See following diagram.
0066340-200-05Y.C
a) Assemble required main boom sections in accordance with Section 5.7.1;
b)
-
Lift the luffing jib pivot section (together with WA-frames 1 and 2) with an auxiliary
crane and swing to main boom head.
-
Attach the luffing jib pivot section to the main boom head from above.
-
Continue lowering the luffing jib pivot piece until it can be pinned to main boom head.
-
Pin the luffing jib pivot piece to main boom head with pin spindles (24) and secure with
bolts (21), locking plates (23), retaining springs (25) and washer (26). (See following
figure.)
A
G12
G21
G27
A view
G12—main boom head
G27—WA-frame 1
G21—luffing jib pivot section
G28—WA-frame 2
G28
0066340-200-05Y.C
Connecting parts of luffing jib pivot section to main boom head
Part
No.
Description
17
Locking plate
18
Bolt
Illustrations
ISO4017-1999(M12×1.4″-8.8)
19
Washer
(0.48″)
20
Pin spindle
21
Bolt
ISO4017-1999(M16×2.2″-8.8)
22
Washer
(0.64″)
0066340-200-05Y.C
23
Locking plate
24
Pin spindle
25
Retaining spring
c) According to actual condition, choose appropriate numbers of luffing jib intermediate
sections 3m (G23), 6m (G24) and 9m (G25) in length, and then pin them together. All jib
intermediate sections are connected with double tapered pins (1), secured on both sides
with retaining springs (2) (see following fig.).
G24
G23
G21
G22
2
1
G25
G21—luffing jib pivot section
G23—3m luffing jib intermediate section
0066340-200-05Y.C
G24— 6m luffing jib intermediate section
G25—9m luffing jib intermediate section
G22—luffing jib head
Connecting parts of luffing jib section have been shown in the following table:
Connecting parts of luffing jib section
Part
No.
Description
1
Double
tapered pin
2
Retaining
spring
Illustration
After the attachment of luffing jib is completed, preassemble partial anchoring rods to WA-frame
2(for the part number appear in the following figure, please refer to Section 5.7.5.2-b “luffing jib rear
anchoring rods”) and pin adjacent anchoring rods on the jib intermediate sections to one another.
A
0066340-200-05Y.C
A view
11
2
14
2
16
2
13
12
8 7
4
2
To WA-frame 2
d) Assemble the tilting-back support of luffing and tilting-back support of WA-frame 2.
Firstly ,connect the tilting-back support of luffing jib to main boom head with a pin spindle
(1) and secure it with a cotter pin (2). And then connect the two ends of strut rod
respectively to tilting-back support of luffing jib and main boom head with pin spindles (3)
and (5), and secure with cotters (4) and (6). Finally, pin one end of the tilting-back support
of WA-frame 2 to WA-frame 2 with a pin spindle (7) and secure with a cotter pin(8).
0066340-200-05Y.C
D
A
C
B
0066340-200-05Y.C
D
A
C
B
0066340-200-05Y.C
A
B
2
4
1
3
C
6
5
D
8
7
Connecting parts of luffing jib tilting back support
Part
No.
Description
1
Pin spindle
2
Cotter pin
3
Pin spindle
Illustration
0066340-200-05Y.C
4
Cotter pin
5
Pin spindle
6
Cotter pin
7
Pin spindle
8
Cotter pin
e) Reeving luffing rope in
1) Turn the switch (60) to right or push down the “reeving winch” on the remote control
box to unwind the rope of reeving winch;
2) Reeve the rope of reeving winch in the reverse direction between the load hook and
the rope pulley on luffing jib head and then pull it to the tail-end of main boom pivot
section. Attach rope end point of reeving winch to rope for hoisting winch 1(or luffing
rope) with rope lock.
3) Turn the switch (60) to left or push the “reeving winch” on the remote control box up
to wind the rope of reeving winch, while simultaneously moving the right control
lever (27) forwards to unwind the rope for hoisting winch 1(if luffing winch is used to
raise or lower the luffing jib, move the right control lever (27) to right to unwind the
luffing rope).
0066340-200-05Y.C
Caution:
1. Before operation, the operator must choose the correct boom configuration by turning “boom
configuration” switch to required position.
2. Working personnel who guides the wire rope should take great care to prevent against falling
down when walking on the boom frame; otherwise, serious accident may occur.
3. The rope unwinding speed from winch 1 must be faster than rope winding speed on reeving
winch.
4) Guided by the rope of reeving winch, the rope for hoisting winch 1(or luffing rope) will
then reach luffing jib head. When the rope for hosting winch 1(or luffing rope) is
unwound long enough, reeve it between the rope pulley on luffing jib head and load
hook according to the method given in Section 4.6.6 “luffing rope reeving”.
5
5
G27
4
2
2
3
4
1
3
1
G28
W1
Winch 1
G27—WA-frame 1 G28—WA-frame 2
f) - Connect required main boom anchoring rods according to assembled main boom
length (See the arrangement and combination of anchoring rods in Section 5.7.1.3 );
- Tie the WA-frame 1 to luffing jib with an attachment chain.
- lift the WA-frame 2 and swing it 90° by an auxiliary crane, and push the right control
lever(27) forwards at the same time to unwind the rope from winch 1(if luffing winch is
used to raise or lower the luffing jib, move the right control lever(27) to right to unwind
luffing rope from luffing winch).
- Attach the luffing jib rear anchoring rods (see Section 5.7.5.2-b “lufffing jib rear
anchoring rods”).
0066340-200-05Y.C
- Connect the other end of tilting-back support of WA-frame 2 to main boom head with
a pin spindle(1) and secure it with a cotter pin (2), then remove the pins on WA-frame
2.
2
1
Connecting parts
Part
No.
Description
1
Pin spindle
2
Cotter pin
Illustration
0066340-200-05Y.C
g) - Remove the auxiliary crane
- push the right control lever(27) backwards to wind the rope onto winch 1(if luffing
winch is used to raise or lower the luffing jib, move the right control lever(27) to left
to wind luffing rope onto luffing winch) until the luffing jib rear anchoring rod is
tensioned slightly.
- insert the pin spindle(2) in corresponding hole in the tilting-back support of
WA-frame 2 and secure it with locking bolt(1) and retaining pin(3)
Connecting parts
Part
No.
Description
1
Locking bolt
Illustration
(M12)
2
Pin spindle
0066340-200-05Y.C
3
Retaining pin
h) - Remove the attachment chain that ties the WA-frame 1 to luffing jib.
- push the right control lever(27) backwards to wind the rope onto winch 1(if luffing winch is
used to raise or lower the luffing jib, move the right control lever(27) to left to wind luffing
rope onto luffing winch) so as to raise the WA-frame 1 to proper position.
- select appropriate length of front anchoring rods according to luffing jib length and then
connect the front anchoring rods with WA-frame 1 (see Section 5.7.5.2-a “luffing jib front
anchoring rods” ).
0066340-200-05Y.C
i. Connect the tilting-back support accumulator cylinder of WA-frame 1 to main boom head as
shown in following figure.
1
Pin spindle
2
Retaining spring
j) - Turn the switch (60) on right control panel (4) to right or push down the “reeving winch”
on the remote control box to unwind the rope of reeving winch.
- Reeve the rope of reeving winch through the rope pulley on luffing jib head and then
pull it back to the tail-end of main boom pivot section.
- Return the switch (60) or the “reeving winch” on the remote control box to neutral
position to stop unwinding rope.
- push the left control lever(17) forwards to unwind the hoisting rope of winch 2 to
tail-end of main boom pivot section, and then attach the rope of reeving winch to
hoisting rope of winch 2 with rope lock.
- Turn the switch (60) to left or push the “reeving winch” on the remote control box up to
wind the rope of reeving winch, while simultaneously unwinding the hoisting rope for
winch 2. Guided by the rope of reeving winch, the hoisting rope for winch 2 will then
reach luffing jib head.
0066340-200-05Y.C
5.9.3 Connect electrics to luffing jib
5.9.3.1 Electrical lines connection
Note:
The following figure shows the connected electrical parts on main boom pivot section. Before
erecting the boom, make sure that all electrical lines are connected and safety measures are
checked.
Layout of electrical pats on main boom pivot section
Description of electrical parts on main boom pivot section
Part No.
Description
Installation position
X15
Socket ,10 hole
201
Angle sensor
main boom pivot section
202
Cable drum 1
main boom pivot section
203
Cable drum 2
main boom pivot section
At the front of slewing table
0066340-200-05Y.C
204
Main boom tension force
sensor
205
Luffing winch
anchoring rod of A-frame1
main boom pivot section(optional)
Layout of electrical parts between main boom head and luffing jib pivot section
Description of electrical parts between main boom head and luffing jib pivot section
Part No.
Description
Installation position
206
anemometer
Main boom head
207
Warning lamp(2)
Main boom head
208
Main boom junction box
Main boom head
209
Control box for Load Moment
Limit on luffing jib
Main boom head
210
Cable drum 3
Main boom head
211
Luffing jib angle sensor
luffing jib pivot section
0066340-200-05Y.C
212
Tilting-back support switch(2)
On tilting-back support of luffing jib
214
Proximity switch
on tilting-back support accumulator cylinder
215
Pressure sensor
on tilting-back support accumulator cylinder
Layout of electrical parts on luffijng jib head
Description of electrical parts on luffing jib head
Part No.
Description
Installation position
213
anemometer
Luffing jib head
214
Warning lamp(2)
Luffing jib head
215
Hoisting limit switch weight
216
Hoisting limit switch
217
Luffing jib junction box
Luffing jib head
218
Luffing jib tension force
sensor
Luffing jib anchoring rod
Connected with hoisting rope on luffing jib head
Luffing jib head, connected with hoisting limit
switch weight
a) Connecting electrics to main boom:
Connect all electrical parts on main boom according to electrics connecting requirement;
Establish electrical connection from the “titling-back support of luffing jib” socket on the
main boom junction box to the “Tilting-back support” switch on tilting-back support of
luffing jib.
0066340-200-05Y.C
b) Connecting electrics to luffing jib:
1) insert the one-end cable plug of cable drum 3 into “to cable drum ” socket on main
boom junction box, meanwhile, pull the other-end cable plug of cable drum 3 to luffing
jib head and insert it into “lead to junction box” socket on luffing jib junction box.
2) Connecting electrics to luffing jib head
Description of luffing jib junction box:
The luffing jib junction box, installed on luffing jib head, has 5 input and output sockets in total,
0066340-200-05Y.C
including:
— “Lead to junction box” socket (12-hole) on the left side, used to establish connection to
cable drum 3 on main boom head.
— “Anemometer” socket (4-pin) on the right side, used to establish connection to
anemometer on luffing jib head.
Other sockets at the bottom of the junction box, from the left to right, are respectively:
— “Warning lamp” socket (2-hole), used to establish connection to warning lamp on luffing
jib head
— “Warning lamp” socket (2-hole), used to establish connection to warning lamp on luffing
jib head
— “Hoisting limit switch for H1” socket (3-pin), used to establish connection to hoisting limit
switch for H 1 connected to luffing jib head.
Insert the cable plug of cable drum on main boom pivot section into the “lead to junction box”
socket on main boom junction box.
Insert the two cable plugs of luffing jib warming lamps respectively into the two “warning
lamp” sockets on the luffing jib junction box.
Inset the cable plug of hoisting limiter for H2 into the “hoisting limit switch for H1” socket on
luffing jib junction box.
Insert the cable plug of anemometer on luffing jib head into the “anemometer” socket on
luffing jib junction box.
Insert the cable plug of titling-back support switch into the “tilting-back support of luffing jib”
socket on main boom junction box.
Caution:
Cable plug which is not used should be protected by seal cover.
c) Electrical connection to Load Moment Limiter
See the Installation Guide& User’s Manual for Load Moment Limiter.
5.9.3.2 Checks before erecting the boom
a) Check warning lamp on main boom head
Set the Master Lighting Switch 39 (see Section 4.1.4) to the second position, and press
“warning lamp on/off” Switch 41 the same time to check that the warning lamp lights up.
b) Check the anemometer
Rotate the vane of anemometer to check whether the wind velocity shown on the display in
0066340-200-05Y.C
the operator’s cab is normal.
c) Check hoisting limit switch for H2
Support and hold the hoisting limit switch weight for H2 to ensure that the switch is
triggered, and then check that the icon “upper limit switch on H2” on the screen will flash
and the buzzer will sound.
5.9.4 Erecting and lowering main boom with luffing jib
5.9.5.1 Requirements
a) All electrical connections have been established.
b) The limit switch control lever has been checked for smooth movement.
c) Check the warning lamp.
d) Check the anemometer.
e) Check the anemometer for smooth rotation and functional working.
f)
Check the hoisting limiter switch.
g) Operate the hoisting winch, and adjust the hoisting limit switch on luffing jib head manually.
Requirement for this operation: the hoisting movement of hoisting winch should be
stopped when the upper limit has been exceeded, and icon “upper limit switch” on the
screen will flash.
5.9.5.2 Requirements for erecting main boom with luffing jib
a) The crane is properly supported and level;
b) Select appropriate boom configurations according to the load to be lifted and the load
capacity chart; ensure that boom sections have been connected and secured;
c) All limit switches has been correctly fitted and are fully operational;
d) All pinned connections have been secured.
e) The hoisting rope has been correctly placed in the rope pulleys and prevented from
jumping out (from rope groove) using rope guard tube;
f)
No person is present in the danger zone;
g) There are no loose parts on main boom;
h) In winter, the main boom, fixed jib and associated components (limit switches, rope
drums, warning light, anemometer etc.) must be kept free of ice and snow.
Danger:
1. Incorrectly fitted or faulty limit switches and falling parts (pins, retaining pins, ice etc.) can cause
0066340-200-05Y.C
injury.
2. Before erecting the boom, check that the tilting-back support for luffing jib is installed correctly.
And ensure the spherical ends of tilting-back support move smoothly in the two guides on luffing
jib pivot section when luffing jib is raised to the limit position. Otherwise, the luffing jib is liable to
tilt backwards if the tilting-back support is not fixed properly.
5.9.3.3 Erecting main boom with luffing jib
a) Set the “luffing jib” operating mode in Load moment limiter in accordance with boom
configurations.
Caution:
Performing slewing motion while the boom is erected from the ground is prohibited.
b) When luffing jib is erected by winch 1,
-- turn “boom configuration” switch to “Main boom” position;
--slowly raise the main boom to a proper position by moving right control lever (27) to the
left;
--unwound wipe rope off winch 1 by pushing right control lever (27) forwards
When luffing jib is erected by luffing winch,
-- turn “boom configuration” switch to “Main boom” position;
-- Slowly raise main boom by moving the right control lever (27) to the left;
--after main boom is raised to a proper position, turn “boom configuration” switch to
“Luffing jib” position;
--unwind luffing rope off luffing winch properly through moving right control lever (27) to
the right.
Carry out the movements “Raise main boom” and “unwind luffing rope” repeatedly and
ensure that the luffing jib head is running with the running wheels on the ground. when the
angle between main boom and luffing jib reaches 90°, move right control lever (27) to
neutral position to stop erecting.
Note:
1. The total weight of luffing jib should be loaded on the running wheel.
2. Check whether the wire rope on luffing winch is slack.
3. In no circumstances can the angle between the main boom and luffing jib be
smaller than 90°. Otherwise, the luffing jib head and luffing jib may be damaged.
4. Wire rope should be checked and guided by an appointed person to prevent it
0066340-200-05Y.C
from being damaged due to crush.
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c) - Turn the “boom configuration” switch to “main boom” position, and then move right
control lever (27) to the left to raise the boom. When luffing jib head is lifted to a proper
position, place the selected load hook under the luffing jib head.
- At this time, turn the “reeving winch” rotary switch (60) on the right control panel (4) to
the right, or push the “reeving winch control” switch on auxiliary remote control box
downwards, to unwind the rope of reeving winch and reeve it in the reverse direction
between rope pulleys on luffing jib head and load hook, finally attach it to hoisting rope
with rope lock.
- After that, turn the switch (60) to the left, or push “reeving winch” switch down, to spool
up reeving winch. At this moment, the hoisting rope, under the guidance of rope of
reeving winch, will be reeved between the rope pulleys on luffing jib head and load hook,
and the rope end point is fixed on the luffing jib head or load hook.
d) Turn the “boom configuration” switch to “main boom” position, and then move right control
lever (27) to the left to raise main boom, at the same time push the left control lever (17)
forwards to unwind the wire rope off the winch 2 to make sure that the load hook will not
be dragged on the ground. After main boom is raised to the required position, return the
left and right control levers (17, 27) to neutral position to make main boom and load hook
stop moving.
Danger:
1. In the erecting process, when main boom is raised to 65° position, the
0066340-200-05Y.C
“assembly mode” must be changed to the “operating mode”.
