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QUY260 Operators Manual 20140603

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1. A 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 coupling and an anode end of the other coupling are often installed on the mounting plate Hydraulic lines connecting diagram Quick release coupling
2. ORT i n 4 XU n AK KX 3 2 XY 0066340 200 05Y C 5 9 3 Connect electrics to luffing jib 5 9 3 1 Electrical lines connection A 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 Ww X15 X16 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 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 0066340 200 05Y C Main boom tension force sensor anchoring rod of A frame1 205 Luffing winch 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 Descript
3. No Description illustration 1 Pin spindle 2 Retaining pin f il Double anchoring 4 9 6A 3 E rod 4 Coupling link Il Single anchoring T 5 rod _ _ p 6 Cotter pin 1501234 1997 0 4 3 8 T 2 2 92 E 7 Coupling link 01 8 1 0066340 200 05Y C Double anchoring 8 rod 9 Pin spindle Y 2 04 2 01 8 10 Single anchoring c E EE A rod MN E AME 4 B VESTES N 17 Double anchoring h ji 19 Single anchoring V rod d _ 4 2 2 91 8 na 20 Single anchoring RET EB ee e rod m 4 com com 21 Double anchoring rod 0066340 200 05Y C A 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
4. 0066340 200 05Y C Component parts of fixed jib rear anchoring rods Part am Description illustration 1 sleeve L 3 2 2 Cotter pin 2 1501234 1997 0 16 x1 2 3 Nut 1504032 1999 M20 8 4 Bolt 1504014 1999 20 8 8 8 5 Anchoring rod Single anchoring 6 rod Double anchoring oit 7 rod N d KD 0066340 200 05Y C 8 Pin spindle 9 Retaining pin Single anchoring eres 10 AMAN rod abaa m 01 6 4 N 11 Coupling link Double anchoring d 12 rod 13 Reducing piece 0066340 200 05Y C 14 Pin spindle 15 Cotter Reducing LN dE 16 double anchoring rod Single anchoring i 17 rod aF ij Single anchoring
5. 018 a gt e TT 810 Cio fb 24 030 041 1 D 40 030 pm mI E 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 FENG 2 X Y IN ee He js Sce IES BERETA 7 ARS 723 b i E H H i h al 000 000 C VN VN Sr o Poy Yer VN YSF oF et et er Ter ye er E et tot Ter Fit together the protective covers of the hydraulic couplings and hydraulic connectors A 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 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 whic
6. 19 Coupling link 20 Cotter Pin 15 1234 1997 0 4 x4 8 21 Pin spindle 0066340 200 05Y C MS uu anchoring rod X 22 connected to 7 A frame t ___ 23 Cotter Pin 1501234 1997 0 32 2 4 24 Pin spindle ES _ A 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 6577 long the length of main boom anchoring rods is 56 1 When main boom length increases by 910 a O 11 long double anchoring rod 8 a 8 10 long single anchoring rod 9 should be added accordingly When main boom length increases by 198 a O l11 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 2 Combi
7. gt 07 107 01 0 07 10 157 0066340 200 05Y C 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 Cif luffing jib is used 203 Cable drum 2 main boom pivot section 204 Main boom tension force anchoring rod of A frame sensor 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 Main boom head Cif luffing jib is used Limit on luffing jib 210 Cable drum 3 Main boom head Cif 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 pu
8. 2 9 6 Safety signs position diagram 2 Maa a 2 Safety signs position diagram 3 0063640 200 03 CY Safety signs position diagram 4 7 lt i ee a ed vote Safety signs position diagram 5 0063640 200 03 CY A Caution 1 When the safety sign is damaged or illegible please order it from appointed service supplier 2 Itis forbidden to cover or take off safety signs casually 3 Ifthe safety sign is covered with dust clean it in time 4 operator s cab should be equipped with an emergency hammer which be used to smash the window in an emergency so that operator can run away from the cab HOIST With forearm vertical fore finger pointing up move hand in small horizontal circle USE WHIPLINE Auxiliary Hoist Tap elbow with one hand then use regutar signals MOVE SLOWLY Use one hand to give any motion signal and place other hand motioniess in front of hand giving the motion signal Hoist Slowly shown as example 0063640 200 03 CY 3 2 9 Hand Signals for Controlling Crane Operations LOWER With arm extended down ward forefinger pointing down move hand in small horizontal circle RAISE BOOM Arm extended fingers closed thumb pointing upward RAISE THE BOOM AND LOWER THE LOAD With arm extended thumb point
9. Y ENON 401 440 AAN Ar Ann 6090mm 19 490mm 4 10 AN AN y N if if Y H N HW 0066340 200 05Y C 29 6 luffing jib intermediate section G25 1490mm 4 10 q 1 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 Assembly sequence of boom Boom Assembly sequence of boom length ft sections length ft sections G1 1 1 1 0820 G13 G14 6xG15 G29 G22 GON 613 614 6xG15 G629 G24 G22 nn G11 T G11 CONTI 6134 61446xG15 629 623 622 07 G13 G14 6xG15 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 boo
10. 82 ULL SL NE JE ux Ex oO 09 262 Drive Track carrier Track pad Track Driven sprocket roller roller 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 A Note Before carrying out the traveling movement the operator must first press the and then operate the control lever traveling switch 0066340 200 04 Left forwards Right crawler forwards Left control lever crawler backwards Right control lever L Right crawler backwards aos Operation of left and right crawler traveling Instructions for traveling movements Description Operation Movement Push forwards Left crawler forwards Left control lever Push backwards Left crawler backwards Return to neutral position Left crawler stops moving Push
11. 2 Cotter pin ES 3 Pin spindle 0066340 200 05Y C Cotter pin SS Pin spindle Cotter Pin spindle Cotter pin ES Reeving luffing rope in 1 2 3 Turn the switch 60 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 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 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 A 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 accid
12. 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 0066340 200 05Y C 8 7 4 2 2 14 2 1 11 6 2 13 12 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 0066340 200 05Y C 0066340 200 05Y C A B LT LAM CL 0 T REA ERR C Connecting parts of luffing jib tilting back support ru Description Illustrati ustration No n 1 Pin spindle
13. Diameter of Bolts Mounting Specification 507412 hole mm Strength grade ISO898 1 10 9 M33 36 Limit of strength N mm 900 Pre tightening moment 10 N 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 07 7 10 Inspection of engine a 9 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 Every day check that the hydraulic components fan drive hydraulic motors and their supply lines are properly sealed and do no leak 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 pr
14. Reducing single 6 m 2 8 anchoring es 7 Pin spindle M9 8 Cotter pin 1501234 1997 0 4 x3 6 ee 9 Reducing double anchoring rod 10 Pin spindle A Note part numbers of anchoring rods given in Section 5 7 4 2 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 1 6 Since the heavy fixed jib can be mounted in the angle of either 14 or 20 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 20 to main boom 0066340 200 05Y C view Swell V4 OL V Serre woog ulew oL VIVO 0066340 200 05Y C Component parts of heavy fixed jib rear anchoring rods De