2. To prevent the luffing jib front anchoring rods from swinging to and fro, the luffing
jib should be erected at constant speed slowly.
e) Turn the “Boom configuration” switch to “luffing jib” position, and then push right control
lever (27) backwards to spool up winch 1 so as to raise the luffing jib. (if luffing jib is
raised/lowered by luffing winch, move right control lever (27) to the left to spool up luffing
winch to raise luffing jib.) Meanwhile, push the left control lever (17) forwards to unwind
the wire rope off the winch 2 to prevent the hook block from being dragged on the ground.
After luffing jib is erected to the working position, return the left and right control levers (17,
27) to neutral position to make luffing jib and load hook stop moving.
f)
Push left control lever (17) backwards to spool up winch 2 until the load hook is lifted.
0066340-200-05Y.C
Caution:
1. When main boom angle is 85°, the luffing jib angle can be adjusted from 15° to 75°.
2. When main boom angle is 75°, the luffing jib angle can be adjusted from 15° to 65°.
3. When main boom angle is 65°, the luffing jib angle can be adjusted from 15° to 55°.
4. When boom angle varies from 65°to 75°or 75°to 85°, we should determine the
corresponding smaller value in the chart as the rated lifting capacity. In order to give full
play to the crane’s performance, please operate the crane under the operating
conditions with three prescribed boom angles.
5. Under crane operation with main boom and luffing jib (with main boom angle of 85°):
when luffing jib angle exceeds 60°, the luffing jib with a load should not be
raised/lowered at high speed. And the load should be the min. lifting capacity under this
boom configuration; otherwise the luffing jib is liable to overturning. Before the load is
detached from the hook, lower the luffing jib to a position less than 60° by the pulling
force of load.
5.9.3.4 Lowering main boom with luffing jib
a) Push left control lever (17) forwards to reel off hoisting winch 2 so as to lower the load
hook. After the load hook is lowered on the ground, it must be moved away from the
position where the boom will lowered;
b) Push right control lever (27) forwards to operate winch 1 in the lowering direction to lower
luffing jib (or move right control lever (27) to the right to lower luffing jib If luffing jib is
lowered with luffing winch.) when the angle between luffing jib and main boom reaches
90°, return right control lever (27) to neutral position to make luffing jib stop moving.
c) Turn the “boom configuration” switch to “main boom” position, and then move right control
lever (27) to the right to lower main boom until the luffing jib head touches the ground with
the running wheels.
Caution:
1. In the lowering process, when main boom is lowered to 65° position, the “operating
mode” must be changed to “assembly mode”.
2. In the process of lowering main boom, the winch 1 must be reeled off to avoid the
hook’s collision with the pulley head.
3. Standing within danger area of crane during operation is prohibited!
4. The boom-lowering movement should be performed slowly and stably. And during
the operation, the crane operator must observe the data shown on the display, while
other workers must observe the surrounding areas for potential dangers.
0066340-200-05Y.C
d) If winch 1 is used to raise/lower luffing jib, turn the “boom configuration” switch to “main
boom” position, and then push the right control lever (27) backwards to spool up winch 1.
And then move the right control lever (27) to the right to lower main boom. Carry out the
movements “Spool up winch 1” and “Lower main boom” repeatedly to ensure that the
luffing jib head is running with the running wheels.
(if luffing winch is used to raise/lower luffing jib, turn the “boom configuration” switch to
“luffing jib” position, and then move right control lever(27) to the right to lower luffing jib.
After that, turn the “boom configuration” switch to “main boom” position, and then push left
control lever(17) backwards to spool up winch 2. when main boom and luffing jib are
lowered on the ground, return right control lever (27) to neutral position.
Caution:
1. Standing within danger area of crane during operation is prohibited!
2. The boom-lowering movement should be performed slowly and stably. And
during the operation, the crane operator must observe the data shown on the
display, while other workers must observe the surrounding areas for potential
dangers.
3. To prevent the wire rope from being damaged due to crush, it should be guided
by a person.
4. In the process of lowering the boom, make anchoring rods of luffing jib hang
down a little.
5. The winding of wire rope should be supervised by a person appointed, and no
person is standing within danger zone during operation.
5.9.3.5 Disamantling of main boom with luffing jib
a) Push left control lever (17) backwards to spool up winch 2;
Note:
The winding of wire rope should be supervised by a person appointed, and no
person must stand within danger zone during operation.
b) Push right control lever (27) forwards to reel off winch 1 (or move right control lever to the
right to reel off luffing winch when luffing jib is lowered with luffing winch). After WA-frame 1
is lowered forwards to proper position, return right control lever(27) to neutral position. At
this moment, separate the anchoring rods of WA-frame 1 from those of luffing jib. And then
lower the WA-frame 1 on the luffing jib and secure them with slings.
0066340-200-05Y.C
c) push right control lever (27) backwards slightly to spool up winch 1 (or move right control
lever to the left to spool up luffing winch when luffing jib is controlled by luffing winch) until
the luffing jib rear anchoring rods is tensioned. At this moment, remove the positioning
pin for tilting-back support of WA-frame 2. After that, push right control lever (27)
forwards to reel off winch 1 (or move right control lever to the right to reel off luffing winch).
Lower WA-frame 2 backwards until the tilting-back support are retracted completely, and
then insert the positioning pin.
Caution:
1. In order to avoid breaking mounting sling, the force should not be too large when
wind luffing rope to tighten the luffing jib rear anchoring rods. Otherwise,
accident will occur.
2. The end of tilting-back support should slide in guiding rails provided for that
purpose.
d) Dismantle the tilting-back support of WA-frame 2 with the help of auxiliary crane ,and then
disconnect luffing jib rear anchoring rods from WA-frame 2;
Note:
When wind luffing wire rope, the mounting sling should not bear any load to prevent it
from being broken.
e) Push right control lever (27) forwards to reel off winch 1 (or move right control lever (27) to
the right to reel off luffing winch when it is controlled by luffing winch), slowly put WA-frame
2 on the WA-frame 1 with the help of auxiliary crane.
Danger:
1. At this time, WA-frame 2 is lowered down with the help of auxiliary crane, not the
hoisting wire rope.
2. After WA-frame 2 is lowered to 45° position in the front, it should be lowered
down by auxiliary crane and mounting wire rope. Do not make wire rope of winch
1 bear force; otherwise, they will be damaged.
f)
Retract the rope of winch 1. push right control lever (27) backwards to wind the rope on the
winch 1 (or move right control lever to the left to spool up luffing winch when luffing jib is
raised or lowered by luffing winch) and fixed it on the winch.
g) Spilt luffing jib sections one by one, leaving the luffing jib pivot section assembled.
h) Detach the luffing jib pivot section (together with WA-frames 1 and 2) from the main boom
0066340-200-05Y.C
head.
Caution:
All crane movements should be carried out smoothly, and all safety precautions
should be followed, otherwise accident may occur.
0066340-200-05Y.C
5.10 Assembly and dismantling of light duty boom (SL)
The SL boom comprises main boom sections and luffing jib sections. Its first 73 long boom is
composed of main boom sections, and the second part of it is composed of luffing jib sections.
The first part of it is connected to the second part by 4 reducing section (G29). The assembly
sequence of boom sections for both parts of it and the arrangement and combination of
anchoring rods as well as safety precautions have detailed in Section 5.7.2 “Light duty boom”.
The connection of 4m reducing section to main boom section and to luffing jib section has
been shown in the following figure.
1
2
3
4
0066340-200-05Y.C
Connecting parts
Part No.
Description
1
Double
tapered pin
2
Retaining
spring
3
Double
tapered pin
4
Retaining
spring
illustration
Connecting electrics
Insert the cable plug of X15 on main boom pivot section into the X15 socket at the front of
slewing table.
Insert the cable plug of cable drum 2 into “lead to junction box” socket on luffing jib junction
box.
For electrical connections to other parts, please see the “Connecting electrics to luffing jib” in
Section 5.9.3.1.
Note:
For erection and lowering of light duty boom as well as safety precautions, please
refer to Section 5.8.4 “Erecting main boom” and Section 5.8.5.1 “Setting down main
boom”
0066340-200-05Y.C
5.11 Assembly and dismantling of main boom with fixed jib (SF)
5.11.1 Preparations
a) The crane is properly supported and level.
b) The main boom is installed;
c) The required counterweight plates have been assembled;
d) An auxiliary crane and working platform are available.;
e) The safe load indicator system of Load Moment Limiter is set according to the data given
in the load capacity charts;
f)
Choose appropriate boom combination and relevant anchoring rods combination
according to operational planning and boom configuration.
g) Choose the correct load hook and rope reeving for the load to be lifted.
h) Change the “operating mode” to “assembly mode”.
Danger:
1. After the “operating mode” is changed to “assembly mode”, all safety device built
in the crane will be deactivated, the assembly, dismantling of the machine
should therefore be carried out with utmost care.
2. Any assembly work on crane should be carried out on safety working ground;
otherwise there is a risk of accident.
3. Do not stand beneath the boom when it is being pinned or unpinned!
5.11.2 Assembling main boom with fixed jib
Caution:
Before operating the crane, set the “Boom configuration” switch to “fixed jib” position.
During transportation, the fixed jib pivot section (G31) and FA-frame (G37) are assembled
together. See following diagram.
0066340-200-05Y.C
G37
G31
a) Assemble required main boom sections in accordance with Section 5.7.1 “ heavy duty
boom”;
b) - Raise the fixed jib pivot section (together with FA-frame) with an auxiliary crane and
swing to main boom head.
-
Attach the fixed jib pivot section to the main boom head from above
-
Continue lowering the fixed jib pivot piece until it can be pinned to main boom head.
-
Pin the fixed jib pivot piece to main boom head with pin spindles (2) and secure with
bolts (5), locking plates (3), retaining springs (1) and washer (4). (See following
figure.)
0066340-200-05Y.C
1
2
3
4
5
Connecting parts connect fixed jib pivot section to main boom head
Part No.
Description
1
Retaining
spring
2
Pin spindle
3
Locking plate
4
Washer
Illustration
(0.64″)
5
Bolt
ISO4017-1999 (M16×2.2″-8.8)
0066340-200-05Y.C
c) According to actual condition, choose appropriate numbers of fixed jib intermediate
sections 6m (G33) in length, and then pin them together. All jib intermediate sections are
connected with double tapered pins (1), secured on both sides with retaining springs (2)
(following fig.).
G32
G33
G31
2
1
Connecting parts of connect fixed jib section
Part No.
Description
1
Double
tapered pin
2
Retaining
spring
Illustration
d) - Connect required main boom anchoring rods according to assembled main boom length
(See Section 5.7.1.3 “combination of main boom anchoring rods”).
- Preassemble partial fixed jib rear anchoring rods to FA-frame (see following A-view, for
the part number appear in the following figure, please refer to Section 5.7.3.2-b “fixed jib
rear anchoring rods”)
- Connect required front anchoring rods according to fixed jib length (for the arrangement
and combination of front anchoring rods, please refer to section 5.7.3.2—a “fixed jib front
anchoring rod”).
0066340-200-05Y.C
A
e) - Assemble the outer pipe of one end of front tilting-back support (G74) and rear
tilting-back support (G75) to FA-frame (G37), and secure them with cotter pin (1).
- lift FA-frame (G37) with an auxiliary crane until the fixed jib front anchoring rods is
tensioned slightly.
- attach the inner pipe of the other end of front tilting-back support (G74) to fixed jib pivot
section with pin spindle (2) and secure with cotter pin (3).
- attach required fixed jib rear anchoring rods (see Section 5.7.3.2-b “fixed jib rear
anchoring rods”).
0066340-200-05Y.C
C
A
B
0066340-200-05Y.C
G11—main boom pivot section
G31—fixed jib pivot section
G37— FA-frame
G74— front tilting-back support of fixed jib
G75—rear tilting-back support of fixed jib
0066340-200-05Y.C
Connecting parts
Part No.
Description
1
Cotter pin
Illustration
ISO1234-1997(0.32″×2.4″)
2
Pin spindle
3
Cotter pin
ISO1234-1997(0.32″×2.4″)
4
Double tapered
pin
5
Retaining spring
f)
- Turn the switch (60) on right control panel (4) to right or push down the “reeving winch”
on the remote control box to unwind the rope of reeving winch.
- Reeve the rope of reeving winch through the rope pulley on fixed jib head and then pull
it back to the tail-end of main boom pivot section.
- Return the switch (60) or the “reeving winch” on the remote control box to neutral
position to stop unwinding rope.
- push the left control lever(17) forwards to unwind the hoisting rope of winch 2 to tail-end
of main boom, and then attach the rope of reeving winch to hoisting rope of winch 2 with
rope lock.
0066340-200-05Y.C
- Turn the switch (60) to left or push the “reeving winch” on the remote control box up to
wind the rope of reeving winch, simultaneously unwind the hoisting rope for winch 2.
Guided by the rope of reeving winch, the hoisting rope for winch 2 will then reach fixed jib
head.
g) Move the right control lever (27) to left to wind derricking rope onto derricking winch.
When main boom is raised to a proper position, lift the rear titling-back support of fixed jib
(G75) with an auxiliary crane, and then connect it with main boom head with pin spindle (2)
and secure with cotter pin(1).
G75
1
2
G75— rear tilting-back support of fixed jib
0066340-200-05Y.C
Connecting parts
Part
No.
Description
2
Pin spindle
3
Cotter pin
Illustration
ISO1234-1997(0.32″×2.4″)
Caution:
1. Make sure that hoisting rope on fixed jib head is not exposed to crushing force.
2. Ensure that the fixed jib head is rolling forwards on the running wheel all the
time.
3. The attachment of rear tilting-back support to main boom head should be carried
out with utmost care.
h) -- Move the right control lever (27) to left to wind derricking rope onto derricking winch.
-- When main boom and fixed jib are raised to a proper position a littler higher than the
height of a load hook, position the selected load hook under the fixed jib head.
-- reeve the rope of reeving winch in reverse direction between rope pulley on fixed jib
head and load hook.
-- attach the rope end point of reeving winch to hoisting rope of winch 2 with rope lock.
-- Turn switch (60) on right control panel (4) to left or push the “reeving winch” switch on
the remote control box up to wind the rope of reeving winch. Guided by the rope of reeving
winch, the hoisting rope for winch 2 will be reeved in desired direction between the rope
pulley on fixed jib head and load hook.
0066340-200-05Y.C
0066340-200-05Y.C
5.11.3 Connect electrics to fixed jib
5.11.3.1 Electrical lines connection
Note:
The following figure shows the connected electrical parts on main boom with fixed jib. Before
erecting the boom, make sure that all electrical lines are connected and safety measures are
checked.
0066340-200-05Y.C
Description of electrical parts attached on main boom with fixed jib
Part No.
Description
Installation position
X15
Socket ,10 hole
At the front of slewing table
X16
Socket ,10 hole
At the front of slewing table
201
Angle sensor
main boom pivot section
202
Cable drum 1
main boom pivot section
203
Cable drum 2
main boom pivot section
204
Main boom tension force
sensor
anchoring rods of A-frame
205
Luffing jib derricking winch
main boom pivot section(optional)
206
Main boom junction box
Main boom head
207
Control box for Load Moment
Limit on luffing jib
Main boom head
208
Cable drum 3
Main boom head
209
Anemometer
Fixed jib head
0066340-200-05Y.C
210
Warning lamp
Fixed jib head
211
Fixed jib junction box
Fixed jib head
212
Hoisting limit switch weight
Connected to hoisting rope on fixed jib head
213
Hoisting limit switch
Fixed jib head, connected to hoisting limit switch
weight
a) Connecting electrics to main boom:
Connect all electrical parts (except anemometer and warning lamp) on main boom
according to electrics connecting requirement
b) Connecting electrics to fixed jib:
1) insert the one-end cable plug of cable drum 3 into “to cable drum ” socket on main
boom junction box, meanwhile, pull the other-end cable plug of cable drum 3 to fixed
jib head and insert it into “lead to junction box” socket on fixed jib junction box.
2) Connecting electrics to fixed jib head
Description of fixed jib junction box:
The fixed jib junction box, installed on fixed jib head, has 5 input and output sockets in
total, including:
— “Lead to junction box” socket (12-hole) on the left side, used to establish connection to
cable drum 3 on main boom head.
— “Anemometer” socket (4-pin) on the right side, used to establish connection to
anemometer on fixed jib head.
Other sockets at the bottom of the junction box, from the left to right, are respectively:
0066340-200-05Y.C
— “Warning lamp” socket (2-hole), used to establish connection to warning lamp on fixed jib
head
— “Warning lamp” socket (2-hole), used to establish connection to warning lamp on fixed jib
head
— “Hoisting limit switch for H1” socket (3-pin), used to establish connection to hoisting limit
switch for H 1 connected to fixed jib head.
Insert the cable plug of cable drum on main boom pivot section into the “lead to junction
box” socket on main boom junction box.
Insert the cable plug of fixed jib warming lamp respectively into “warning lamp” sockets
on the fixed jib junction box.
Inset the cable plug of hoisting limiter for H2 into the “hoisting limit switch for H1” socket
on fixed jib junction box.