15. No TA 573300 Ib load hook ON a a NN LS 2 352800 Ib 220500 Ib load hook 0066340 200 04 v mu 4 E B l4 A pond CN A CX 110250 Ib load hook 35280 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 Winch 1 1 3 0066340 200 04Y C 74 9 2 Winch 1 1 3 X16 t 2 2 2 I 2 2 on Winch 1 1 3 O Winch 1 1 3 0066340 200 04Y C Winch 1 1 3 352800 Ib 220500 Ib load hook Winch 1 1 3 0066340 200 04Y C Winch 1 1 3 Winch 1 1 3 55 Winch 1 1 3 0066340 200 04Y C x 8 o 4 Winch 1 1 3 7 Winch 1 1 3 x 6 0 Winch 1 1 3 0066340 200 04Y C 0
16. 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 ry 1 jc i Traveling direction table gt 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 04 AIRES f P Ld Operator s cab in working position A 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
17. gt 3 2 ee ee ee 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 A Counterweight base plate B counterweight plate C Counterweight lifting cylinder 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 counter
18. 0066340 200 05Y C Connecting parts of pivot section Description illustration No Double tapered pin 2 Retaining spring EN b p SUA A 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 Turn the switch 6
19. Length of light Length of light Combination of light anchoring rods between anchoring duty boom ft anchoring rods ft rods of heavy duty boom and luffing jib head 31177 69 2 4 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 20417 19 21 282 0 39 8 10 3 4 5 7 8 10 17 19 21 m 5 7 2 2 3 Total length of anchoring rods of light duty boom Possible total length of anchoring rods of light duty boom Total length Length L of Combination of Lenath of of anchorin anchoring anchoring rods of light light duty rods of ight rods of heavy of om duty boom anchoring rods boom ft duty boom duty boom between A frame and ft ft luffing jib head 311 7 300 5 2312 692 L LA 301 9 290 7 2312 59 4 L LB 0066340 200 05Y C 291 11 280 9 932 49 6 L LC 282 0 27011 03125 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 art 17 of light anchoring rods
20. Tow owz ox T ooze fone ooze f oer T 0902 e 91 91 SI 91 SI 4 91 9 91 l 10077 ooze fous 0 Toor owz oo 005 0 00 0 oor zv 0907 00507 91 9I Sl 91 Sl 9 Sl 91 008 00071 0077 70077 005 Fo ooze fone 00 0077 00127700877 005 0 ooze oo oz 0067027 0902 91 Sl 9I SI 91 SI 91 0001 00597 00 0 ToT cuz Fox 045 Toor pour Poor vows 770077 0045 ox oz or oar oe oo cy LI 91 91 SI 9 9 SI 9 9 vl 00 lt 6 ooze fone 0077 ooze 00 low 002770077 00 5 Fox ooze ow 0077 00 0 oo l on T 0902 91 Sl 9 Sl 91 SI 91 61 0001 00505 00 0 00 00 0 0 0 00 6 GAH 00 5 Foo ouz oT 00 5 Fox 00 5 oai oor T 0017 007 e Lu 9 91 Sl 91 5 9I Sl 91 SI 91 vi 00071 owz ox p one ox 005 ox our ow ous Poor ooze 0 005 ox our ox ows 0046 ox or ox oz ox or 00665 e L 91 91 SI 9 9I S
21. Check bolts and nuts for tight fit Rope support Check rope support in boom intermediate sections and boom head for deformation damage and wear 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 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 A 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 Connecting pin anchoring rod and lock pin Check them for damage and tight fit Bolt and nut Check bolts and nuts for tight fit Tilting back supports Check tilting back support of main boom and tilting back support of jib for damage and deformation 0066340 200 06Y C A 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 A 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 Check wire rope for damage
22. gt 331001 should be used Do not stand on the lattice boom when it is assembled Do not stand beneath the boom when it is being pinned or unpinned 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 amp 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 See ee UD EE ee ees
23. 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 amp 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 I 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 indic
24. 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 2 ZOOMLION 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
25. 1 2 3 4 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 If the icon Engine oil pressure T 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 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 al to the 2nd position and a then pressing Working light on off switch During operation always check the indicators 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 04 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
26. 1 2 Switch off the engine and remove the ignition key Attaching a warning sign s to the plant in appropriate positions 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 Replacement and removal of components 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 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
27. Right control lever Spool up hoisting winch 1 Operation of hoisting winch 1 Instructions for the movements of hoisting winch 1 Description Operation Movement Push forwards Reel off hoisting winch 1 to lower the load hook Push backwards Spool up hoisting winch 1 to lift Right control lever the load hook Return to neutral position Hoisting winch 1 stops working 0066340 200 04 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 pool up hoisting winch 2 Operation of hoisting winch 2 Instructions for the movements of hoisting winch 2 Description 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 Left control lever Return to neutral position Hoisting winch 2 stops working A 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 0066340 200 04 High speed operation o
28. 5700 0 2700 300 570 300 2700 300 570 2700 300 5700 2700 3001 5700 00 2700 soo 5700 1 1 2700 300 2700 420 1200 300 1100 1 420 360 300 62100 3 6 80908 6 8 6 8 9 6 8 9 8 6 80908 6 8 9 9 101 3 14 17 1819 22 5700 2700 300 1901 5700 2700 570 0 2700 300 5700 1 00 1 2700 7 5700 00 2700 3o 2700 420 1 1200 p 1100 420 300 59100 3 6 9 6 8 4 6 80908 6 80908 6 80908 6 89 89 1001 3 14 17 18 19 8 22 5700 300 2700 300 2700 5700 300 2700 300 5700 2700 300 a 5700 2700 300 5700 300 2700 00 2700 400 420 1200 300 1100 1 420 L 300 100 3 6 80908 5 8 9 8 6 8 9 6 8 9 6 8 9 8 9 10 Ti 13 14 17 188 19 22 570 300 2700 300 570 soo 2700 300 570 2700 300 5700 2700 1 5700 00 2700 300 2700 420 1200 300 1100 420 360 500 53100 3 6 8 9 8 6 8 6 80908 6 8 9 8 6 8 9 9 1001 13 17 18 19 8 22 5700 10 2700 5700 57 10 1 2700 1 500 1 2700 1 5700 1 300 2700 400 220 1200 300 soo 1100 420 360 300 50100 3 6 8 9 8 9 8 6 8 9 6 8 9 6 809 89 101 13 17 18 19 22 5700 2700 2700 1
29. 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 0066340 200 04 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 con
30. ES 5 J N TIX N 7 Jj N N M HON f IF N N p N N J N H N N jj H H 7 N 7 52 f W WV a Y 19 8 fixed jib intermediate section width 4 1 6171bx8 6060mm 19 10 1060mm 3 5 Fixed jib head width 4 1 1411Ibxl 1060mm 3 5 6430mm 21 1 N 0066340 200 05Y C FA frame width 4 11 16541bx1 7970n 600mm 9 11 7 9445mm 30 11 1850mm 6 0 id 9 10 luffing jib intermediate section width 57 6 6171bx1 3090mm 10 1 1490mm 4 10 Er qo 19 8 luffing jib intermediate section width 57 6 11031bx2 6090mm 19 11 1490mm 4 10 rS N N HN SN N 0066340 200 05Y C 29 6 luffing jib intermediate section width 5 6 15001bx8 1490mm 4 10 6540mm 21 5 WA frame 2 width 5 8 3837Ibx1 25 1180mm 3 10
31. Low engine oil pressure will impair the working efficiency of engine Add diesel oil in time if the oil level is too low If air filter is clogged the icon air filter clog will flash At this moment clean or change air filter 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 The maximum in service wind speed should not exceed 9 8m s 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 The battery master switch must be switched on to electrify the machine To protect the battery switch off the battery master switch if the crane will not work for a long time 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 1 position or the 274 position the LED on the switches of the control panel will light up Windshield wiper and washer Turn on front windshield wiper and roof windshield wiper by pressing the front windshield wiper NE and roof windshield wiper switch re
32. 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 pi
33. ae IL Crawl er carrier 540001bx2 i eee ES Gnda LLL adr b nri 1200 3 11 1400mm Counterweight base plate 419001bx1 627mm 2 0 260mm 0 10 Rear counterweight plate 146001bx10 450mm 1 5 1700mm 5 6 0066340 200 05Y C Central counterweight plate 353001b tx2 3 260t 5733001b Load hook 92611 1 160t 100t 3528001b 2205501b Load hook 61741bx1 3 2180mm 50t 1102501b load hook 37481bx1 612mm 2 0 30t 661501b oad hook 23601b tx1 0066340 200 05Y C 16t 352801b load 176415 1 160mm 3 9 He Main boom pivot section Width 7 7 6659Ibx1 ie 1 Main boom head width 7 7 7453Ibx1 2120mm 6 11 9 10 main boom intermediate section width 7 7 1588Ibx1 mr fu 2120mm t 9 gt 1 19 8 main boom intermediate section width 7 7 2646Ibx1 6120mm 20 0 2120mm 6 11 0066340 200 05Y C 29 6 main boom intermediate section width 7 7 3925Ib 6 29 10 2120mm 6 11 p hh
34. and RR support cylinder Extend positions and then push the toggle switch 116 to Extend position to Al extend four cylinders simultaneously Note the switch 116 is a self return r switch Release it after the cylinder is retracted to prescribed position suppo f ihe Place the switches 109 110 111 and 112 in FL support cylinder RL support cylinder FR support cylinder and 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 and then push the toggle switch 116 to Extend position Note the switch Left Extend 4 116 is a self return switch Release it after the cylinder is extended to crawler i prescribed position carrier 7 moe Place the switch 109 in Left crawler carrier extension cylinder position and then push the toggle switch 116 to Retract position Note the switch cylinder Retract 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 and then push the toggle switch 116 to Extend position Note the switch Right Extend i 116 is a self return s
35. 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 Dirty wire ropes must be cleaned regularly the best results may be achieved by brushing 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 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 ti
36. d Crawler Type Lower Note 2 A 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 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 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 88 Ib Actual useful load of the crane 63702 Ib In this case the load to be lifted may no exceed 63702 Ib 0063640 200 03 CY 3 2 6 1 Counterweight The required counterweight should be installed prior to operation ac
37. 4 2 2 5 Function key line 93 94 95 96 97 98 99 100 Function key line No Description Operation and function E Pressing this key in any other screen can switch to main m Rd screen directly The main screen is shown in Section 4 2 2 94 Key Press this key to enter into I O screen In this screen all the input output points of PLC can be checked for correction 95 Key Parameter Adjust relevant parameters of main motions adjustment 96 Key Fault diagnosis At present this function is not set in the control system of crane Pressing this key can switch to Working conditions screen 97 pe wong Under this screen the working conditions for main crane conditions movements can be checked i 98 lt lt ge up 99 gt gt Page down 100 Key Enter Confirm the previous operation or save the modified parameters A Caution Never adjust the parameters without the permission of our technicians 0066340 200 04 4 3 Startup of crane 4 3 1 Adjustment of crane operator s seat a Vertical adjustment of headrest 1 The height of headrest is adjusted manually p 7 15 4 N 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 0066340 200 04 Adjustment of the height of
38. 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 33 more above the ground level 8 Keep all handles steps handrails platforms landing and ladders free from dirt oil 0066340 200 01 Y C snow and ice e Safety consideration during advanced maintenance 1 2 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 Restrict access to the maintenance area to essential staff only Where appropriate erect barrier guards and post warnings The fastening of loads and instructing of crane operators should be entrusted to qualified persons only 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 Always ensure that any safety fitment such as locking wedges securing chains bars or struts are utilized as indicated in the operating instructions Particularly make sure that any part of the plant raised for any reason is prevented from falling by securing in a safe reliable manner Never work under unsupported equipment Never work alone f Safety consideration
39. 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 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 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 A Caution 2 the process of lowering main boom the winch 1 must be reeled off to avoid the 3 Standing within danger area of crane during operation is prohibited 4 The boom lowering movement should be performed slowly and stably And during 1 In the lowering process when main boom is lowered to 65 position the operating mode must be changed to assembly mode hook s collision with the pulley head the operation the crane operator must observe the data shown on the display while other workers must observe the surrounding areas for potential dangers d 0066340 200 0
40. A di YN A s o _ p VN 7 WA frame 1 width 4 6 33521 1 600mm 1 11 10210mm 33 5 E m s 0066340 200 05Y C 5 15 Requirement for crane transport Transport means and safety precautions for transport a b After being dismembered the crawler crane be transported by 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 During transportation all component parts should be fixed to prevent them from jostling and sliding 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 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 wit
41. 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 20 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 wit
42. ins i ind track roller and track carrier roller 9 months or 2 11 Visual PVEN 480 Mounting bolt for slewing bearing Tight fit hours inspection 6 3 4 Every 6 months or 12 Undercarriage centre section Damage and crack Operation every 600 hours Note The serial number in above table should be consistent with that in following context 0066340 200 06 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 Pin anchoring rod and cotter pin Check connecting pins anchoring rods and cotter pins for damage and tight fit 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 Valves Check valves for leaks Support cylinder for basic machine and pin pulling device Check them for leaks and damage Centre revolving joint Check centre revolving joint for leaks 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 10