Insert the cable plug of anemometer on fixed jib head in the “anemometer” socket on
fixed jib junction box.
Caution:
Cable plug which is not used should be protected by seal cover.
c) Electrical connection to Load Moment Limiter
See the Installation Guide& User’s Manual for Load Moment Limiter.
5.11.3.1 Checks before erecting main boom with fixed jib
a) Check warning lamp
Set the Master Lighting Switch 39 (see Section 4.1.4) to the second position, and
press “warning lamp on/off” Switch 41 at the same time to check that the warning
lamp lights up.
b) Check the anemometer
Rotate the vane of anemometer to check whether the wind velocity shown on the
display in the operator’s cab is normal.
c) Check hoisting limit switch for H2
Support and hold the hoisting limit switch weight for H2 to ensure that the switch is
triggered, and then check that the icon “upper limit switch on H2” on the screen will
flash and the buzzer will sound.
5.11.4 Erecting and lowering main boom with fixed jib
5.11.5.1 Requirements
a) All electrical connections have been established.
0066340-200-05Y.C
b) The limit switch control lever has been checked for smooth movement.
c) Check the warning lamp on the boom head.
d) Check the anemometer.
e) Check the anemometer for smooth rotation and functional working.
f)
Check the hoisting limiter switch.
g) Operate the hoisting winch, and adjust the hoisting limit switch on fixed jib head manually.
Requirement for this operation: the hoisting movement of hoisting winch should be
stopped when the upper limit has been exceeded, and icon “upper limit switch” on the
screen will flash.
5.11.5.2 Requirements for erecting main boom with fixed jib
a) The crane is properly supported and level;
b) The counterweight plates have been attached in accordance with the lifting capacity
charts
c) Select appropriate boom configurations according to the load to be lifted and the load
capacity chart; ensure that boom sections have been connected and secured;
d) All limit switches has been correctly fitted and are fully operational;
e) All pinned connections have been secured.
f)
The hoisting rope has been correctly placed in the rope pulleys and prevented from
jumping out (from rope groove) using rope guard tube;
g) No person is present in the danger zone;
h) There are no loose parts on main boom or jib;
i)
In winter, the main boom, fixed jib and associated components (limit switches, rope
drums, warning light, anemometer etc.) must be kept free of ice and snow.
Danger:
Incorrectly fitted or faulty limit switches and falling parts (pins, retaining pins, ice etc.)
can cause injury.
0066340-200-05Y.C
5.11.5.3 Erecting main boom with fixed jib
a) Select the “fixed jib” operating mode in the Load Moment Limiter in accordance with boom
configurations.
Caution:
Performing slewing motion while the fixed jib is being erected off the ground is
prohibited.
b) - Move the right control lever (27) to the left to raise the boom, and push the left control
lever(17) forwards at the same time to reel off hoisting winch 2 so that the load hook will
not be dragged on the ground.
- when main boom is raised to 30° position,
“operating mode” automatically.
the “assembly mode” will change to
- move the left control lever(17) and right control lever (27) to neutral position.
c) Move the right control lever(27) to the left to erect the boom . When the main boom with
fixed jib is raised to requried working position, move the right control lever (27) to neutral
position.
Caution:
1. when main boom is raised to 83°, the movement of derricking boom up will be switched off
automatically along with warning being sent out, but the main boom can still be derricked up
by pressing the “bypass key button”(54). However, when main boom is raised to 86° position,
the movement of derricking boom up will be switched off automatically along with warning
being sent out. Under this condition, even though “bypass key button” is pressed, the main
boom can not be raised any more.
2. The boom should be erected or set down stably at even speed.
0066340-200-05Y.C
5.11.5.4 Lowering and dismantling main boom with fixed jib
a) Move the right control lever (27) to the right to lower the boom. When the main boom is
lowered to 30° position, return the right control lever (27) to neutral position.
b) Push the left control lever (17) forwards to lower the hook on the ground.
Note:
To avoid load hook’s colliding with the pulley head, the load hook must not be lifted too high in the
process of lowering main boom with fixed jib.
c) Move the right control lever (27) to the right to reel off the derricking winch so as to make
the fixed jib head come into contact with the ground, then disconnect the inner pipe of rear
tilting-back support of fixed jib (G75) from the main boom head(See following figure).
0066340-200-05Y.C
G75
1
2
G75—rear tilting-back support of fixed jib
Connecting parts
Part
No.
Description
2
Pin spindle
3
illustration
Cotter pin
ISO1234-1997(0.32″×2.4″)
0066340-200-05Y.C
d) -Keep on moving the right control lever (27) rightwards to reel off the derricking
winch so as to make the fixed jib head rolls forwards on the running wheel until the entire
boom gets into contact with the ground.
- Move the right control lever (27) to neutral position to stop the movement.
Caution:
1. The boom-lowering movement should be performed slowly and stably. And during
the operation, the crane operator must observe the data shown on the display,
while other workers must observe the surrounding areas for potential dangers.
2.
Standing within an area where the crane movement is carried out is prohibited.
3. To prevent the wire rope from being damaged due to crush, it should be guided by
a person.
e) Push right control lever (27) backwards to wind the hoisting rope onto the winch 2 and
secure it.
Caution:
The winding of wire rope should be supervised by a person appointed, and no
person is standing within danger zone during operation.
f)
- Lift FA-frame by an auxiliary crane, and then dismantle the front and rear tilting-back
support of fixed jib.
- with the help of the auxiliary crane, tilt the FA-frame forwards to an appropriate position,
and then disassemble the fixed jib front and rear anchoring rods;
g) Spilt the fixed jib sections one by one, leaving the fixed jib pivot section assembled.
h) Detach the fixed jib pivot section (together with FA-frame) from the main boom head.
Caution:
All crane movements should be carried out smoothly, and all safety precautions
should be followed, otherwise there is a risk of accident.
0066340-200-05Y.C
5.12 Assembly and dismantling of main boom with heavy fixed jib (SFV)
For the assembly, dismantling and erecting as well as lowering of main boom with heavy
fixed jib, please refer to section 5.11 “Assembly and dismantling of main boom with fixed
jib”.
Connecting electrics to main boom with heavy fixed jib:
For electrical connections to main boom, please refer to section 5.8.3 “Connect electrics”;
In this boom configuration, the hoisting limit switch is mounted on heavy fixed jib, it should be
connected to “hoisting limit switch for H1” on junction box.
5.13 Assembly and dismantling of tip boom
Crawler crane QUY260 has two tip booms, i.e., tip boom on main boom head, and tip boom
on luffing jib head.
Assembly of tip boom on main boom head:
1
2
G12
G10
G10—tip boom on main boom head
G12—main boom head
3
0066340-200-05Y.C
Connecting parts of tip boom on main boom head
Part No.
Description
1
Pin spindle
2
Retaining
spring
3
Pin spindle
illustration
0066340-200-05Y.C
Assembly of tip boom on luffing jib head:
A
B
G22
C
A
G20
C
B
5
4
3
6
7
0066340-200-05Y.C
Connecting parts of tip boom on luffing jib head
Part No.
Description
1
Pin spindle
2
Retaining spring
3
Pin spindle
4
Retaining spring
5
Pin spindle
6
washer
illustration
(0.64″)
0066340-200-05Y.C
7
Retaining spring
0066340-200-05Y.C
5.14 Transport dimensions and weights of main components
All Length values are given in mm.
Basic machine—(105800Ib)
Crawl
er carrier—54000Ib×2
Counterweight base plate—41900Ib×1
Rear counterweight plate----14600Ib×10
0066340-200-05Y.C
Central counterweight plate----35300Ib t×2
260t (573300Ib)Load hook---- 9261Ib ×1
160t/100t(352800Ib /220550Ib) Load hook----6174Ib×1
50t (110250Ib)load hook----3748Ib×1
30t(66150Ib)l oad hook----2360Ib t×1
0066340-200-05Y.C
16t (35280Ib)load hook----1764Ib×1
Main boom pivot section (Width: 7′7″)—6659Ib×1
Main boom head (width: 7′7″)—7453Ib×1
(9′10″) main boom intermediate section (width: 7′7″)—1588Ib×1
(19′8″) main boom intermediate section (width: 7′7″)—2646Ib×1
0066340-200-05Y.C
(29′6″) main boom intermediate section (width: 7′7″)—3925Ib×6
(13′1″) reducing section (width: 7′7″)—1808Ib×1
Fixed jib pivot section (width: 5′0″)—1036Ib×1
(19′8″)
fixed jib intermediate section(width: 4′1″) —617Ib×3
Fixed jib head (width: 4′1″)—1411Ib×1
0066340-200-05Y.C
FA-frame (width: 4′11″)—1654Ib×1
Luffing jib pivot section (width: 5′6″)—2007Ib×1
Luffing jib head (width: 5′6″)—2426Ib×1
(9′10″)
luffing jib intermediate section (width: 5′6″)—617Ib×1
(19′8″)
luffing jib intermediate section (width: 5′6″)—1103Ib×2
0066340-200-05Y.C
(29′6″)
luffing jib intermediate section (width: 5′6″)—1500Ib×3
Heavy fixed jib (width: 5′1″)—2205Ib×1
WA-frame 2 (width: 5′8″) —3837Ib×1
WA-frame 1 (width: 4′6″) —3352Ib×1
0066340-200-05Y.C
5.15 Requirement for crane transport
Transport means and safety precautions for transport
a) After being dismembered, the crawler crane can be transported by a low-loader, train
or by other transport equipment for a long distance. During transportation, the crane
is fixed by rope, with its doors and windows locked up. If necessary, take preventive
measures against rain. The crawler crane should be dismembered and transported in
accordance with the permissible load carrying capacity of transport vehicle and the
weight, dimensions of dismantled parts which are shown in the previous figures. The
transport vehicle is forbidden to be overloaded.
b) During transportation, all component parts should be fixed to prevent them from
jostling and sliding.
c) To understand the detailed transport means, please consult our company.
If the crane is permanently inactive for more than 6 months, take the following protective
measures.
a) Wipe off the dust and oil dirt to keep the crane clean;
b) Retract all the piston rods of the cylinders completely;
c) Put the battery in a dry and ventilating place and charge it periodically;
d) Bared surfaces of all components should be greased to prevent them from
corroding;
e) Clean the wire ropes and grease them again with ZG-3 graphite calcium base
grease;
f)
The crane should be stored in a garage. If it is placed in the open air, it must be
covered up with water-proof cloth to prevent it from corroding, and in winter
antifreeze measure should be taken;
g) Starting the machine once a month and running all mechanisms with no load to
check whether they are in good condition;
h) Assign a person responsible for completeness of the crane so that it can be put into
operation at any time.
0066340-200-05Y.C
5.15 Requirement for crane transport
Transport means and safety precautions for transport
a) After being dismembered, the crawler crane can be transported by a low-loader, train
or by other transport equipment for a long distance. During transportation, the crane
is fixed by rope, with its doors and windows locked up. If necessary, take preventive
measures against rain. The crawler crane should be dismembered and transported in
accordance with the permissible load carrying capacity of transport vehicle and the
weight, dimensions of dismantled parts which are shown in the previous figures. The
transport vehicle is forbidden to be overloaded.
b) During transportation, all component parts should be fixed to prevent them from
jostling and sliding.
c) To understand the detailed transport means, please consult our company.
If the crane is permanently inactive for more than 6 months, take the following protective
measures.
a) Wipe off the dust and oil dirt to keep the crane clean;
b) Retract all the piston rods of the cylinders completely;
c) Put the battery in a dry and ventilating place and charge it periodically;
d) Bared surfaces of all components should be greased to prevent them from
corroding;
e) Clean the wire ropes and grease them again with ZG-3 graphite calcium base
grease;
f)
The crane should be stored in a garage. If it is placed in the open air, it must be
covered up with water-proof cloth to prevent it from corroding, and in winter
antifreeze measure should be taken;
g) Starting the machine once a month and running all mechanisms with no load to
check whether they are in good condition;
h) Assign a person responsible for completeness of the crane so that it can be put into
operation at any time.
Chapter 6
Maintenance
0066340-200-06Y.C
6.1 General
maintenance of the crane shall conform to ANSI B30.5:2007 section 5-2.3
In order to ensure a good and safe condition of the crane all the time, the maintenance worker
must service and maintain the crane periodically.
6.1.1Crane maintenance
Before inspecting and maintaining the crane, following prerequisites must be fulfilled:
—The boom is laid down on the ground;
—The engine is switched off;
—All the safety devices are locked;
—The key is taken out from the ignition starter switch to prevent the engine from being
switched on by an unauthorized person.
Caution:
Failing to observe this regulation may result in death or serious injury.
6.1.1.1 Basic requirements for crane maintenance
a) The maintenance worker should wear specified clothes during maintenance;
b) The crane should be set up on level and firm ground, where a warning board marked
“Inspection” is placed around the crane;
c) Use ladder and safety belt when working in high position 2m above the ground;
d) When there is a need to move the crane for maintenance, the operator must operate
the crane according to the signals;
e) When inspecting or maintaining the hydraulic system, dust and impurities are not
allowed to enter into the system;
f)
If several parts need to be repaired and adjusted, please repair and adjust them
immediately;
g) If the crane needs to be repaired, the customer must contact a local service station of
Mobile Crane Branch Company of Zoomlion;
h) In order to ensure the performance of the crane, please use the accessories and
lubricating grease specified by Zoomlion;
i)
The expendable parts such as filter cartridge must be changed in time to avoid the
malfunction;
j)
If uncertain failure is found during inspection or maintenance, please contact a local
service station of Mobile Crane Branch Company of Zoomlion.
0066340-200-06Y.C
k) Place crane where it will cause the least interference with other equipment or
operations in the area.
l) Set all controls in the off position and ensure all operating features are secured from
inadvertent motion by brakes, pawls, or other means.
m) Lower the boom to the ground, if possible, or otherwise secure against dropping.
n) Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing
hydraulic components.
6.1.1.2 Notes on crane maintenance and service
a) Set up the warning board during maintenance
Before carrying out the inspection and maintenance, put a warning board marked
“Never start engine during inspection and maintenance.” on the ignition starter switch.
b) Use clean lubricating grease
The room for storing lubricating grease must be kept clean. Never allow dust and
water to enter into container. Ensure that the used lubricating grease is not mixed with
water.
c) Keep machine clean
Clean the machine to make operator easy to check whether some abnormal
phenomena occur such as oil leakage, crack and loosing of connector. Especially
keep the grease nipple, air vent and oil dipstick clean.
0066340-200-06Y.C
Note:
1. After cleaning the machine, lubricate the propeller shafts and rotary parts.
2. The steering wheel, operating desk, control panel and floor inside the operator’s cab
must only be washed by warm water with cleaning agent.
3. Never use a corrosive cleaning agent.
d) Oil clean up
When adding or changing fuel, hydraulic oil and lubricating grease, or when replacing
the filter cartridge, the oil will be spouted out. At this moment, wipe off oil to prevent a
fire.
e) Never spray water on the electric elements and the fittings when washing the
machine.
f)
Prevent a fire
The rubbish attached with oil stain or other flammable substances must be placed in a
safe place. Know about the position of fire extinguisher and master its use methods.
g) Pay attention to the rotary parts
0066340-200-06Y.C
When checking the fan belt or the water pump, the operator could be hurt. Therefore,
he should first switch off engine, and then check the belt or the water pump.
h) Pay attention to the water temperature and the oil temperature
It is very dangerous to drain water, oil or replace filter cartridge immediately after the
engine stops. This operation must be done only when the temperature of engine has
fallen down. If the oil temperature is too low, heat oil to make its temperature reach
20~50℃, and then drain the oil.
i)
Check waste oil and old filter cartridge
Check if there has metallic bits or impurities when changing the oil or filter cartridge.
j)
Prevent dust from entering
The dismantled hydraulic pipes and hydraulic elements must be protected by plugs or
sealing covers to avoid dust entering into these pipes and elements.
0066340-200-06Y.C
k) Clean joint face
After dismantling O ring or other washer, clean the sealing surface and replace the
sealing elements with new ones. During assembly, apply oil on the sealing elements.
l)
Pay attention to pressure inside
As there is pressure produced in the hydraulic system, air compressing system and
fuel system, the operator must release pressure first before dismantling their pipelines,
fittings and other components.
m) Notes when carrying out welding operation
Cut off power supply; disconnect power lead of battery; never constantly apply the
voltage more than 200v; set up the grounding device away from the welding point 1m.
Never install the sealing device or bearing between the welding point and the
grounding point. Before carrying out welding operation in the vicinity of load moment
limiter or controller, demount them first to prevent them against damage.
n) Deal with waste oil
First drain waste oil into a container, and then deal with it according to the
requirements for industry discharge substances.
o) Unauthorized personnel are prohibited to maintain the crane and replace the parts.