43. q Anyone is not permitted to climb on the load hook slings or 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 F RC EET Ns it 2s ma TED 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 li
44. 1 5700 00 2700 1 5700 2700 300 5700 300 2700 300 2700 400 420 1200 1100 360 1 300 47100 3 6 80908 5 8 9 6 80908 6 8 9 9 00 1 13 04 17 18 19 22 soo 570 2700 300 5700 0 2700 300 5700 300 2700 soo 44100 5700 300 2700 2700 400 420 1200 oo 1100 420 300 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 G17 0066340 200 05Y C 13 1 reducing section G29 luffing jib pivot section G21 1490mm 4 10 Luffing Jib head G22 N JN 7 7 N N M N N V ML 9445mm 30 11 gt Itf 1850mm 6 0 9 10 luffing jib intermediate section G23 1490mm 4 10
45. 12 Glass ladder handrail and Damage crack and Visual guardrail tight fit inspection 13 Operational ads Tor Operation malfunction daily when used All hydraulic hoses particularly those that flex in normal 14 operation of crane functions Visual should be visually inspected inspection once every working day when used Electrical apparatus for 15 Mauneuaning pigs of Operatiof excessive deterioration dirt and moisture accumulation 16 Hydraulic system for proper oil Visual level daily when used inspection 0066340 200 06Y C Maintenance Serial Inspection Component Item interval No method Operation and 17 Fan belt Damage and tight fit visual inspection Visual 18 Radiator and oil cooler Leakage and damage inspection Operation and Foundation bolt and damping 19 Damage tight fit visual rubber cushion of engine inspection Leak d Audiovisual 20 Hydraulic motor and reducer bio d X ee abnormal sound inspection 6 2 2 Visual Every month 21 Valves Leakage inspection or every 100 Leakage and Visual hours 22 Hydraulic pump abnormal sound inspection Audiovisual 23 Erection cylinder Leakage and damage inspection d Functional work and Bete MI 24 Refueling pump and hose visual damage 1 inspection 25 Taieri Leakage and Audiovisual abnormal sound inspection O tor b tilti 26 P 52 F
46. 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 0066340 200 04 Swing free running button O ZA Left control lever f PEON 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 A 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 prohibi
47. 7 3 6 8 9 9 8 6 8 9 Q8 6 8 9 8 6 80908 6 6 8 9 8 6 8 9 8 9 10 H 1 14 17 18 19 22 5 300 2700 soo 270 57 2700 300 5700 2700 30a 570 90 2700 soo 570 1 1 2700 soo 5700 1 1 2700 1 5700 300 2700 300 2700 4001 420 1200 500 1100 420 360 300 00 3 6 80908 5 8 9 8 6 8 9 8 6 8 9 8 6 8 9 8 6 8 9 8 6 8 9 9 10 t 13 14 17 08 19 8 22 570 300 2700 1 5700 0 270 0 50 0 2700 570 1 2700 570 2700 300 5700 300 2700 soa 5700 2700 300 2700 4001 420 1200 1100 420 360 300 71100 3 6 80908 6 8 6 god 17 6 8 9 8 6 80908 6 80908 6 8 9 8 9 10 M 13 14 17 18 19 22 soo 5700 10 2700 50 2700 1 5700 2700 soa 5700 2700 5700 570 300 2700 309 2700 400 420 1200 300 1100 420 300 68100 3 6 8 9 80908 6 80908 6 80908 6 80908 6 6 8 9 9 0001 5 17 18 19 tee 22 0 5700 300 2700 300 2700 300 5700 2700 5700 2700 300 5700 2700 1 570 1 2700 300 5700 300 2700 300 2700 400 420 1200 300 1100 420 360 500 65100 8 6 80908 6 80908 6 809 08 6 80908 6 8 9 8 6 8 9 8 9 460 0U 4 d 17 18 19 me 2
48. Exhaust pipe of air compressor clean 5 Engine suspension f Every 5000 hours or every four years Valve clearance adjust A 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 9 connector 5 When ambient temperature is less than 18 C or more than 3
49. Join the lower connecting holes in the same way 0066340 200 05Y C 5n 3 Connecting parts of main boom section Part Description illustration No 1 Double tapered pin 2 Retaining spring S Av 2 4 3 Double tapered pin i 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 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 Join the upper connecting holes with double tapered pins 1 and secure properly on both sides with retaining springs 2 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 Join the lower connecting holes with double tapered pins 1 and secure on both sides with retaining springs 2 Disconnect the main boom pivot section from mounting cylinder on A frame by removing the lifting chain
50. 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 62 mt Hi aH Z 1 nm Counterweight plates 14600Ibx10 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 la A Te VD WI WI WI WU UJ II
51. 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 pelivery Add oil Replace date oil A 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 mi
52. left crawler backwards 25 Symbol slew to the left 26 Symbol slew to the right 0066340 200 04 1 The crane movements 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 4 1 3 Right control box 0066340 200 04 32 34 36 Components of right control box Names of the No components Remarks 27 Right control lever 28 Deadman s button 29 Switch Not assigned Control the high speed of hoisting winch1 hoisting winch 2 30 High speed switch luffing jib derricking winch and travel gear For details please refer to section 4 5 Symbol extend 31 mounting cylinder on Reserved A frame Symbol retract 32 mounting cylinder on Reserved A frame 33 Symbol reel off H1 H1 refers to hoisting winch 1
53. not by the wind sock 2 Light 16 3 Wind can be felt on the face the leaves rustle wind breeze sock moves slightly Gentle Leaves and thin twigs move Wind extends a small 3 3 4 5 3 breeze breeze flag Moderate Swirls up dust and loose paper moves twigs and thin 4 5 5 7 8 breeze branches 5 Fresh 8 10 6 Small deciduous trees begin to sway foam forms at breeze sea Strong Thicker branches move telephone lines begin to 6 10 8 13 7 me breeze whistle umbrellas are difficult to use 7 Stiff wind 13 9 17 Entire trees swaying difficult to walk into wind 8 Gale force 17 2 206 Breaks twigs off trees walking becomes difficult wind 0 Minor damage to property chimney tops and roofing 2 208 245 tile are blown off 10 jp 24 7 28 3 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 LI Wu ueque Jone Urn 494 Lord Vals Operating Bas Uie qi Praeses linet 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 ow
54. 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 Lower A frame down the slewing table A 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 A 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 c
55. rod L 2 Single anchoring p NE 6 d NI rod 7 A Note The part numbers of anchoring rods given in Section 5 7 5 2 a 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 Twepewr we ws ws Tae wes Yves oar Teme wr wc Tor Tort ws Teme qos 00 00 2 DOE 90g 00 2 00 006 00 2 00 sus prp wp ws pep wwe ws Tug ur we we por wr por on vs T Top os fus 0066340 200 05Y C four 00 00 2 00 00 2 ang 00 6 00 i l Earth For fur Tor au 6 8 6 c wey Wy wg VG 04 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 A View To WA frame 2 AK AA LM TATATA A ih WAA y N WA
56. 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 Connecting parts of connect fixed jib section Part No Description Illustration Double tapered pin d d Retaining uo 7 spring 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 lt SST aer ONDES s A To A frame 4 11 N 1 10 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
57. self assembly amp 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 A 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 cylinde