0066340-200-06Y.C
6.1.2 Requirements for crane inspection
In order to know about the working conditions of crawler crane and its components, please
carry out inspection in accordance with the following requirements. Inspect them before the
crane is working for the first time, after the crane has not been used for a long time, or before
the crane is working for the first time after maintenance. The inspection result list refers to
attached table.
a) Check the daily record of work to ensure that all regular inspections, maintenance and
repair work is performed.
b) Check lowering limiter, boom angle indicator, tilting-back supports and other safety
devices for functional work.
c) Check the load-bearing parts carefully, such as wire rope (hoisting rope, derricking rope
and sling etc.), boom frame, support cylinders and load hook.
d) Check if there are some bolts, nuts and pins lost, and the components are cracked or
damaged.
e) Ensure that no modification has been made to the crane without permission, e.g.,
increase or decrease in counterweight plates, and improper repair of boom frame.
f)
Check the fuel lines and the hydraulic oil lines for leakage.
g) Check if the values shown on instruments are correct after starting up the engine.
h) Check if control mechanisms are working normally.
i)
Check brake and clutch. Test the braking performance by lifting a load away from the
ground and holding it in the air for a moment.
j)
Under working condition, the brakes for hoisting and derricking system will bear a limit
torque which is 33% larger than the torque transmitted from winding drum to brakes.
k) Mechanisms with dynamic brake systems (e.g. hydraulic brake valve, electrical braking)
shall have a secondary holding brake system which is independent of the dynamic
brakes restraining the same torque as for the primary holding brake.
l)
In order to avoid free fall of winch, the holding brake shall perform the function of an
emergency brake in the event of failure of dynamic brake system. The holding brake will
work automatically when energy supply is switched off.
m) The deceleration in an emergency case should not lead to damage to the structure, wire
rope and winding drum as well as mechanisms.
0066340-200-06Y.C
6.1.3 Attached tools for maintenance
Attached tools for maintenance
Serial
No.
Code
Designation
Quantity
Serial
No.
1
CSH G1/4″/WD
Test joint
1
1
2
CSH/M12*1.5/WD
Pressure testing joint
1
2
3
CSH/M14*1.5-1500A
Test hose
2
3
4
CSH/M14*1.5/WD2103-01-14.00
Pressure testing joint
1
4
5
CSHS10-L
Test joint
1
5
6
CSHS15-L
Test joint
2
6
7
VDDKO10-L
Joint
1
7
8
VDDKO15-L
Joint
1
8
9
A15-ML/WD
Joint
2
9
10
HM63-400-R-M14*1.5
Pressure gauge
2
10
11
HM63-60-R
Pressure gauge
1
11
12
GJX160-91-0
Toolbox assembly
1
12
13
SJ26-0
Load handling device
4
13
14
ST159
Arch buckle
1
14
15
ST009 5T-10000
2
15
Flexible belt with two
ends fastening
0066340-200-06Y.C
6.2 Superstructure maintenance and inspection plan
Maintenance
interval
Serial
No.
1
2
6.2.1
Every day or
every 5
hours
Component
Fuel pipe or hydraulic pipe
Item
Damage
Inspection
method
Visual
inspection
Visual
inspection
A-frame
Deformation and crack
3
Engine
Start-up, leakage or
noise
Start-up and
audiovisual
inspection
4
Slewing brake
Functional work
Operation
5
Slewing lock
Functional work
Operation
6
Horn, lamps and wiper
Functional work
Operation and
visual
inspection
7
Air filter
Blockage
Visual
inspection
8
Pin, anchoring rod and cotter
pin
Damage and tight fit
Visual
inspection
9
Bolt and nut
Tight fit
Visual
inspection
10
Hoisting limiter
Functional work
Operation
11
Derricking limit switch
Functional work
Operation
12
Glass, ladder, handrail and
guardrail
Damage,crack and
tight fit
Visual
inspection
13
Operational aids for
malfunction:daily, when used
Operation
14
All hydraulic hoses, particularly
those that flex in normal
operation of crane functions,
should be visually inspected
once every working day, when
used.
Visual
inspection
15
Electrical apparatus for
malfunctioning, signs of
excessive deterioration, dirt,
and moisture accumulation
Operation
16
Hydraulic system for proper oil
level: daily, when used
Visual
inspection
0066340-200-06Y.C
Maintenance
interval
6.2.2
Every month
or every 100
hours
Serial
No.
6.2.4
Every 6
months or
every 600
hours
Item
Inspection
method
17
Fan belt
Damage and tight fit
Operation and
visual
inspection
18
Radiator and oil cooler
Leakage and damage
Visual
inspection
19
Foundation bolt and damping
rubber cushion of engine
Damage and tight fit
Operation and
visual
inspection
20
Hydraulic motor and reducer
Leakage and
abnormal sound
Audiovisual
inspection
21
Valves
Leakage
Visual
inspection
22
Hydraulic pump
Leakage and
abnormal sound
Visual
inspection
23
Erection cylinder
Leakage and damage
Audiovisual
inspection
Functional work and
damage
Operation and
visual
inspection
24
6.2.3
Every 3
months or
every 250
hours
Component
Refueling pump and hose
25
Transfer case
Leakage and
abnormal sound
Audiovisual
inspection
26
Operator’s cab tilting
mechanism
Functional work
Operation
27
Engine oil
Change
28
Engine oil filter
Change
29
Engine oil separator filter
Change
30
Filter cartridge of fuel fine filter
Change
31
Filter cartridge of coolant filter
Change
32
Slewing table
33
Engine air filter
Damage and crack
Visual
inspection
Change
Note: The serial number in above table should be consistent with that in following context.
6.2.1 Maintain and inspect superstructure every day or every 5 hours
1) Fuel pipe or hydraulic pipe
Check fuel pipe or hydraulic pipe for leaks and damage.
0066340-200-06Y.C
Note:
1. If pipeline leaks oil, wipe it clean at once and repair the leaking point completely.
2. If maintenance work will be carried out near the engine, the person must not step
onto the fuel pipe.
2) A-frame
Check A-frame for damage.
Note:
If A-frame is damaged, please contact a local service station of Mobile Crane Branch
Company of Zoomlion.
3) Engine
Start the engine and check it for starting condition and abnormal noise.
4) Slewing brake
Check slewing brake for functional work. (Turn slewing brake switch in “ON” position to
operate the slewing movement. If the slewing brake is valid, the slewing movement will
not be carried out.)
5) Slewing lock
Check that slewing lock pins can be inserted smoothly, and check the lock pins and
connecting rods for deformation.
6) Horn, lamps and wiper
Switch on the switches to check that the horn, lamps and wiper work properly.
7) Air filter
When air filter is clogged, the indicator will display red color.
8) Pin, anchoring rod and cotter pin
Check connecting pins, anchoring rods and cotter pins for damage or tight fit.
9) Bolt and nut
Check bolts and nuts for tight fit.
10) Hoisting limiter
Check hoisting limiter for functional work.
0066340-200-06Y.C
11) Derricking limit switch
Check derricking limit switch for functional work.
12) Glass, ladder, handrail and guardrail
Often wipe the glass, ladder, handrail and guardrail with a clean cloth, especially when
they are polluted by grease.
13)Operational aids for malfunction: daily, when used
14)All hydraulic hoses, particularly those that flex in normal operation of crane functions,
should be visually inspected once every working day, when used.
15)Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, and
moisture accumulation.
16)Hydraulic system for proper oil level: daily, when used.
6.2.2 Maintain and inspect superstructure every month or every 100 hours
13) Fan belt
Check the tension of fan belt. Press its middle position; if deflection is between 10mm and
15mm, it is normal.
Caution:
Switch off engine before checking the fan belt; otherwise serious injury may occur.
14) Radiator and oil cooler
Clean the radiator core and check the radiator and the oil cooler for deformation and
abnormal condition.
15) Foundation bolt and damping rubber cushion of engine
Check the foundation bolt for tight fit and damping rubber cushion for damage.
16) Hydraulic motor and reducer
Check following mechanisms for leakage and abnormal sound:
Hydraulic motor and reducer of slewing gear
Hydraulic motor and reducer of winch 1 and 2
Hydraulic motor and reducer of derricking winch
17) Valves
Check valves for leaks.
0066340-200-06Y.C
18) Hydraulic pump
Check hydraulic pump for leaks and abnormal sound.
19) Erection cylinder
Check erection cylinder for leaks and damage.
20) Refueling pump and hose
Check refueling pump for functional work.
Check hose for damage.
21) Transfer case
Check transfer case for leaks and abnormal sound.
22) Operator’s cab tilting mechanism
Check operator’s cab tilting mechanism for functional work.
6.2.3 Maintain and inspect superstructure every 3 months or every 250 hours
23) Engine oil
24) Engine oil filter
25) Engine oil separator filter
26) Filter cartridge of fuel fine filter
27) Filter cartridge of coolant filter
Please change these five devices in accordance with the requirements after 250 operating
hours.
Note:
On no conditions should diesel oil be attached on the engine house, otherwise, the fire will
arise. Keep the engine house clean to the utmost, especially when changing the filter and
releasing the air. If diesel oil is spilled on the engine house, wipe it off at once. Before
replacing the filter, the operator had better put a cloth on the house to absorb the fuel.
6.2.4 Maintain and inspect superstructure every 6 months or every 600 hours
28) Slewing table
Check slewing table for crack and deformation.
29) Engine air filter
0066340-200-06Y.C
If the icon
at upper right-side of control panel flashes, it means that the engine air
filter is clogged. At this time, the engine air filter must be changed.
6.3 Undercarriage maintenance and inspection plan
Maintenance
interval
Serial
No.
1
6.3.1
Every day or
every 5 hours
2
3
4
5
6.3.2
Every month
or every 100
hours
6
7
6.3.3
Every 3
months or
every 250
hours
6.3.4
Every 6
months or
every 600
hours
Item
Pipeline and pipe fitting
Leakage
Visual
inspection
Pin, anchoring rod and cotter pin
Damage and tight fit
Visual
inspection
Bolt and nut
Tight fit
Visual
inspection
Hydraulic motor and reducer
Leakage and
abnormal sound
Valves
Leakage
Visual
inspection
Support cylinder for basic
machine and pin pulling device
Leakage and damage
Visual
inspection
Centre revolving joint
Leakage
Visual
inspection
Slewing ring
Abnormal sound
Listening
and
monitoring
Crawler
Tension, wear and
damage
Visual
inspection
Drive sprocket, driven sprocket,
track roller and track-carrier roller
Leakage and damage
Visual
inspection
Mounting bolt for slewing bearing
Tight fit
Undercarriage centre section
Damage and crack
8
9
10
11
12
Inspection
method
Component
Audiovisual
Inspection
Visual
inspection
Operation
Note: The serial number in above table should be consistent with that in following context.
0066340-200-06Y.C
6.3.1 Maintain and inspect undercarriage every day or every 5 hours
1) Pipeline and pipe fitting
Check pipeline and pipe fitting for damage and leaks.
2) Pin, anchoring rod and cotter pin
Check connecting pins, anchoring rods and cotter pins for damage and tight fit.
3) Bolt and nut
Check bolts and nuts for tight fit.
6.3.2 Maintain and inspect undercarriage every month or every 100 hours
4) Hydraulic motor and reducer
Check hydraulic motor and reducer for leaks and abnormal sound.
5) Valves
Check valves for leaks.
6) Support cylinder for basic machine and pin pulling device
Check them for leaks and damage.
7) Centre revolving joint
Check centre revolving joint for leaks.
8) Slewing ring
Check slewing ring for abnormal sound.
Maintenance for slewing ring:
a) When slewing ring leaves from the factory, a little No.2 extreme pressure lithium
base grease (GB7323-1994) is applied on the inside of roller. The user can supply
new lubricating grease according to different working conditions.
b) Generally speaking, lubricate ball-type slewing ring every 100 hours, and roller-type
slewing ring every 50 hours. However, when slewing ring is running continuously
under adverse circumstances (e.g., high moisture, full of dust, considerable change
in temperature), it must be lubricated every week.
Supply enough lubricating grease before or after the machine stops working for a
long time.
Supply lubricating grease to the inside the roller of slewing ring until the grease flows
out from the sealing positions. When supplying lubricating grease, run the slewing
ring slowly to apply the lubricating grease evenly.
c) Clean the surface of slewing ring teeth and apply lubricating grease every 10 days.
0066340-200-06Y.C
Table of selecting lubricating grease
Support
structure
Working condition
Plastic separate
block
Rubber sealing
ring
Low-temperature, normal
temperature, moisture:
-20℃ +60℃
Metal separate
block
Labyrinth seal
High
temperature,
moisture
-40℃
~
120℃
80℃
~
180℃
Normal temperature,
corrosion resistance
~50℃
Lubricating
point
Name
Quality
indicator
Roller bed
Extreme pressure
lithium base grease
No.1 /2
Gear
Graphite base
grease
ZG-S
Extreme pressure
lithium base grease
No.1 /2
M0S2 compound
calcium base grease
No.2
Gear
No.4
high-temperature
grease
No.4
Roller bed
M0S2 compound
calcium base grease
No.2
Gear
No.4
high-temperature
grease
No.4
Roller bed
No.2 compound
aluminium base
grease
No.2
Gear
No.4 aluminium
base grease
No.4
Roller bed
Since the working conditions of slewing ring are complicated, the user can adopt the
optimum lubricating grease according to actual conditions.
d) Check the pre-tightening force of fixing bolts after the slewing ring is operated for
100 hours. And check them again after 500 operating hours to ensure sufficient
pre-tightening force. Generally speaking, change the bolts after 14000 operating
hours or 7 service years.
e) Pay attention to the running condition of slewing ring during operation. If noise
becomes loud, impact force and power increase suddenly, check the vehicle
immediately and eliminate the failures. If necessary, dismantling of the vehicle is
also needed.
f)
The slewing ring in use should not be exposed to strong sunlight. Never wash the
slewing ring directly using water in order to prevent the water from entering the roll
path. Precautions are taken against hard objects from approaching to or entering
the meshing area.
g) Check sealing strip regularly. The sealing strip, if damaged, should be changed, and
0066340-200-06Y.C
if falls off, should be retuned to original position.
9) Crawler
Check crawler for tension and wear.
Caution:
1. If track shoes are connected with each other tightly, they will be worn out quickly so as to
make connecting elements broken. On the other hand, if they are connected loosely, the
crawler will fall off from drive sprocket and driven sprocket.
2. It is normal that the crawler tension length varies from 10mm to 20mm. As long as
crawler travels the same distance forward as its length, the upper crawler will appear a
certain degree of relaxation.
6.3.3 Maintain and inspect undercarriage every 3 months or every 250 hours
10) Drive sprocket, driven sprocket,track roller,track-carrier roller
Check them for leaks and damage.
11) Mounting bolt for slewing bearing
Check mounting bolt for tight fit.
Note:
If the bolt looses, demount it for check. If it is damaged, replace it. If the demounted
bolt is not damaged, wipe it clean, grease NO. 242 LOCTITE glue (or similar glue)
on it and then screw it down with 2.8KN.m (2060ft-lbs) tightening torque.
6.3.4 Maintain and inspect undercarriage every 6 months or every 600 hours
12) Undercarriage centre section
Check undercarriage centre section and crawler carrier for crack and damage.
Note:
If uncertain failures are found during inspection or maintenance, please contact local
service station of Mobile Crane Branch Company of Zoomlion.
6.4 Boom frame maintenance and inspection plan
Maintain and inspect following components of boom frame system every day or every 5 hours.
0066340-200-06Y.C
Maintenance
interval
Serial
No.
Item
Inspection
method
1
Upper﹠lower pulley
block
Deformation and crack
Visual
inspection
2
Load hook and safety
catch
Damage and tight fit
Visual
inspection
Rope support
Deformation,damage and
wear
Visual
inspection
Rope pulley
Deformation,damage and
wear
Visual
inspection
Deformation and damage
Visual
inspection
Damage and tight fit
Visual
inspection
Tight fit
Visual
inspection
Deformation and damage
Visual
inspection
Deformation and damage
Visual
inspection
Wire rope
Deformation , damage and
wear
Visual
inspection
Load hook 1 and 2
The deficiencies that may
impair safety
Visual
inspection
3
4
5
Every day or
every 5
hours
Component
6
7
8
9
10
11
Main boom and jib
Connecting pin,
anchoring rod and lock
pin
Bolt and nut
Tilting-back support
A-frames
Note: The serial number in above table should be consistent with that in the following context.
1) Upper﹠lower pulley block
Check upper & lower pulley block for deformation and crack.
Note:
1. It is prohibited to touch wire rope with bare hands. Otherwise, the operator will
be injured by rope’s convex section.
2. Keep yourself away from rotary drum and running wire rope.
3. Failure to observe this regulation may result in death or serious injury.
4. Keep ladder, platform and guardrail clean and dry. When climbing the crane,
tighten the safety belt. Otherwise, the operator may fall down from crane.
2) Load hook and safety catch
Check pulley, bearing of load hook and safety catch for damage.
0066340-200-06Y.C
Check bolts and nuts for tight fit.
3) Rope support
Check rope support in boom intermediate sections and boom head for deformation,
damage and wear.
4) Rope pulley
Rope pulley on main boom head
Deflection pulley
Rope pulley for load hook 2
Rope pulley on jib head
Rope pulley on A-frames
Check above rope pulleys for deformation, damage and wear.
5) Main boom and jib
Check main boom and jib for deformation and damage.
Do not use deformed and (or) damaged main boom and jib.
Replace or repair deformed or damaged main boom and jib.
Note:
Since main boom and jib are made of high-tensile steel, if they need special art
technology for maintenance, please contact a local service station of Mobile Crane
Branch Company of Zoomlion.
6) Connecting pin, anchoring rod and lock pin
Check them for damage and tight fit.
7) Bolt and nut
Check bolts and nuts for tight fit.
8) Tilting-back supports
Check tilting-back support of main boom and tilting-back support of jib for damage and
deformation.
0066340-200-06Y.C
Note:
If they need special art technology for maintenance, please contact a local service
station of Mobile Crane Branch Company of Zoomlion.
9) A-frames
Check A-frames for damage and deformation.
Note:
If they need special art technology for maintenance, please a contact local service
station of Mobile Crane Branch Company of Zoomlion.
10) Wire rope
a、Check wire rope for damage and deformation. Never use wire rope with wire breaks
and knot. If wire rope is broken during operational period, serious accident will occur.
Therefore, wire rope must be inspected periodically. It is forbidden to use the corroded,
abraded wire rope or wire rope with wire breaks. As to the determinant of safety degree
and discard standard for wire rope, please refer to the 《Practical Criterion for Inspection
and Scrap Wire Rope of Crane ISO 4309;1990》 or local relevant regulations for
machine use. The methods for common situations are listed in following table.
Serial
No.
1
Conditions of wire rope
There is 10% wire breaks in a strand (not including filling thread).
It is very difficult to check the inner wire breaks. Bend wire rope
forcibly to expose wire breaks in groove. If there is wire breaks in
groove, which means there is wire breaks inside the rope.
Therefore, wire rope reaches its fatigue limit.
2
The diameter of wire rope is narrowed by 7% than nominal size
due to corrosion.
3
The evidence of knot
4
Excessive deformation and wear
5
Excessive extension because of overloading or jumping out of
the rope pulley
6
Having been used as lead of short circuit
7
Burned wire rope due to short-circuiting, gas-cutting or wire rope
exposed to high temperature
Measures
Change wire rope at
once
Change wire rope as
soon as possible
b、Heavy wear and/or broken wires may occur in sections in contact with
equalizer sheaves or other sheaves where rope travel is limited, or with
saddles. Particular care shall be taken to inspect ropes at these locations.
0066340-200-06Y.C
c、All rope which has been idle for a period of a month or more due to shutdown
or storage of a crane on which it is installed shall be given a thorough
inspection before it is used. This inspection shall be for all types of
deterioration and shall be performed by an appointed or authorized person
whose approval shall be required for further use of the rope.
d、Rotation-resistant rope shall be given special care during installation as it is
easily damaged.
e、Socketing shall be done in the manner specified by the manufacturer of the
wire rope or fitting.
f、 maintenance of the rope shall conform to ANSI B30.5:2007 section 5-2.4
11) Maintenance of load hook 1 and 2
Since load hook 1 and 2 are used in different operating conditions, they should be
inspected every day (begin with alternate operation). Carefully observe any deficiencies
that may impair safety in operational period. Do not use load hook 1 and 2 until the
deficiencies are overcome.
Daily check and maintenance include following contents:
a. Wipe load hook 1 and 2 clean;
b. Lubricate rope pulley (when equipped with grease nipple), rotary part and other
parts which are mentioned in “Lubrication Guide”, and equipped with grease nipple;
c. Check all bolts and screws, and ensure all cotter pins are complete;
d. Check whether the groove and flange of rope pulley are abraded evenly, and
inspect whether rope pulley is fitted tightly; if not, it means bearing or bearing bush
are damaged;
e. Check that the rotary connection of load hook can move easily, and the clearance is
not too large. If hook rotates stiffly, it means the bearing and bearing bush are
damaged or lubricated insufficiently;
f.
Check load hook for easy rotation: rotate the hook by hand. If it is stiff, it indicates
that the bearing has been damaged;
g. Check the load hook 1 is damaged due to overloading: side plate and diameter of
bore are extended, and bolt is bended, extended or cracked;
h. Check the rope fixation for wear and wire breaks. Check the rope lock for crack and
tighten the bolt on the rope clamp;
i.
Check safety catch is in perfect condition;
j.
Check load hooks and snap rings.
Check load hook and snap ring at least once a year by using coloring, magnetic
particle methods, ultrasonic wave methods or X radiographic methods.
0066340-200-06Y.C
Note:
1. The load hook and snap ring should not be repaired by welding, furthermore, the load
handling devices are not allowed to be welded without the permission of manufacturer and
they should be welded with proper methods if necessary.
2. The safety catch must keep loosening sling and other load handling devices on the hook,
however, it can not be loaded. The sling and other load handling devices must be placed on
the hook, and not on safety catch.
6.5 Maintenance and inspection for engine
This chapter only briefly introduces some notes on maintaining engine. As to how to maintain
and service engine, please read Engine Maintenance Manual carefully.
Maintenance must be carried out conscientiously within the specified intervals. Apply the
maintenance interval that comes first.
a) Daily check or adding oil
1) Air intake pipe ---- check
2) Cooling fan ---- check
3) Pipe of crankcase breather ---- check
4) Engine coolant ---- check
5) Water separator ----drain
6) Engine oil level ---- check
b) Every 250 hours or every 3 months
1) Air resistance indicator for air filter --- check
2) Air-to-air intercooler pipe ----check
3) Air-to-air intercooler ---- check
4) Mounting element of fuel injection pump ---- check
5) Mounting element of air compressor ---- check
c) Every 500 hours or every 5 months
1) Fuel filter ---- change
2) Cooling system ---- check
3) Coolant filter ---- check
4) Engine oil filter and engine oil ---- change
0066340-200-06Y.C
5) Battery ---- change
6) Battery cable and terminal ---- check
d) Every 1000 hours or every one year
1) Drive belt ---- check
2) Belt driven fan hub ---- check
3) Cooling fan belt tensioning device ---- check
e) Every 2000 hours or every two years
1) Cooling system ---- discharge air/ wash/ add coolant
2) Rubber damper---- check
3) Engine ---- wash with steam
4) Exhaust pipe of air compressor ---- clean
5) Engine suspension
f)
Every 5000 hours or every four years
Valve clearance ---- adjust
Note:
1. It is not allowed to repair or maintain engine or its parts especially those relevant
to safety of engine. However, the parts listed in our operating manual and
engine maintenance manual should be repaired or serviced periodically.
2. Before carrying out welding operation on the machine, the operator must
disconnect cables from positive pole and negative pole of battery. When
connecting electric welding machine to its earthing cable, make sure that this
cable is not farther than 0.61m from the welded part. Do not connect the
earthing cable with ECM or cooling plate of ECM. Never perform welding
operation on engine or the parts of engine.
3. When cleaning the parts with solvent, acid cleaning agent or alkaline cleaning
agent, the operator must wear goggles and put on protective clothing to protect
him from damage. And he must adhere to methods recommended by engine
manufacturer to clean parts.
4. When cleaning the parts with steam, the operator must wear goggles and put on
protective clothing.
Following parts can not be cleaned with steam:
a) Electrical parts;
0066340-200-06Y.C
b) Conducting wire;
c) Fuel injector;
d) Belt and hose;
e) Bearing (ball-type or conical roller-type);
f)
ECM;
g) ECM connector
5. When ambient temperature is less than -18℃ or more than 38℃, or when crane
works in dust conditions or engine is shut down frequently, the maintenance
interval of engine should be shortened accordingly.
6. Take particular precautions regarding cleanliness when replacing diesel and oil
filters. Any fuel or diesel oil that has leaked shall be completely cleaned up.
Check oil pipeline and hydraulic system for leaks.
7. All electrical lines and wires must be arranged and fastened properly. They
should be kept away from exhaust pipes. Examine all wiring insulation or
casings for signs of chafing or brittleness as a result of operational activities.
Any wiring that is not in perfect condition shall be immediately and professionally
replaced.
8. Over the years, fuel and oil lines can become brittle or porous due to aging. Any
lines that appear to be excessively porous should be replaced immediately.
9. It is especially important to note that under no circumstances may pipelines and
hoses installed in the engine room be stepped upon during repairs and service
work. This is particularly important for fuel injection pipelines. Protect the engine
with a board or similar support plate if stepping on the hoses is unavoidable
during assembly.
10. To prevent pollution, engine oil, gear oil, hydraulic oil, lubricating grease and fuel
as well as coolant should not be spilled onto the ground and they also should
not flow into ground water, sewage or wastewater system. Comply with the
regulations specified by local authorities before disposing of any of these items
or substances.
11. As to detailed engine maintenance and service, please observe Engine
Maintenance Manual.
12. Relief valve settings shall be specified and any change in relief valve settings
without the consent of the manufacturer shall be the responsibility of the user.
6.5.1 Maintenance guidelines for damageable parts
When replacing drive components such as diesel engine, gear, axles and so on, you must
observe the following:
0066340-200-06Y.C
—Before putting these components into service, ensure to add specified oil to the max.
marking; for the type of oil, check data tag and lubrication chart.
—Conduct initial maintenance according to Chapter “Periodic maintenance”; thereafter,
maintain in accordance with the specified periodic maintenance intervals.
Category I operational aids and alternative measures.
Operational aids listed in this paragraph that are not working properly must be
repaired no later than 7 calendar days after the deficiency occurs. Exception: If the
employer documents that it has ordered the necessary parts within 7 calendar
days of the occurrence of the deficiency, the repair must be completed within 7
calendar days of receipt of the parts. See § 1926.1417(j) for additional
requirements.
Category II operational aids and alternative measures.
Operational aids listed in this paragraph that are not working properly must be
repaired no later than 30 calendar days after the deficiency occurs.
Exception: If the employer documents that it has ordered the necessary parts
within 7 calendar days of the occurrence of the deficiency, and the part is not
received in time to complete the repair in 30 calendar days, the repair must be
completed within 7 calendar days of receipt of the parts. See § 1926.1417(j) for
additional requirements.
6.6 Instructions for lubrication and oil change
6.6.1 Hydraulic oil
When crane is delivered to you from the factory ready for operation, it is supplied with hydraulic
oil GB 11118.1-94(The hydraulic oil used in the crane now corresponds with ESSO NUTO H32
hydraulic oil.) or low condensed hydraulic oil L-HV32. The volume is of 800 liter.
Note:
The product is full hydraulic driven. The quality, viscosity and cleanliness of
hydraulic oil are the most important factors to crane’s functional working. The
customer’s ignoring replacing hydraulic oil in time will bring on various kinds of
malfunctions and reduce its service life greatly. Our company will not take the
responsibility for all the consequences caused by customers failing to comply with
the requirement stipulated in this manual to replace and filter hydraulic oil.
6.6.1.1 Oil checks and oil change interval
The normal oil change interval is 2000 operating hours. If hydraulic oil is obviously polluted,
it must be changed in time without considering operating hour. The inspected item and oil
change interval are shown in following table.
0066340-200-06Y.C
Oil checks and oil change interval
(in hour)
Serial
No.
Inspected
Item
1
Check oil level
2
Clean oil tank
3
Change
hydraulic oil
5
500
Remarks
2000
○
Main oil
Tank
○
○
800litre
6.6.1.2 Oil sample checking and oil change criteria
Take a sample of hydraulic oil for inspection periodically. For crane working under normal
condition, its hydraulic oil should be checked every 3 months; for crane working frequently
or working in adverse environment, its hydraulic oil should be checked every month. The
inspected item and limitation value should comply with the requirements in following table.
For hydraulic oil which does not reach limitation value, change it at once.
Hydraulic Oil Physical & Chemical Character Variation Limitation
Value
Inspected item
L-HS
NUTO H46,L-HV
L-HM
Kinematic viscosity
(40 ℃) mm2/s
±10%
±10%
±10%—15%
Acid value addition
mgKOH/g
0.3
0.3
0.3
Moisture
%
0.1
0.1
0.1
Flash point
°C
-60
-60
-60
20/16
20/16
20/16
Solid grain pollution grade
6.6.1.3 Recommended brand of hydraulic oil used in different ambient temperature
Ambient
temperature
below -30°C
above -30°C
The lowest
temperature
of cold start
(without load)
The lowest
temperature
of cold start
(with load)
The lowest
working
temperature
with load
The highest
temperature
of hydraulic
oil
-40℃
-35℃
-15℃
50℃
-35℃
-22℃
-5℃
60℃
-28℃
-15℃
0℃
70℃
Hydraulic oil brand
SH 0358-95
10
aviation
hydraulic oil
☆ESSO
NUTO H32
0066340-200-06Y.C
between
-20°C
and
40°C
above
40°C
-20℃
-5℃
-10℃
-3℃
5℃
20℃
80-85℃(*)
100℃ ( **)
☆ESSO
NUTO H46
ESSO
NUTO H68
Caution:
1. If crane starts in cold area, it should first run without load for a while. After the lowest
working temperature is reached, the load can be added gradually and the system can
work.
2. The oil property should be identical with that of the original brand when changing oil. The
original oil should be washed away thoroughly. The hydraulic oil of different types and
different brands can not be mixed together!
3. The domestic brand of hydraulic oil mainly includes Kunlun, the Great Wall, Tongyi,
Haibrand, Daqing, Hengyun, Guta, Jiali, Jiarun, Haili, etc. and foreign brand such as
ESSO, Mobil, etc. are also available in china.
4. If you find any special operating conditions which are not listed in the above table,
please consult the related departments of our company.
5. Check and measure oil temperature of system at any time!
6. The suitable oil temperature for hydraulic system in working condition is 20℃ to 80℃.
The 85℃ may occur for a short time or in some position.
7. When the oil temperature is too high (nearly 100°), pay attention to the cooling of
system. The working load should not be too heavy and the working frequency should not
be too high.
6.6.1.4 Procedure for changing oil
First change hydraulic oil in the tank. Drain hydraulic oil from the tank, and then
dismember the master oil return pipe. Clean the tank and the oil filter carefully. First clean
them by using the chemical cleaning agent of solid particle pollution grade less than
18/15. After airing, wash them with the clean hydraulic oil of solid particle pollution grade
less than 18/15 and then add new hydraulic oil after draining off oil.
Actuate engine and run it at low speed to let the oil pump start to control mechanisms.
0066340-200-06Y.C
Use new hydraulic oil to drain used oil out of every circuit in the system until the new oil
flows out of the master oil return pipe. The used oil is not allowed to return to the
hydraulic oil tank. At this time, the oil pump stops running. While the used oil in each
return line is changed, the new oil should be added into hydraulic oil tank continuously to
prevent the oil pump from inhaling air.
Connect master oil return pipe with oil tank, make each component to initial state and add
hydraulic oil to oil tank until the oil level reaches prescribed position.
Note:
1. Filter or change hydraulic oil in time whenever it is polluted seriously.
2. Select proper hydraulic oil according to ambient temperature.
3. Hydraulic oil of different brands can not be mixed.
4. Service life of hydraulic oil can not exceed 24 months. The hydraulic oil can not
be used even though it is filtered, if it has been used for 24 months.
6.6.1.5 Temperature of hydraulic oil
Observe the temperature of hydraulic oil from the scale on the liquid temperature meter,
and the highest temperature of hydraulic oil is 80°C.
6.6.1.6 Volume of hydraulic oil
When crane is in traveling condition, inspect oil level. Observe the temperature and the
level of hydraulic oil from the scale on the liquid temperature meter. The scale of 0°C is the
lowest oil level. So when oil level is below this line, top crane up with oil.
6.6.1.7、Air exhaust of hydraulic system
Prior to the initial starting of engine or after the oil changing of hydraulic system, remove
the upward oil drain plug on the motor and main hydraulic pump, and add oil with an oiler,
then tighten the oil drain plug, finally restart engine.
If the engine has not worked for more than a day, the hydraulic system must be deaerated
after engine starts. To exhaust the air in hydraulic system, you should first run the engine at
low speed of less than 1000rpm for 10 minutes and keep the motor in low-load(or no- load)
condition and then operate the mechanisms of crane in proper order for 3-4 times.
6.6.2 Gear oil
Use gear oil recommended in this manual. Before crane leaves the factory, such devices as
hoisting winch reducer, derricking winch reducer, slewing reducer and reeving winch have
0066340-200-06Y.C
already been filled with L-CKD220 industrial closed gear oil. The power divider of drive gear
has been filled with GL-5 85W/90 heavy-duty vehicle gear oil.
6.6.2.1 Table of gear oil change interval
Delivery
date
Three months
Add oil
Every 12 months
Replace
oil
Caution:
1. If gear oil is polluted seriously, replace it at once even though it has not reached the oil
change interval.