58. 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 A 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 ji
59. 0066340 200 04 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 0066340 200 04 Note 1 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 mu
60. 0066340 200 05Y C Component parts of luffing jib rear anchoring rods Part No Description illustration 1 Retaining pin Ik ul E 7 Cos DF Double m anchoring rod 3 Pin spindle 1 bp ae 4 Coupling link 5 Cotter pin 1501234 1997 0 4 x3 6 6 Pin spindle 0066340 200 05Y C 7 Single anchoring rod p 8 Reducing Fe dis piece single N 932 9 Pin spindle 10 Cotter 1501234 1997 0 4 x4 8 Reducing Ud ag piece double T Single TN anchoring rod 0066340 200 05Y C 13 M Coupling link Singl E ing e V anchoring rod 2 5 E 15 Sue anchoring rod e 5 3 FN pA Singl du 16 idi anchoring rod 4 Double S T anchoring rod 0066340 200 05Y C A Note The part
61. 2 5 Checking safety measures 3 2 6 Crane operation with a load 3 2 7 Electromagnetic influences 3 2 8 Safety signs 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 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 moun
62. 34 PIA XP H1 refers to hoisting winch 1 Symbol right crawler 35 forwards 36 Symbol right crawler backwards 0066340 200 04 37 Symbol spool up E refers to derricking winch and W1 refers to luffing jib E W1 derricking winch spare 38 Symbol reel off E refers to derricking winch and W1 refers to luffing jib E W1 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 04 4 1 4 Control panel assy 39 40 43 44 x 47 48 49 Rocker switches on the control panel Description of the rocker switches Names of the No rockon switches The key Remarks T HER 1 position LED on the switches of control aster lighting 39 switch panel 1918 27 position master
63. 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 0 0066340 200 06Y C 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 IV 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
64. 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 c Fasttravelling Koes High speed switch A Right control lever Speedse 9 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 i i a traveling switch and then operate the control lever 0066340 200 04 2 Only when deadman s button is pressed 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 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 Opera
65. C No 4 alumini A 0 4 aluminium No 4 base grease Since the working conditions of slewing ring are complicated the user can adopt the optimum lubricating grease according to actual conditions d 9 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 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 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 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 A 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 spr
66. Crane Operations Cont d 0063640 200 03 CY EXTEND BOOM Telescoping Boom RETRACT BOOM Telescoping One Hand Signal One fist in front of Boom One Hand Signai One fist in chest with thumb tapping chest front of chest thumb pointing ward and heel of fist tapping chest Fig 17 Standard Hand Signals for Controlling Crane Operations Cont d A 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 0066340 200 04Y C 4 1 Operating and control instruments 4 1 1 Overview of crane operator s cab Overview of crane operator s cab 0066340 200 04 Components in crane operator s cab No Description Position and function 1 Fan At the rear right side of operator s cab 2 Interior light On the top of operator s cab Display the images from the video camera near the slewing 3 Monitor table The rocker switches rotary switches and ignition starter 4 Right control panel switch are fitted on the control panel For details
67. Double anchoring rod Part 10 of light anchoring rods single anchoring rod 00 w gt CON m 5 URL SS n N X NN is gum c Se ee ONSE EE 1 Ber Connecting position between 13 1 reducing section tensioning rope and light anchoring rods 2 22 2 10 417 19 21 To luffing jib To anchoring rods of heavy head duty boom gt o o Combination of light anchoring rods of 2820 light duty boom A 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 Part 17 of light anchoring rods single anchoring xod rods Double anchoring rod 0 P 2 Aen N By oW NI Ws JU N N N N N 8 E NA NL I _ N ONSE oe N 7 f 13 1 reducing Section aan Connecting position between tensioning light anchoring rods 4 8 To luffing To anchoring rods of jib head heavy duty boom 300 420 Itm enm 1400 300 C
68. 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 A 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 G10 tip boom on main boom head G12 main boom h
69. 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 s 4 0 6m s 8 0 4m s 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
70. PN 18 rod ay 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 2 Length of Fixed jib fixed jib angle to 5 Combination of fixed jib rear anchoring rods between main boom to main 1 FA frame boari 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 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 1978 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
71. Parameters 5 Heavy duty boom Spy Ted a SL Light duty boom SL 282 1 311 8 7 Luffing jib on heavy duty S 755 2034 boom W 68 10 196 10 S 95 T2525 SF Fixed jib on heavy duty boom F 234 9 98 5 Heavy fixed jib on heavy duty S 134 5 252 6 boom FV 19 8 1 2 0066340 200 02Y C 2 2 2 Description of component parts 0066340 200 02Y C 2 6 48 2 1 5 V Re 1 6 5 17 gt rosa 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 Luffing jib derricking winch 1 9 Engine A Note The luffing jib derricking winch 2 8 is optional 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 20711 Travel device The cra
72. Winch 1 1 3 0 Winch 1 1 3 0066340 200 04Y C 110250 Ib load hook 0 Winch 1 1 3 Winch 1 1 3 0 Winch 1 1 3 0066340 200 04Y C 66150 Ib load hook Main winch 1 3 35280 Ib load hook QP Main winch 1 3 0066340 200 04 4 6 1 2 Main boom with tip boom S A DOD Winch 2 1 4 i isi d 9 4 Winch 2 1 4 o d 0 5 3 0066340 200 04 4 6 2 Light duty boom SL 4 6 2 1 Hoisting rope guidance and reeving Om Winch 1 1 3 Winch 1 1 3 0066340 200 04 4 6 2 1 Hoisting rope guidance for tip boom Winch 2 1 4 0066340 200 04 4 6 3 Fixed jib heavy duty boom SF Winch 2 1 4 1 9 2 Winch 2 1 4 0066340 200 04 4 6 4 Luffing jib on heavy duty boom 4 6 4 1 Hoisting rope guidance and reeving 6 5 ire Winch 2 1 4 ls 2 2 2 2g Winch 2 1 4 0066340 200 04Y C f Winch 2 1 4 t 4 5 9 4 Winch 2 1 4 Winch 2 1 4 0066340 200 04Y C x2 Winch 2 1 4 e Fr Winch 2 1 4 0066340 200 04 4 6 4 2 Hoisting rope guidance for tip boom on the luffing jib gt T Ll load hook Winch 2 1 4 4 6 5 Main boom derricking r
73. 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 Conditions of wire Measures 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 1 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 Change wire rope at 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 Change Wire Tepe soon as possible 7 Burned wire rope due to short circuiting gas cutting or wire rope exposed to high temperature b Heavy wear and or broken wires may occur in sections in contact wi