2. Often check oil level. If necessary, add oil.
3. The gear oil of different brands can not be mixed!
4. Use proper gear oil according to ambient temperature, since unqualified gear oil or gear
oil with improper viscosity will damage reducer mechanism.
6.6.2.2 Replaced Gear Oil Volume for Each Mechanism
Description
Brand of gear oil
Volume (liter)
Hoisting winch reducer
L-CKD220 industrial closed gear oil
9
Derricking winch reducer
L-CKD220 industrial closed gear oil
8.5
Slewing reducer
L-CKD220 industrial closed gear oil
12
Traveling reducer
L-CKD220 industrial closed gear oil
90
Reeving winch reducer
L-CKD220 industrial closed gear oil
1
Drive gear of transfer case
GL-5 85W/90
6
6.6.2.3 Change gear oil
a) Change gear oil of hoisting winch reducer and derricking winch reducer
1) Unscrew and remove oil drain plug and oil filler plug on the winch reducer, and drain
original gear oil;
2) Screw down oil drain plug;
3) Put funnel head into oil filler to add specified gear oil to inspection hole until the oil is
visible in the middle of inspection hole;
0066340-200-06Y.C
4) Screw down oil filler plug.
Add oil after removing this plug.
When add oil, remove the plug of
inspection hole to check if the inspection
hole is completely full of oil.
Drain off oil after removing oil drain plug.
b) Change gear oil of slewing reducer
1) Unscrew and remove oil drain plug and oil filler plug on slewing reducer, and drain original
gear oil;
2) Screw down oil drain plug;
3) Put funnel head into oil filler to add specified gear oil to inspection hole until the inspection
hole is completely full of oil;
4) Screw down oil filler plug.
Check oil level
Drain oil after removing oil drain
plug.
0066340-200-06Y.C
Note: The gear oil volume is about 6.6 L.
c) Change gear oil of transfer case
1) Volume of lubricating oil:
There is volume of lubricating oil on name plate of transfer case for reference. However, the
oil level must be subject to the mark left on oil dipstick. Therefore, the inspector should check
oil level with oil dipstick according to the specified requirements. After adding oil to transfer
case for the first time, the inspector should check oil level when power is started for 15mins
to 30mins. If oil is going down, add oil to specified position.
2) Changing lubricating oil:
Generally speaking, change lubricating oil after first 200 operating hours. After that, change
lubricating oil after 2000 operating hours or 12 months at least.
6.6.3 Lubricating grease
Use the lubricating grease recommended in this manual and this crane uses ZL-2 and ZG-3
lubricating grease.
Injecting method: grease or inject with gun.
Parameter
Appearance
Drop point
(℃)
Work wimble
degree
(1/10mm)
Moisture
(%) no more
than
Type
ZL-2lubricating
grease
Smooth inunctum with the color
from pale yellow to brown
175
265~295
——
ZG-3
lubricating
grease
Equal inunctum with the color
from pale yellow to brown
90
220~250
2.5
In order to keep crane in good working condition, all machinery parts that need lubrication
0066340-200-06Y.C
should be supplied with specified grease periodically. All of them, except for those purchased
components, are marked in following diagram.
6.6.3.1 Add lubricating grease to superstructure and undercarriage
a) Diagram of superstructure and undercarriage lubricating points
Every day or
every 5 hours
1
2
Every week or
every 25 hours
3
Every
year
or
every 1000 hours
4
5
6
0066340-200-06Y.C
b) Table of superstructure and undercarriage lubricating points
Serial
No.
Lubricating points
Lubricating
interval
Lubricating Method
lubricating Grease
Type
1
Ratchet mechanism
Every day
Grease
ZL-2 lithium base
grease
2
Slewing ring
Every week
Grease and inject
with gun
ZL-2 lithium base
grease
3
Connecting rod and pin
spindle
Every week
Grease and inject
with gun
4
Track roller
Every year
Grease and inject
with gun
GL-5 85W/90
5
Track-carrier roller
Every year
Grease and inject
with gun
GL-5 85W/90
6
Driven sprocket
Every year
Grease and inject
with gun
GL-5 85W/90
6.6.3.2 Add lubricating grease to boom frame system
a) Diagram of boom frame system lubricating points
Crane operation
with main boom
Crane operation with main
boom and fixed jib
Crane operation with main boom
and luffing jib
Every day or every 5 hours
Every week or every 25 hours
Every month or every 200 hours
According to working condition
0066340-200-06Y.C
b) Table of boom frame system lubricating points
Serial
No.
Lubricating point
Lubricating
interval
Lubricating
method
Lubricating
grease type
1
Pivot section bolting
cylinder
Every day
Grease and inject
with gun
ZL-2 lithium
base grease
2
Pin spindle of A-frame
Every day
Grease and inject
with gun
ZL-2 lithium
base grease
Inject with gun
ZL-2 lithium
base grease
Inject with gun
ZL-2 lithium
base grease
Inject with gun
ZL-2 lithium
base grease
Inject with gun
ZL-2 lithium
base grease
Inject with gun
ZL-2 lithium
base grease
3
4
Luffing jib main shaft
WA-frame shaft
Every week
Every week
5
Upper&lower pulley
block spindle
Every month
6
Auxiliary hook swivel,
spindle
Every month
7
Main hook swivel, spindle
Every month
8
Derricking rope
according to
working
conditions
9
10
Hoisting rope for winch 1
Hoisting rope for winch 2
according to
working
conditions
according to
working
conditions
Grease
ZL-2 lithium
base grease
Grease
ZL-2 lithium
base grease
Grease
ZL-2 lithium
base grease
Note:
1. The oil cup and the surface to be oiled should be wiped clean before adding
oil.
2. The sliding surfaces which are not listed in above table must be greased
periodically.
3. The lubricating grease of different brands can not be mixed.
4. Add grease to bush, shaft and bearing until the used grease is squashed out.
5. Switch off engine before lubrication.
6. Keep ladder, platform and guardrail clean and dry. When climb the crane,
tighten safety belt. Otherwise, the operator may fall down from crane.
7. Failure to observe such regulation may result in death or serious injury.
0066340-200-06Y.C
8、Set all controls in the off position and ensure all operating features are
secured from inadvertent motion by brakes, pawls, or other means。
9、Lower the boom to the ground, if possible, or otherwise secure against
dropping
6.6.4 Engine oil
6.6.4.1 Check engine oil level
Checking oil level refers to Operation Manual for Engine.
The engine applies 15W/40CH-4 diesel oil with 35liter.
Check engine oil level before operation. Take out the dipstick, wipe it with a clean cloth
and re-insert it as far as possible. If oil level is between the MIN and MAX markings on the
dipstick, it is normal.
Caution:
The crane must be level when checking engine oil level. Otherwise, the oil level will be
measured inaccurately.
6.6.4.2 Change engine oil
a) Unscrew and remove oil drain plug at the bottom of oil pan, and drain original engine
oil.
b) Screw down oil drain plug.
c) Put the funnel head into oil filler to add specified engine oil until oil level is within the
MAX and MIN markings on the dipstick.
d) Screw down the cover of oil filler.
Caution:
1. When replace engine oil, the filter cartridge should be replaced together.
2. Don not remove oil drain plug when engine oil is still hot. Otherwise, you may get
scalded.
3. Failure to observe this regulation may result in death or serious injury.
0066340-200-06Y.C
6.6.5 Fuel
Check and change fuel.
Serial No.
Fuel checks and fuel change
interval (in hour)
Inspected item
5
1
Clean fuel tank
2
Change engine fuel
Volume
1000
○
700 liter
※
Note: The sign “※” means the fuel needs to be changed.
1) Clean fuel tank
Remove the oil drain plug to drain water and sediments.
2) In order to reduce sediments, top up fuel tank after work everyday.
If there is no refueling pump, add fuel through oil filler.
Caution:
1. Firing around fuel is forbidden.
2. Never run refueling pump with fuel.
3. Smoking is forbidden when add fuel. Otherwise, fire hazard will arise, which will
lead to property loss and personnel injuries.
All fuels shall be transported, stored, and handled to meet the rules of Subpart F of 1926.550.
When fuel is transported by vehicles on public highways, Department of Transportation rules
contained in 49 CFR Parts 177 and 393 concerning such vehicular transportation are considered
applicable
6.6.6 Coolant
Check and change coolant.
Serial
No.
Inspected item
1
Check coolant level
2
Change coolant
Coolant checks and coolant change interval
(in hour)
5
100
250
500
Volume
1000
○
○
43 liter
Note:
The above change interval is applicable to normal conditions. For other kinds of coolant,
change it every 6 months.
0066340-200-06Y.C
6.6.6.1 Check coolant level
a) Remove radiator cover to check coolant level, and check fluid level of auxiliary water
tank.
b) When coolant is insufficient, add softened water to water injection hole, and top up
auxiliary water tank.
Caution:
1. Do not open the radiator cover when crane is warm up. Remove cover with thick cloth or
gloves after coolant does not bolt. When engine is in working temperature, the coolant has
high temperature and pressure.
2. Failing to observe this regulation may result in death or serious injury.
6.6.6.2 Change coolant
a) Remove the plug at the bottom of radiator to drain coolant.
b) Mix softened water with durable coolant, and then add the mixed fluid to radiator until it
is visible at the bottom of water injection hole. In order to avoid air entering into the
radiator, the water should be added slowly. When the fluid level no longer falls down,
screw down the lid.
c) Start engine and run it for one minute, then stop to check the fluid level. If the fluid level
is not enough, add water again.
Caution:
1. Do not drain coolant when crane is warm up, since hot coolant may burn the skin. Only
when coolant has been cooled down, can it be drained out.
2. Failing to observe this regulation may result in death or serious injury.
6.6.7 Lubrication and maintenance of crane in irregular conditions
6.6.7.1 Lubrication and maintenance in dust circumstance
Item
Measures
Air filter
Clean or replace in time
Radiator, oil cooler
Clean in time to prevent them from being blocked.
Filter, filter cartridge
Replace them in time
Engine oil
Replace oil in time
Slewing gear ring
Lubricate it in time
0066340-200-06Y.C
Wire rope
Clean and lubricate in time
6.6.7.2 Lubrication and maintenance under coast circumstances
Item
Measures
Lubrication
Lubricate all lubricating points and joints which have not been fitted with grease
nipple completely and carefully.
Basic machine
Clean crane body, radiator and oil cooler in time to get rid of salt.
6.6.7.3 Lubrication and maintenance in cold area
Item
Measures
Points for attention
Use engine oil suitable for this temperature(see Operating
Manual for Engine)
CH-4,CG-4 of API classification
Engine oil
The
ambient
temperature
when
engine
starts
-250C~
-200C
-10C~
200C
-150C~
400C
Viscosity of
engine oil
SAE10W/30
SAE20W/30
SAE15W/40
Use fuel suitable for following temperature
Ambient temperature
Type
0
Above -5 C
Fuel
0
JIS#2 light diesel oil
0
Between -5 C and -15 C
0
Below -15 C
JIS#3 light diesel oil
JIS special #3 light
diesel oil
Drain water before working and top up oil tank after
working.
When add the oil, the
oil of different brands
or different quality
grades can not be
mixed. The volume of
all replaced oil is 35
liter.
0066340-200-06Y.C
Make proper proportion of antifreeze fluid to water in
accordance with ambient temperature.
(volume of coolant: 43 liter)
Coolant
Ambient
temperature
Water
Antifreeze
fluid
(condensing)
-40C
39 liter
4 liter
0
-7 C
37 liter
6 liter
0
32 liter
11 liter
0
30 liter
13 liter
0
28 liter
15 liter
0
26 liter
17 liter
0
24 liter
19 liter
0
22 liter
21 liter
-13 C
-17 C
-21 C
-25 C
-31 C
-40 C
Battery
Fully charge (The proportion of electrolyte is more than
1.22)
The electrolyte of fully-charged battery is more
anti-freezing than that of that of under-charged battery in
low temperature.
Sometimes,
proportion
is
different according to
difference brands of
antifreeze fluid.
It is recommended to
use final antifreeze
fluid that has already
been
matched
according
to
difference
temperature.
After adding distilled
water, run engine to
mix it with electrolyte.
Chapter 7
Crane inspections
0066340-200-07Y.C
7.1 General
Initial Inspection. Prior to initial use, all new and altered cranes shall be inspected by a
qualified person to verify compliance according to local rules.
The crane has been tested by manufacturer’s facilities prior to shipment
The safety level achieved during initial commissioning may not be attainable during operation.
Examples of the root cause of such deviation include; e.g., wear and tear, corrosion, effects of
forced operations, changes in the environment and changes to the mode of operation. The
operator is responsible for taking the necessary steps to ensure that the maximum level of
safety is maintained. For that reason, the crane must be inspected by a competent inspector,
depending on application situations and the operating condition, at least once a year, counting from the
day of initial service.
The crane must be inspected by a competent inspector, depending on the application situations
and the operating conditions, at least once a year, counting from the day of initial service.
Before operating the crane, a visual inspection must be performed to prevent accidents by
detecting deficiencies in a timely fashion.
Any deficiencies determined by the inspector must be documented, corrected, and
subsequently re-inspected.
Note:
1. When significant changes are made to the crane or repairs are made to the load bearing
parts, the operator must have the crane inspected by a competent inspector before putting
it into service.
2. National and local regulations must be observed.
3. A competent inspector is someone who has a thorough understanding of crane based on
technical training and experience and is knowledgeable about the relevant regulations, e.g.
labor laws, OSHA regulations, accident prevention regulations and generally accepted
engineer principles and is able to assess that the crane is safe to operate(they are specially
trained personnel).
4. A competent engineer is someone who engages in the designing, manufacturing and
servicing crane and is knowledgeable about all the relevant regulations and standards, and
is a position to judge whether the crane functions normally through inspection so as to
ensure long-term safe operation.
A number of important examples of items that are particularly important during crane
re-inspections are listed in the following. Adhere to the following inspection guidelines and
intervals; otherwise, serious accident may occur.
0066340-200-07Y.C
7.2 Inspection of steel bearing structures
Steel bearing components such as boom must be carefully inspected at least once a year. Even
though weld joints are not normally situated at maximum load locations, it is nevertheless
important that they should be inspected with particular care during the periodic inspections.
If the crane was subjected to excessive operating loads, for example an unusual shock or
impact, the load bearing components must be inspected immediately.
If damage (e.g., cracks) is found in any part of the steel structure, the total extend of the
damage must be determined by qualified specialists using appropriate material test methods,
such as magnetic crack detection, ultrasound or X-ray. The specialists should then advise
whether or not the damaged area can be repaired by welding or other means.
The welds or steel structural zones that require inspection may be present more than once and
in various forms. The joints or zones must be inspected all around at the locations identified by
arrows.
Note:
The scope and extent of all inspections remain the sole responsibility of the inspectors.
The following diagrams are provided to assist the inspector. The diagrams are only examples
and are not necessarily 100% complete!
Welding joints on main boom
0066340-200-07Y.C
Welding joints on luffing jib
0066340-200-07Y.C
Welding joints on fixed jib
0066340-200-07Y.C
Crawler carrier (left)
0066340-200-07Y.C
7.3 Inspection of hosting and luffing winches
The hoisting and luffing winches and slewing reducer are designed using integrated planetary
gears. The gears are designed for long service life and the drive shaft and drive gear are rated
for endurance. Even though these gears are designed for long service life, an external visual
inspection is not adequate, since their life can be significantly affected by bad maintenance
(insufficient oil), defective seals, improper operation or overuse. The inspection must therefore
be carried out by a competent inspector in accordance with the following guidelines.
7.3.1 Inspections
a) Inspection intervals
Every 1000 operating hours, at least once a year(annually)
b) Inspecting oil level
Check oil level. For hoisting and luffing winches, we recommend that the oil be drained and
the amount compared to the specified oil quantity.
c) Checking oil color
Assume that the oil has been overheated if it is black and/or a burnt oil smell is detected. In
this case, the oil must be changed.
d) Checking for foreign substances
This inspection should be carried out in a qualified laboratory. The used oil shall be dribbled
onto the specified filter medium. The oil sample is visually checked under a microscope for
foreign particles. If any particles are detected, the oil must then be sent to a qualified
laboratory and analyzed to determine the makeup of the particles.
e) Evaluation of foreign substances found in the oil
1) The maximum permissible quantity of foreign material measured by weight is 0.15%
of total oil weight.
2) maximum permissible foreign particle size from fine abrasion is 0.229mm。
3) If above values are exceeded, the gearbox must be dismantled to determine the root
cause of increased contamination and then the gearbox should be refilled with fresh
oil.
Caution:
These repairs may only be carried out by specialists with appropriate equipment
knowledge.
f)
Visual inspection
The drive devices shall be checked for leakage, since any loss of oil, in addition to polluting
the environment, can lead to gearbox failure.
g) Inspection the drive device breaks.
Check the brakes at the same check the drive devices.