74. and the buzzer will sound 5 9 4 Erecting and lowering main boom with luffing jib 5 9 5 1 Requirements All electrical connections have been established The limit switch control lever has been checked for smooth movement Check the warning lamp Check the anemometer Check the anemometer for smooth rotation and functional working Check the hoisting limiter switch 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 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 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 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 A D
75. 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 l
76. b Raise lower luffing jib 1 Use hoisting winch 1 to raise lower luffing jib WI Winch Assembly 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 0066340 200 04 Instructions for the movements of hoisting winch 1 Description Operation Movement Push forwards Reel off hoisting winch 1 to lower luffing jib Right control lever Push backwards Spool up hoisting winch 1 to raise luffing jib Return to neutral Hoisting winch 1 stops working position oOx High speed switch Right control lever Hisp 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 A Note 22 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 0066340 200 04 2 Use luffing jib derricking winch to
77. backwards mechanism right control lever left and right 6 Winch 2 wich1 luffing jib Left control lever forwards and backwards ay right control lever forwards and backwards 7 Slewing mechanism winch 1 Left control lever left and right right control luffing jib lever forwards and backwards 8 Winch 1 luffing jib derricking Operate the right control lever in 20 70 winch range 9 Winch 2 luffing jib derricking Left control lever forwards and backwards winch right control lever left and right 10 Winch 1 luffing jib derricking Left control lever left and right right control winch 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 04 Swivel arm of Operator s cab operator s cab J 0097 EET N x BN B x nimi Operator s cab tilting cylinder
78. being pinned or unpinned 5 11 2 Assembling main boom with fixed jib A 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 G3 31 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 Connecting parts connect fixed jib pivot section to main boom head Part No Description Illustration NY j e aining E 2 as spring E 2 Pin spindle Y 3 Locking plate M MA 4 Washer 0 64 1504017 1999 M16x2 2 8 8 0066340 200 05Y C c According to actual condition choose appropriate numbers of fixed jib intermediate
79. can clearly read boom angle shown on the indicator SS ZOOMLION lol o 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 04 For SW boom configuration 1 2 When the main boom is raised to 80 position the main boom derricking speed will be slower When the main boom is raised to 85 position the system will cut off hoisting movements automatically and gives an alarm When the main boom is lowered to 65 positi
80. 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
81. current Manual ACCEL adjuster value is the maximum adjustable speed of engine Turn the switch to left hoisting winch 1 H1 will not work Turn the switch to right hoisting winch 1 H1 can work For details please refer to section 4 4 Lowering bypass 55 For details please refer to section 4 4 switch 56 57 58 59 60 61 Derricking bypass Switch A frame erecting lowering switch Tilt forwards backwards switch W1 winch Assembly switch Synchronization switch Reeving winch switch For details please refer to section 4 4 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 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 Synchronization switch includes Reeve sync position and Mast E sync position Reeve sync For detailed description of Mast E sync For
82. 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
83. dimensions e 194 zenne jm E m Li ES es uper I o 460mm 4 9 I tes 21 _ _ _ nnpne E ECT T LL annar 2 4 Technical data 2 4 1 Main technical parameter a Weight Central counterweight 70600 Ib 0066340 200 02Y C b Speed Hoisting winch 1 360 min maximum speed of single rope the 112 6 layer th Hoisting winch 2 360 9 min maximum speed of single rope the 6 112 Main boom derricking 95 1 maximum speed of single rope the 112 winch 6 rope layer Luffing jib derricking 150 10 min maximum speed of single rope the 112 winch 6 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
84. 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 Aperson 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 N f lt 2 T WED gt b No person is allowed to stand on slewing table during operation Itis forbidden to lift load over people 9 Overloading operation and lifting staggered load is prohibited Never pull load obliquely 0063640 200 03 CY f Itis forbidden to lift load hidden in the gr
85. forwards Right crawler forwards Right control lever Push backwards Right crawler backwards Return to neutral position Right crawler stops moving 0066340 200 04 1 Before carrying out traveling movement the operator must first press traveling switch and then operate the control lever 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 4 In normal operation stop the crane movements by returning the control lever to neutral position a 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 A Note When crane is traveling with a crawler the operator had better change into low speed shift
86. 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 A 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 A Caution 1 When replace engine oil the filter cartridge should be replaced together 2 Donnot 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 Fuel checks and fuel change Serial No Inspected item interval in hour Volume 5 1000 1 Clean fuel tank 2 Change eng
87. 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 oollective L1 Load collective factor 0 125 Theoretical service life D 10600 hours A 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
88. 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 Drop point Work wimble Moisture Appearance CO degree 96 no more Type 1 10 than ZL 2lubricati S th i t ith th ubricating mooth inunctum wi e color 175 265 295 grease from pale yellow to brown 26 3 lubricati Equal i t ith th ubricating Equal inunctum wi e color 90 220 250 25 grease from pale yellow to brown 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 Every week or every 25 hours Every year every 1000 hours 0066340 200 06 b Table of superstructure and undercarriage lubricating
89. limited The tricolor light sends out yellow early warning and red warning continuously The buzzer sounds continuously The cont will be shown on the display 0066340 200 04 The following operation can bypass the limited crane movements temporarily Derrick Release Setup switch Derricking bypass 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 will be shown the display 2 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 55 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 derric
90. 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 1 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 0 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 engine
91. lines connecting diagram Quick release coupling 0066340 200 05 Y C 01 J 1 230 216 MA MR 5 M12X15 Mlexis ni l 630 pa 30 ey eee e ia p 095 f 222 ell 210 t S Hue res fo T F To pot S gt ES 510 018 010 218 2 _ eld Mmes 2 To port T p 010 010 2 i li d H P lins to To control ol Ine 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 e
92. load and thereof are 1 1 working load subjected 5 to 1 6 of the running time maximum with dead load and 50 100 loading 2 3 working load Running time relatively 1 the running time often but with dead load and normally 1 3 working load only 50 of the running operate at time only with dead light load load Heavy Drive 50 of the running Km 0 5 Load Q3 device time at maximum L3 parts load dead load and thereof are 1 1 working load frequently 50 of the running subjected time only with dead to load 50 100 maximum Running time 96 loading and normally operate at medium load Very heavy Drive 90 of the running Km 1 Load Q4 device time at maximum 100 L4 parts load dead load and 80 thereof 1 1 working load En regularly 10 of the running subjected time only with dead to near load 50 100 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 07 operating time for the superstructure 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 A Note The percentage sta
93. 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 the rope of reeving rope in the reverse direction between rope pulleys Ill and rope pulleys 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 0066340 200 05Y C Rope reeving plans the hoisting rope is led by rope of reeving winch 573300 Ib load hook reeving 20 Attach the two ropes together 0 2 Rope pulleys I cc yy Hoisting winch 1 ES lu Rope pulleys II Rope pulleys 16 amp Reeving winch 00 2 573300 Ib load hook reeving 18 n d Attach the two ropes together OS DO N 21 Rope pulleys I Hoisting winch 1 SS OS y Rope pulleys II 555 SIS abblobblotelsy 7 Rope pulleys d pe pulley D Nd 9 9 Reeving winch 573300 Ib load hook rope reeving 16 5 Attach the two ropes together DOES Hoisting winch 1 e Rope pulleys eee R
94. load oil 40 C 35 C 15 C 50 C SH 0358 95 below 30 C 10 aviation 35 C 22 C 5 C 60 C mee hydraulic oil ESSO above 30 C 28 C 15 C 70 C NUTO H32 0066340 200 06Y C between wESSO 20 C 20 C 10 C 5 C 80 85 C NUTO H46 40 C ESSO b NUTO H68 2 5 3G 20 C 100 C A Caution 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 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 The domestic brand of hydraulic oil mainly includes Kunlun the Great Wall Tongyi Haibrand Daqing Hengyun Guta Jiarun Haili etc and foreign brand such as ESSO Mobil etc are also available in china If you find any special operating conditions which are not listed in the above table please consult the related departments of our company Check and measure oil temperature of system at any time The suitable oil temperature for hydraulic system in working condition is 20 C to 80 C The 85 C may occur for a short time or in some position When the oil temperature is too high nearly 100 pay attention to the cooling of system The working load sh
95. 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 A Note The scope and extent of all inspections remain the sole responsibility of the inspectors The following diagrams are provided to assist the in
96. monitored The following icons will flash when the limits are reached No Description Function When engine oil pressure is too high the icon 72 Icon Engine oil pressure will flash When water temperature reaches the specified 73 Icon Water temperature E value the icon will flash 74 Icon Preheating When engine is being preheated the icon 9929 will flash 75 Icon Air filter clog When air filter is clogged the icon will flash 76 Icon Oil inlet return pipe When oil inlet pipe oil return pipe is clogged clog the icon will flash rd When load hook 1 comes into contact with the 77 Icon switch on hoisting limit switch weight during its upward movement the icon 157 will flash 78 Icon Lower limit switch on When there are only three windings of wire H1 left on H1 the icon 142 will flash U limi itch When load hook 2 comes into contact with the 79 PESE imit switch on hoisting limit switch weight during its upward H2 movement the icon 2457 will flash Icon Lower limit switch on When there are only three windings of wire rope 80 s H2 left on H2 the icon 29 will flash i Icon main boom When main boom angle reaches 85 the icon 85 will flash 0066340 200 04 4 2 2 3 Monitored additional functions 10 Wind grade O Ed 0 0 mis 83 82 10 10 Voltag
97. 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 a 0066340 200 04 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 Up Cabin Down IL ca GJ ay SS wey C 5 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 Tilting operator s cab forwards When operator s cab is tilted backwards turn the tilt cab forwards back
98. 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 0066340 200 05Y C A G37 G75 G74 B fixed jib rear anchoring rods main boom anchoring rods 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 Illustration D 1 Cotter pin 1501234 1997 0 32 x2 4 2 Pin spindle r lt E 3 Cotter pin 1501234 1997 0 32 x2 4 j Double tapered pin 355 Fn RT dj LN 5 Retaining spring 5 2 a a 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 hoi
99. points Serial Lubricatin lubricating Grease Lubricating points Lubricating Method d No interval Type ZL 2 lithium base 1 Ratchet mechanism Every day Grease grease ZA Grease and inject 21 2 lithium base 2 Slewing ring Every week f with gun grease Connecting rod and pin Grease and inject 3 Every week spindle with gun Grease and inject 4 Track roller Every year GL 5 85W 90 with gun Grease inject 5 Track carrier roller Every year GL 5 85W 90 with gun Grease inject 6 Driven sprocket Every year GL 5 85W 90 with gun 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 b Table of boom frame system lubricating points 0066340 200 06Y C Serial Lubricating Lubricating Lubricating No SP interval method grease type 1 Pivot section bolting Every day Grease and inject ZL 2 lithium cylinder with gun base grease 2 Pin spindle of A frame Every day Grease and inject ZL 2 lit
100. 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 A 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 th
101. raise lower luffing jib W1 winch Assembly switch Neutral position Reel off luffing jib derricking winch 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 Operation Movement Move to left Spool up luffing jib derricking winch to raise luffing jib Right control lever Move to right Reel off luffing jib derricking winch to lower luffing jib Return to neutral position Luffing jib derricking winch stops working 0066340 200 04 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 A 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 0066340 200 04 4 5 3 Operation of synchronizing A frame and main boom derricking winch synchronizing reeving winch and working winch 1 The functions of synchronizing A frame and derricking winch o
102. rear anchoring rods Length of Heavy fixed heavy fixed jib Combination of heavy fixed jib rear anchoring rods between main jib angle to rear anchoring boom to FA frame main boom rods ft 20 42 8 7 16 13 12 11 7 10 7 10 7 6 5 14 9277 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 9710 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 9185mm 30 1 1490mm 4 N FN N VAN 9 10 luffing jib intermediate section G23 1490mm 4 10 3090 10 1 r 7 IS a I2 Y 6090mm 19 11 1490mm 4 10 29 6 luffing jib intermediate section G25 G25A 0066340 200 05Y C 9090mm 29 9 1 490mm 4 10 IX IX IN N if VAAN fF N f Jf f f Ff N A f y ff 2 1 V er WA frame 2 G28 10210
103. regularly for signs of corrosion Eroded spots must be repainted The anchoring rod must not be stored in aggressive agents such as sea water Deformation The anchoring rod once being distorted should be replaced immediately A 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 07 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 la