0066340-200-07Y.C
If the brakes cannot hold the specified test load of 33% rope tension increase on a single
rope strand and fully spooled drum, they shall be dismantled to determine the cause.
Whenever a planetary gearbox is dismantled because of increased contamination, the
brakes shall also be inspected.
Caution:
Only qualified personnel with specialized knowledge can inspect the gearboxes and
brakes.
h) Documenting the completed inspection
The results of the annual inspections and maintenance work, including all competed tasks,
shall be documented by the competent inspector, if necessary, and signed off by inspection
station or specialty shop.
7.3.2 Requirements for monitoring the winches
a) Theoretical service life
Crane winches are classified according to FEM98 as follows:
Drive group:
M2
Load collective:
Load collective factor:
Theoretical service life D:
L1
0.125
1600 hours
Caution: the “theoretical service life” is not equal to the real (true) life of a winch.
The actual life of a winch is affected by many additional outside factors, for example:
1) Overloads: because the crane was not used as intended.
2) Inadequate maintenance: oil is not changed at the proper intervals
3) Improper operation: excessive acceleration or deceleration of load; load falling onto
the cables;
4) Improper maintenance:
--Using the wrong type of oil
--Too much or too little oil
--Contamination during oil change
5) Assembly errors during repair and maintenance
6) Undetected oil leakage
7) Improperly set safety devices
8) Hidden damage from accidents
9) Extreme environmental conditions:
--extremely low or high temperatures
0066340-200-07Y.C
--corrosive atmosphere
--dust and dirt
b) Used portion of theoretical service life
The crane operator is obligated to have the crane inspected at least once a year.
The used portion of theoretical service life must also be determined. If necessary, the
crane operator can subcontract this work to an authorized inspector.
The actual operating conditions (load collective) and the winch operating hours at each
inspection interval are required to determine the proportion of the theoretical service life
that has actually been used. The operator is responsible to have it documented in the
crane inspection log.
c) Determining the operating condition (load collective)
The load collective of the crane is classified into groups, please refer to FEM9.5.11.
Note: For mobile cranes in assembly operation, we normally use the load collective
L1(Q1),with the load collective factor km=0.125
Load
collective
Operating
Definition
time
components
classification
Drive
10% of the running
Q1
device
L1
parts
load(dead load and
thereof are
1/1 working load)
subjected
40% of the running
time
at
time with dead load
maximum
and
loading
load
in
50% of the running
cases, but
time only with dead
normally
load
operate at
very
load.
light
Km=0.125
Load %
working
exceptional
only
Graph
maximum
to
1/3
collective
factor
Light
or
Load
Running time%
0066340-200-07Y.C
Medium
Drive
1/6 of the running time
Q2
device
L2
parts
load(dead load and
thereof are
1/1 working load)
or
at
Km=0.25
Load %
maximum
subjected
to
1/6 of the running time
maximum
with dead load and
loading
2/3 working load
relatively
1/6of the running time
often,
but
normally
Running time %
with dead load and
1/3 working load
only
50% of the running
operate at
time only with dead
light load.
load
Heavy
Drive
50% of the running
Q3
device
L3
parts
load(dead load and
thereof are
1/1 working load)
frequently
50% of the running
subjected
time only with dead
to
load.
or
time
at
Km=0.5
Load %
maximum
maximum
Running time %
loading
and
normally
operate at
medium
load
Very heavy
Drive
90% of the running
Q4
device
L4
parts
load(dead load and
thereof are
1/1 working load)
regularly
10% of the running
subjected
time only with dead
to
load
or
near
time
at
Km=1
Load %
maximum
maximum
Running time %
load
d) Determining the effective operating hours Ti
The control system of the crane can record the operating hours of engine which can be
read directly from the display. For mobile cranes used in assembly operations, the
0066340-200-07Y.C
operating time for the superstructure can be estimated at 60% of the total operating hours
of the crane. If the hoist winch proportions is estimated at 20% of the superstructure
operating hours, the resulting hours as a percent of the total crane operating hours is:
12%.
Note:
The percentage staged above normally applies to main hoist winches. For auxiliary hoist
winches or lufffing winches, the proportion of the total operating hours can be significantly less
and should therefore be estimated by the operator.
e) Determining the actual used portion of the theoretical service life
The actually used proportion Si of the theoretical service life is given by the following
formula:
kmi
Si = ———— × Ti
km
Where,
km = Load collective factor that was used to select the winch ratings. This factor is
given in the operating manual.
kmi = load collective factor for inspection interval i
Ti = effective operating hours for inspection interval i
The actually used hour proportion is subtracted from the remaining theoretical service life
Di after each inspection interval (see example).
If the remaining theoretical service life is not long enough to cover the next operating
period, a general overhaul of the winch is required.
If the theoretical service life D has been reached, the winch may only be operated after
conducting a general overhaul.
Note:
1. A general overhaul of the winch is required not later than 10 years after putting the crane into
service
2. The general overhaul shall be arranged by operator and carried out by the manufacturer or the
manufacturer’s authorized representatives and must be documented in the inspection log.
Example
According to the manufacturer’s operating manual, a mobile crane with a separate elapsed
time meter for the crane engine and the crane drive is classified as follows:
Drive gear group: M2
Load collective: light L1, km = 0.125
theoretical service life: D = 1600 h
0066340-200-07Y.C
Actual used proportion S of the theoretical service life is calculated using the individual
inspection intervals as follows:
First inspection (year 1)
The crane was used for assembly work during the past year:
Load collective L1, which means km1 = 0.125.
The hour meter for crane engine indicates 1800 hours. The winch operated about 12% of the
time, i.e. T1=216.
The actual used proportion S of the theoretical service life at the time of the first inspection is
therefore:
0.125
S1 = ————× 216 h =216 h.
0.125
Remaining theoretical service life:
D1 = 1600 h – 216 h = 1384 h
Second inspection (year 2)
Load collective L2, which means km2 = 0.25.
The hour meter for crane engine indicates 3400 hours, i.e. during this period:
3400-1800 h=1600 h (1800h were used during the first year of operation)
The winch operated about 12% of the time, i.e.,T2 =192 h.
The actual usage proportion S2 of the theoretical service life at the time of the second
inspection is therefore:
0.25
S2 = ————
×192 h = 384 h
0.125
Remaining theoretical service life:
D2 = 1384-384=1000h
Do the same for the rest calculation.
0066340-200-07Y.C
7.4 Inspection of load hook
The load hook must be inspected annually by a competent inspector.
These inspections are made to prevent accidents through early detection of deficiencies.
Any deficiencies determined by the inspector must be documented, corrected, and
subsequently re-inspected.
a) Check the hook for distortions; e.g., at the hook jaw.
b) Inspect all bolts and screws, and ensure all cotter pins are complete and opening is
stretched.
c) Check that the rotary connection of hook can move easily, and the clearance is not too
large;
d) Check the easy rotation of the hook: rotate the hook by hand. If it is stiff, it indicates that
the bearing has been damaged.
e) Check the safety catch for integrality and functional work.
f)
Check the hook for corrosion and wear
Note:
In case corrosion and wear is found on the threads, the load hook may no longer be used. In
such a case, contact the mobile crane branch company of Zoomlion.
7.5 Inspection of rope pulleys
a) Check the rope pulley all around for damage and cracks
b) If rope pulleys have been hit during crane operation (for example on buildings) or if they
were subjected to other stress factors, they must be then extensively checked for damage
or cracks.
c) Check for wear on the rope groove. Replace the pulley if the bottom of the rope groove
has been worn down more than 1/4 of the rope diameter.
d) If any damage or cracks are found, then the rope pulley must be replaced immediately. If
this is not observed, there is great danger of causing a serious accident!
e) Check rope pulley for tight fit and shakes; loose and shaken rope pulley means that the
bearing and bearing bush is damaged.
Caution:
If any damage or cracks are found, then the rope pulley must be replaced immediately. If this
is not observed, there is great danger of causing a serious accident!
0066340-200-07Y.C
7.6 Inspection and maintenance of anchoring rods
All anchoring rods fitted or used must be checked at least once a year by a specialist, and
subjected to additional checks depending on working ground and actual operating conditions.
Increase use of the machine shortens the inspection interval. A comprehensive inspection
should be carried out on anchoring rod during assembly, including concealed surface and
inside holes.
The anchoring rods should be checked for the following defects:
a) Cracks and notches
The anchoring rod must be checked at least once a year using magnetic powder test to
make sure that there are no cracks or notches. If any cracks or notches are detected, the
rods must be replaced immediately; rod repairing is prohibited.
b) Elongation
The elongation of the rods must be inspected by measurement. Maximum permissible
elongation is 0.2%; for example, over a length of 7000mm=14mm
c) Wear and abrasion
The inside holes and pins must be inspected for signs of wear and abrasion, including the
spring keepers and cotter pins used for securing the pins.
d) Enamel coating
The anchoring rod coating must be inspected regularly for signs of corrosion. Eroded spots
must be repainted. The anchoring rod must not be stored in aggressive agents, such as
sea water.
e) Deformation
The anchoring rod, once being distorted, should be replaced immediately.
Note:
If any of the damaged listed above is detected, the anchoring rod must be replaced
immediately; damaged and faulty anchoring rods may lead to serious accident!
0066340-200-07Y.C
7.7 Inspection and maintenance of wire rope
Being a crucial component for crane lifting, the wire rope will directly affect the assembling
work and safety on the construction site. Therefore, much emphasis should be put on the use,
maintenance and regular inspection of wire rope.
7.7.1 Handling and transport of wire rope
The wire rope should be handled and transported with utmost care. When loading a wire rope
down, never push it down directly from a higher position in order to avoid causing any damage
to the rope or to the reel.
A proper means of transport is to make use of a steel bar through the middle hole or axle of the
reel. The reel can then be lifted with a forklift or directly with a sling attached to a crane. When
the reel or coil is rolling on the ground, the illustrated bar can only be placed underneath both
flanges of the reel, without getting in contact with the rope. The ground should be even, and
the rope is not allowed to contact the sharp objects or the fork of the forklift, even if the outer
lay of the rope is protected.
Improper methods:
Proper methods:
0066340-200-07Y.C
7.7.2 Inspection of wire rope
Any torsional stresses and sudden acceleration of load caused by impact loaded on wire rope
and load hook will cause serious damage to wire rope, a comprehensive check should be
therefore performed on the wire rope. While checking, pay attention to the following points:
a)
whether the rope end connections are in proper order;
b)
notches on pulley groove;
c)
corrosion, wear and tear and rope deformation;
d)
Type and number of wire breaks, and location and consequence of wire break;
e)
Narrowing of the rope diameter during the operational period
Caution:
For crane that has been idle for a period of over 6 months shall be give a complete
inspection by a qualified person conforming with the requirement of this clause before
being placed in services.
7.7.3 Discard of wire rope
Wire rope must be discarded immediately if any one of the following defects is found:
a) Broken strand or formation of broken wire clusters(In running ropes, six
randomly distributed broken wires in one lay or three broken wires in one strand
in one lay)
b) Wear of one-third the original diameter of outside individual wires. Kinking,
crushing, bird caging, or any other damage resulting in distortion of the rope
structure (Figure 1).
c) Basket formation( Figure 2);
d) sharp protruding strands or strand clusters(figure 3)/loop formation;
e) Reductions from nominal diameter of more than one-sixty-fourth inch for
diameters up to and including five-sixteenths inch, one-thirty-second inch for
diameters three-eighths inch to and including one-half inch, three-sixty-fourths
inch for diameters nine-sixteenths inch to and including three-fourths inch,
one-sixteenth inch for diameters seven-eighths inch to 1 1/8 inches inclusive,
three-thirty-seconds inch for diameters 1 1/4 to 1 1/2 inches inclusive;
f)
10% corrosion or wear (figure 4);
g)
loosening of the rope structure(figure 4);
h)
contractions(figure 5);
i)
flattening and sharp bends(figure 6+8);
0066340-200-07Y.C
j)
kinking section of snapped strands(figure 7).
k) In standing ropes, more than two broken wires in one lay in sections beyond end
connections or more than one broken wire at an end connection (figure 6).
Caution:
1. If there is any doubt about the operational safety of any ropes, please consult with crane
specialist.
2. Should any of the above damages are discovered or any other damages occur, the cause
must be established before attaching or mounting a new rope.
3、wire rope safely factors shall be in accordance with American National Standards Institute
B30.5-1968 or SAE J959-1966
Wire ropes are sensitive and they should be kept clean and dray, and be prevented from
coming in contact with the ground; Wire rope transporting and replacing must be carried out
according to actual requirements;When replacing ropes, the new ropes must be of the same
strength rating and diameter as the old ones. Should another type of wire rope be used,
permission must first be obtained from the crane manufacturer.
Procedure for changing wire ropes and Notes
a) Preparation
1) The rope is usually replaced with a rope that is of the same type as the original. If the
spare rope is of another type, the user must ensure that the rope characteristics are
at least as good as those of the rope that was taken down;
2) When cutting a certain length of wire rope out of a longer one, the area where the cut
will take place should be treated properly beforehand, or appropriate technical means
should be taken to prevent the rope from coming loose at the cutting point;
0066340-200-07Y.C
3) Before installing a new wire rope, the grooves of the rope drums and pulleys must be
checked in order to ensure that they can accommodate the spare rope correctly;
4) Before starting to use the rope on an equipment the user must ensure that all
components that are associated with the rope have been set up in such a way that
they will operate correctly.
b) Unwinding of wire rope
The wire rope can be unwound from a reel or uncoiled on the floor. If the later method is
applied, the floor should be clean and even; otherwise, foreign substances such as sand
grains stuck to lubricating grease will damage the wire rope when it passes through the
rope pulley.
In no circumstances shall the rope be pulled from a reel or a coil which is laying on its side,
otherwise a twisting force will be inevitably generated on each rope layer. Every twisting
force will change the twist pitch of rope strand; alter the proportion of each component part
in every section of rope length; and at last change load-bearing location of wire rope.
Since the unwound wire rope from the reel will resist the previous twisting force, the rope
will form loops and be kinked permanently.
Kinked wire rope can no longer be used and must be discarded.
c) Installation of wire rope
The optimal installation of wire rope can be achieved depending on different type of crane.
The installation of a rope must be carried out very carefully to ensure that the rope can be
unwound from a reel or uncoiled from a coil without generating torque and causing any
outer damages. This point also applies when reeving the rope in the rope pulley. If the
rope is not installed under a load, any contact area between the wire rope and the
equipment should be protected properly.
0066340-200-07Y.C
It is recommended that the old rope should be removed prior to fitting a new rope. If the old
rope is used as a lead rope to pull the new one through the reeving system, do not
connect them together by directly welding or binding their rope ends; instead, they should
be connected with a Chinese finger. There is still another way to change a rope: use a
thinner rope as a lead rope to pull the new one through the reeving system. This way is
usually applied to the installation of a rope on new equipment.
1) Unwinding the rope from the reel onto the drum
In the manufacturing process, when a rope is wound onto a reel, the rope suffers bending
with a special direction. After the rope is delivered to customer, it is also bended towards
the same direction. Therefore, when the rope is unwound from a reel onto drum, it is
advantageous to maintain the direction of bending as it leaves the reel (see the above
figure).
If the above mentioned method is not observed, the wire rope will be kinked between the
reel and the drum or resume its original bending direction when used, which will result in
changes in the structure of rope.
2) Installing the rope under load
To achieve the best spooling condition of rope on a multiple-layer coiling system
(especially wound onto a cable drum of crane), it is very important to install the rope under
a tensioning load.
If the first rope layer is not tensioned on the rope drum, the outer rope layer will cutting into
the lower rope layer under loading, which would result in serious damage to wire rope.
And the unwound rope can even get stuck, which will result in the reverse rotation of the
rope drum during the unwinding of rope, and thus causing the sudden increase in tension
0066340-200-07Y.C
force and the drum winding downwards.
The tensioning load should be 1-2% of the minimum breaking force. In many cases, the
rope should be unwound or wound properly with the help of an external force.
Enough tensioning load can be generated on the reel by depressing the wooden board
underneath one flanges of the reel or holding the braking bar that is connected with the
reel axles (see the figure above).
Note: we should on no account produce the tensioning force by means of compressing the
wire rope, such as putting the wooden board directly underneath the wire rope,
because the changes incurred in rope structure will make the rope deformation
irremediable.
3) Installing a new rope with the help of the old rope or a lead rope
For the spooling operation itself, the new rope is attached to the old rope or to a lead rope.
They can be connected by means of a rope hose or welded ring. However, please make
sure that the new rope is not twisted by the old or lead rope.
4) Testing of wire rope
After the installation of wire rope and before starting to use it on the crane system, the
rope should experience normal “trial running” with a low load several times. After
0066340-200-07Y.C
undergoing “trial-running”, all components of the rope can be adjusted to real operating
condition.
The crane should be used for lifting at approximately 10% of the normal load in order to
stabilize the rope.
During the trial-running, crossing, kinking, twisting, and excessive bending as well as
scratch of wire rope should be avoided.
7.7.4 Maintenance and care of wire rope
The wire rope should be protected against exposure to such dangerous medium as heat
source, acid and alkali. And it should be free of sands and dirty adhered, and be greased.
Regular maintenance and care of the ropes enhances the safety of crane operation and
substantially increases the rope’s service life.
a) Wire ropes must be greased or oiled at regular intervals, especially around the drums and
pulleys, areas where they are turned and flexed the most. The grease or oil must be
compatible with that already on the ropes. Well lubricated wire ropes demonstrate 4 times
as much flex-play as unduplicated ones.
b) Dirty wire ropes must be cleaned regularly; the best results may be achieved by brushing.
c) If the lower layers on the drum are hardly used or not used at all, they are loose and must
be unwound and then rewound under a preliminary tension.
d) A rope works most economically when its entire length is used. Therefore, an
appropriately adapted rope length should be used for crane operation of long durations. If
partial sections of a rope are subject to different and varying loads, the rope, after a
certain time, can be turned around. In doing so, the previously free end of the rope is
attached onto the drum so that the part of the rope which has been subjected to the most
wear and hard use is now in the “quiet” zone, and vice-versa. The service life of a rope
can be noticeably increased.
e) If wear results mainly from the multi-layer winding of the drum, the service life of the rope
can be increased by shortening it by a length equivalent to 1/3 of the drum circumference.
f)
Extension torsion in torsion free hoisting rope and its elimination
1) A torsion compensation is not only required after a new rope has been placed, but also
if extension torsion has been established after a long working period, resulting from
stretching and settling of the rope structure.
2) Torsion compensation can be noticed when the hook block turns in multi reeve
operation and when the load is set down and / or the outer strand seem to loosen up.
In extreme cases, the rope shows an arch formation.
3) If a crane is operated for a long period of time with the same reeving, without
unreeving or changing the hoisting rope reeving, then we recommend installation of a
rope twist catcher on the fixed point of the hoisting rope.
0066340-200-07Y.C
Caution: if this is not observed, the rope can be damaged!
g) Measures to eliminate torsion compensation
1) Set down the load hook
Lower the load hook as much as possible, so that the greatest rope length between
pulley block and load hook is exposed to compensation (twist, point 4).
2) Determine the rope lay direction\turning direction of rope
First determine in which direction the load hook is twisted.
The turning directions are shown in the illustration with a continuously lined arrow.
When the hoisting height is large, it is very difficult to check the turning direction of
rope by the turning direction of the dashed arrow. The “braid” must be dissolved.
3) Loosen the rope on the fixed point
When the direction of rotation has been determined, release the rope on the fixed
point on the load hook.
It is advantageous for torsion compensation if the load hook has been reeved in an
uneven number of that such a member will be reeved.
In this case, the fixed point of the rope is easily accessible on the load hook and it can
easily be released.
4) Turn the end of the rope by 180° to 360° carefully to compensate for the turn of the
load hook. To compensate for the turn, turn the separately shown end of the rope as
marked by the solid line arrow.
Note: it is important that the correct reference point is taken and that the crane operator
should hold the cable in from of him.
The rope(Z) with right-hand lay direction, as shown in figure 1 and the rope(S) with
left-hand lay direction as shown in figure 4 are turned in for compensation, while the
rope(Z) with right-hand lay direction as shown in figure 2 and the rope(S) with
left-hand lay direction as shown in figure 3 should be turned out for compensation.
The rule for torsion compensation is that the end of the rope must be turned against
the rope lay direction, which causes the release of the ‘braid” in the above test.
The rope section should be as long as possible for the turn. Through a hoisting
movement without a load, this turn should be distributed over the complete length of
the cable.
Under no circumstances turn the cable by force over a short section, because this
would destroy the cable structure permanently.
5) Reattach the rope on the fixed point
The end of the rope must be reattached and secured on the fixed point after the turn.
6) Carefully lift the load hook and raise it without a load repeatedly, if necessary
0066340-200-07Y.C
Since a non-stretch rope construction is relatively safe from torsion and it can only be
stretched a little (actually, the torsion will not make the rope deviate from the groove of
rope pulley), the hoisting movements without a load must be repeated several times.
after getting the compensating turn to the end of the rope, reattach the rope end again
to the fixed point and repeat the hoisting movements without a load one or several
times so that the torsion compensation can be distributed over the complete length of
the rope past the rope pulley.
Note: if necessary, in case the stretch was especially severe (multiple twisting of the
lower pulley block and /or slackening of the outer strands over a long stretch, or
at several points) then repeat this procedure several times, depending on hoist
rope length.
0066340-200-07Y.C
7.7.5 Wire rope shall be taken out of service when any of the following conditions exist:
a) Evidence of any heat damage from any cause;
7.8 Inspection of oil and fuel tanks
Oil and fuel tanks shall be inspected at lest once a year and checked all around for leakage in
the subsequent inspections every four years.
Repairs shall only be carried out by trained and knowledgeable specialists.
Improper repairs such as welding, brazing or soldering are not permitted without
consulting our company.
7.9 Inspection of load bearing components
Check the mounting bolts of slewing ring and winch.
Overloading or load impact may cause impact on bolting joints, resulting in damage to bolts.
Check the bolts carefully for elongation, cracks or deformation. If such defects are found on the
bolts, they should be changed immediately; otherwise accidents may happen.
The slewing ring is an important load bearing component, so much attention should be given to
the following points:
a) Check the pre-tightening force of fixing bolts of slewing ring after the slewing ring is
operated for 100 hours. And check them again every after 500 operating hours to ensure
sufficient pre-tightening force. Generally speaking, the bolts should be changed after
14000 operating hours or 7 service years.
Mounting bolts of slewing ring for QUY260
Diameter of
Bolts
Mounting
Specification(ISO7412)
hole
(mm)
Strength grade(ISO898-1)
M33
36
10.9
2
Limit of strength σsmin (N/mm )
3
Pre-tightening moment(10 N)
900
412
b) Pay attention to the running condition of slewing ring during operation. If noise becomes
large, impact force and power increase suddenly, check vehicle immediately and
eliminate the failures. If necessary, dismantling of the vehicle is also needed.
c) The slewing ring in use should not be exposed to strong sunlight. Never wash the slewing
ring directly using water in order to prevent the water from entering the roll path.
Precautions are taken against hard objects from approaching to or entering the meshing
area.
d) Check sealing strip regularly. The sealing strip, if damaged, should be changed, and if
falls off, should be retuned to original position.
0066340-200-07Y.C
7.10 Inspection of engine
a) The engine must be inspected prior to every operation; i.e., daily check that all oil and fuel
lines are leak-free and dry. The fuel filter, oil filter and injection pumps shall also be
inspected for leakage.
b) Every day, check that the hydraulic components, fan drive hydraulic motors and their
supply lines are properly sealed and do no leak.
c) Check the exhaust system, especially the exhaust flanges and the exhaust flap brakes,
and make sure that they seal and move properly. The return springs that open the exhaust
flaps must function properly, because seized (therefore closed) exhaust flaps during
operation will cause increases in temperature and considerable overheating.
d) Check if electrical lines are functioning and mounted properly, and ensure that there is
sufficient clearance to hot exhaust pipes. Ensure that they are not damaged and still
properly insulated.
e) To reduce noise emission, noise reducing mats are installed in the engine area (engine
covering) for certain types of cranes. The fiberglass mats, after being cleaned, are
flame-resistant and fireproof.
f)
If engine compartments are not cleaned regularly, oil and fuel may splash on the mats
while conducting maintenance and repair work. Oil and fuel soaked on noise reducing
mats must be removed, as they are flammable. The same is true for insulating mats in the
exhaust system area.
g) Clean the engine compartment only with nonflammable cleaning fluid. In addition, the fluid
may not be corrosive or chemically damaging to hoses and cables.
7.11 Cranes Not in Regular Use
a) A crane that has been idle for a period of 1 month or more, but less than 6 months,
shall be given an inspection by a qualified person conforming with the requirements
of paras. Chapter 6 6.2 before being placed in services.
b) A crane that has been idle for a period of over 6 months shall be give a complete inspection
by a qualified person conforming with the requirement of paras. Chapter 6 6.2、6.3 before
being placed in services.
c) Standby cranes shall be inspected by a qualified person at least semiannually in
accordance with the requirements of paras. Chapter 6 6.2、6.3 Cranes that are exposed to
adverse environmental conditions should be inspected more frequently.
7.12 Inspection classification
7.12.1 "Initial inspection." Prior to initial use all new and altered cranes shall be inspected to
insure compliance with provisions of this section.
7.12.2 "Regular inspection." Inspection procedure for cranes in regular service is divided into two
general classifications based upon the intervals at which inspection should be performed.
The intervals in turn are dependent upon the nature of the critical components of the crane
and the degree of their exposure to wear, deterioration, or malfunction. The two general
0066340-200-07Y.C
classifications are herein designated as "frequent" and "periodic", with respective intervals
between inspections as defined below:
a) Periodic inspection: 1- to 12- month intervals, or as specifically recommended by the
manufacturer.
7.12.3 "Frequent inspection." Items such as the following shall be inspected for defects at intervals
as defined in paragraph (d)(2)(i) of 1910.180 or as specifically indicated including observation
during operation for any defects which might appear between regular inspections. Any
deficiencies such as listed shall be carefully examined and determination made as to whether
they constitute a safety hazard
a) All control mechanisms for maladjustment interfering with proper operation: Daily.
b) All control mechanisms for excessive wear of components and contamination by lubricants or
other foreign matter.
c) All safety devices for malfunction
d) Deterioration or leakage in air or hydraulic systems: Daily.
e) Crane hooks with deformations or cracks. For hooks with cracks or having more than 15 % in
excess of normal throat opening or more than 10 deg. twist from the plane of the unbent hook.
f) Rope reeving for noncompliance with manufacturer's recommendations.
g) Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, and moisture
accumulation.
7.12.4 "Periodic inspection." Complete inspections of the crane shall be performed at intervals as
generally defined in paragraph (d)(2)(ii) of 1910.180 depending upon its activity, severity of
service, and environment, or as specifically indicated below. These inspections shall include
the requirements of paragraph (d)(3) of 1910.180 and in addition, items such as the following.
Any deficiencies such as listed shall be carefully examined and determination made as to
whether they constitute a safety hazard:
a) Deformed, cracked, or corroded members in the crane structure and boom.
b) Loose bolts or rivets.
c) Cracked or worn sheaves and drums.
d) Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking
devices.
e) Excessive wear on brake and clutch system parts, linings, pawls, and ratchets.
f) Load, boom angle, and other indicators over their full range, for any significant inaccuracies.
g) Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with
safety requirements.
h) Excessive wear of chain-drive sprockets and excessive chain stretch.
i) Travel steering, braking, and locking devices, for malfunction.
0066340-200-07Y.C
j)
Excessively worn or damaged tires
7.12.5 "Cranes not in regular use."
a) A crane which has been idle for a period of one month or more, but less than 6 months,
shall be given an inspection conforming with requirements of paragraph (d)(3) of 1910.180
and paragraph (g)(2)(ii) of 1910.180 before placing in service.
b) A crane which has been idle for a period of six months shall be given a
complete inspection conforming with requirements of paragraphs (d) (3) and (4)
of 1910.180 and paragraph (g)(2)(ii) of 1910.180 before placing in servic
c) Standby cranes shall be inspected at least semiannually in accordance with requirements
of paragraph (d)(3) of 1910.180 and paragraph (g)(2)(ii) of 1910.180. Such cranes which
are exposed to adverse environment should be inspected more frequently.
7.12.6 "Inspection records." Certification records which include the date of inspection, the signature
of the person who performed the inspection and the serial number, or other identifier, of the
crane which was inspected shall be made monthly on critical items in use such as brakes,
crane hooks, and ropes. This certification record shall be kept readily available.
7.13 The employer shall comply with the manufacturer's specifications and limitations applicable to
the operation of any and all cranes and derricks. Where manufacturer's specifications are
not available, the limitations assigned to the equipment shall be based on the
determinations of a qualified engineer competent in this field and such determinations will be
appropriately documented and recorded. Attachments used with cranes shall not exceed
the capacity, rating, or scope recommended by the manufacturer.
7.14 Hand signals to crane and derrick operators shall be those prescribed by the applicable
ANSI standard for the type of crane in use. An illustration of the signals shall be posted at
the job site.
7.15 The employer shall designate a competent person who shall inspect all machinery and
equipment prior to each use, and during use, to make sure it is in safe operating condition.
Any deficiencies shall be repaired, or defective parts replaced, before continued use.
7.16 A thorough, annual inspection of the hoisting machinery shall be made by a competent
person, or by a government or private agency recognized by the U.S. Department of Labor.
The employer shall maintain a record of the dates and results of inspections for each
hoisting machine and piece of equipment.
Chapter 8
8章
Additional equipment
0066340-200-08.CY
8.1 Air conditioning
8.1.1 Control panel for air conditioning
The air conditioning system mainly consists of compressor, condenser (including
liquid reservoir), evaporator etc.
When cooling performance is activated, its power is supplied by the compressor
which is driven by the engine.
And the heating is achieved by utilizing the heat of engine circular water supplied by
the evaporator fan.
The air conditioning in the cab is a heating & cooling air conditioning. Its control
panel is on the air conditioning cover behind the seats.
1
2
3
1 Switch
Control the fan speed to obtain proper air volume.
2 Switch
Adjust the temperature of cab when cool mode functions.
3 Switch
Switching between cooling mode and heating mode
Ⅰ—— cooling mode; Ⅱ—— heating mode
0066340-200-08.CY
8.1.2 Methods for operating air conditioning
When air conditioning is used for the first time, turn the switch (1) to high gear
position and hold it for 5 minutes after engine starts, then turn the switch (2) to
“COOL” position. At this time, the temperature in the cab starts to fall down.
When the required temperature is obtained, turn the switch (2) anticlockwise slowly
until the indicator light goes out and the compressor stops working. At this moment,
set this temperature to the rated value.
When the temperature in the cab is higher than this value, the indicator light lights up,
the compressor starts automatically and the cooling system begins to work.
When the temperature in the cab is lower than this value, the indicator light goes out,
and the compressor and cooling system stop working.
Adjust the angle of air outlet to change the direction and angle of cold wind;
Adjust the switch (1), one of three fan speeds can be set for the heating or air
conditioning.
Note: Do not turn switch (2) to “COOL” position and rotate switch (1) to low gear
position when using air conditioning. Otherwise, evaporator may get frost and
cooling performance may be influence.
Note:
1. During “three guarantee” period, it is forbidden to dismantle air conditioning
system without manufacturer’s permission.
2. Check the tension of compressor straps periodically and adjusts it in time.
3. Wash off the dirt on the surface of condenser radiating rib. In this way, the
cooling performance can be protected.
4. When changing the components of air conditioning system, add freezing oil
according to the requirements. As there’s difference between compressors in
system, the brand and type of new freezing oil should be the same as that of
freezing oil used in the compressor. Different freezing oil, which is not given
explanation of being capable of mixing with the freezing oil in the system, is
never permitted to fill into the system.
5. When add or change refrigerant, its brand and type should be the same as that
of refrigerant used by original system.
6. Lower the temperature in the cab with the evaporator at high gear position, and
keep the temperature in cab at middle gear position or low gear position.
7. When the components in the system break down, they should be replaced with
the spare parts supplied or designated by manufacturer. Otherwise, the system
0066340-200-08.CY
may be damaged.
8. Under the condition of low temperature & high humidity, the evaporator should
not work at low speed. Otherwise, it may be frozen.
9. If air conditioning is not used in winter, switch air conditioning on once a month
and let it run for about 10mins. This minimum running is required to keep the
whole system adequately lubricated.
8.1.3 Maintenance of air conditioning system
Component
Maintenance content
Maintenance interval
Condensing fan
and motor
Check and repair
Once a quarter
Evaporating fan
and motor
Check and repair
Once a quarter
Condenser
Check condenser for blockage.
If necessary, clean it.
Once a month or increase
maintenance times according to
its working condition
Evaporator
Check evaporator for functional work and
abnormal sound.
Clean the air inlet.
Once a month or increase
maintenance times according to
its working condition
Electromagnetic
clutch
Check that it works properly.
If necessary, clean it
Once a quarter
Connector
Check that the wire connector is fitted
tightly.
Once a month
8.2 Media Player
QUY260 crawler crane can be equipped with radio or CD, DVD player according to
customer’s demands.
Note:
Radio or CD, DVD player are not the basic allocations of crane. Customers can
select to assemble according to their different demands.
Chapter 9
9-0
Crane
inspection log
0066340-200-09
9.1 Crane inspection log(8 pages in total)
Table (1)
No.
Actions
(inspection, testing,
Component inspected
maintenance, repair)
9-1
Date
1340-000-09
Table(2)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(3)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(4)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(5)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(6)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(7)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
1340-000-09
Table(8)
Actions
No.
(inspection, testing,
maintenance, repair)
Component inspected
Date
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