104. 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 A 1 Warning Suspended load 2 Warning Dragging entanglement 3 Danger Crush hazard 4 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 E O gt 0063640 200 03 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 ANEL JE CAREFUL IN THE WORKING RADIUS a 2 9 6 2 Safety signs position diagram 1 0063640 200 03 CY 15
105. see Section 4 1 4 and 4 5 Digital display Consists of display of load moment limiter and display of 5 control system system f For details see Section 4 2 6 on At the bottom of front windshield wiper 7 Accelerator pedal Control the engine speed 8 Foot operated Actuate the horn switch 9 Rearview mirror At front left side of operator s cab 10 Control the motions of hoisting winch 2 slewing mechanism and left crawler For details see Section 4 1 2 and 4 5 Control the motions of hoisting winch 1 derricking 11 Control box right mechanism right crawler and self assembly amp dismantling mechanism For details see Section 4 1 3 and 4 5 Two working floodlights front 1e NOR Toes en One working floodlight rear 13 CD player 14 Roof windshield At the roof of operator s cab wiper 15 Warning light At the rear left side of operator s cab 0066340 200 04 4 1 2 Left control box Components of left control box No Names of the components Remarks 16 Emergency stop button For details please refer to section 4 4 1 17 Left control lever 18 Deadman s button ECT NEUE HR 20 Swing free running switch For details please refer to section 4 5 4 3 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
106. 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 lt lt gt is WT 4 va vw s uo 4 k When load is suspending in the air the operator is not allowed to leave the cab should be carried out stably Never operate control lever out switchover operation Operation and gently jerkily and carry abruptly 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 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 Incase 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
107. 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 A 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 A Danger 1 Atthis 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 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 Spilt luffing jib sections one by one leaving the luffing jib pivot section assembled Detach the luffin
108. 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 A 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 0066340 200 04 Instructions for the movements of slewing mechanism Description Operation Movement Move to left Superstructure slews to left Move to right Superstructure slews to right Left control lever Return to neutral Stop slewing position High P igh speed e switch of left 4i N Left control control lever lever A 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
109. the operating manual are prohibited Always bolt on the shorter intermediate sections first If the main boom head is lifted by an auxiliary crane at least two pieces of lifting chain with a breaking force215t should be used Do not stand on the lattice boom when it is assembled 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 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 Liftthe 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 G12 G21 G27 628 G12 main boom head G21 Juffing
110. 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 07 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 A 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 sho
111. 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 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 A 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 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 tim
112. 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 STE Mounting balance valve installation position of quick release coupling Hydraulic lines connecting diagram Mounting Mounting inda balance vl m oli bod hydraulic To mam hoisting ol ok 7 7 34 Von red chamber 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 A 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 Depressuri
113. 0 360 60 5700 300 2700 1 3001 5700 300 2700 400 420 vo 300 300 1100 420 360 300 23100 E 6 9 9 9 10 1 13 1 17 18 19 22 300 2700 400 420 1200 m so 1100 420 360 300 20100 j 6 8 9 8 9 10 11 13 14 17 18 19 88 22 600 5700 300 2700 300 9 2700 420 d imo sa wl 1100 420 360 300 17100 83m 80m 77m 74m 68m 65m 62m 47m 0066340 200 05Y C Connecting diagram of main boom anchoring rods 3 6 80908 6 8 9 8 6 6 80908 6 80908 6 80908 6 80908 6 8 9 9 10 1 13 14 17 18 19 8 22 570 2700 300 5700 0 2700 soo 570 50 2700 300 570 2700 300 5700 300 2700 soo 5700 300 2700 5700 2700 570 2700 300 2700 001 420 1200 300 1100 L 420 1 L 300 80100 3 6 80908 5 8 6 80908 6 8 9 6 80908 6 80908 6 8 9 6 8 79 X Wd 44 10 13 de o d 19 22 5700 2700 300 5700 1 5700 0 2700 son 5700 1 300 2700 570 2700 300 5700 00 2700 300 570 0 2700 soo 5700 2700 1 2700 400 420 1200 300 1100 420 360 500
114. 0 1060 3 5 Fixed jib head G32 1060mm 3 5 6430mm 21 1 1650mm 5 4 FA frame G37 600mm 9 11 270mm 23 10 SN 4 7 T 4 Front tilting back support of fixed jib G74 10 2 12 0 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 2xG344G32 59 0 G31 G34 G32 98 4 G31 3xG344G32 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 394 the fixed jib front anchoring rods is composed by the following component parts 0066340 200 05Y C A view 6 DUCES XII UT 2 OLA 0066340 200 05Y C Component parts of fixed jib front anch
115. 0 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 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 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 A JP N BIN VA VAI V Rope pulleys I Rope pulleys II Load hook pulleys II 2 Hoisting rope reeving method for 260t
116. 0 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 A 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 chang
117. 0 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 06 Table of selecting lubricating grease 5 rt Lubricatin ape Working condition 3 Quality structure point Name PN indicator Plastic separate Extreme pressure Low temperature normal Roller bed M No 1 2 block lithium base grease Ribperseding temperature moisture 20 C 60 C Graphite base ring Gear i ZG S grease Ext Xtreme pressure No 1 2 lithium base grease 40 Roller bed 052 compound No 2 120 calcium base grease Metal separate High No 4 block temperature Gear high temperature No 4 Labyrinth seal moisture grease 52 Roller bed Mec 2 80 C calcium base grease m No 4 180 C Gear high temperature No 4 grease No 2 compound Normal temperature Roller bed aluminium base No 2 corrosion resistance grease 50
118. 09 No Actions inspection testing maintenance repair Component inspected Date Table 8 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date
119. 4 3 Hoisting rope reeving and specification of wire rope 2 4 3 1 Hoisting rope reeving table Lifting capacit Lifting capacity Lifting capacit 5 6 7 Reeving Reeving Reeving 207270 14 388080 A Note 1 If crane is working with hoisting reeving less than the value listed 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 Hoisting rope for Hoisting rope for winch Derricking rope intended use winch 2 dc d or Yes Yes No Nominal rope diameter 1 12 1 12 1 12 Rope length 157474 157474 450 2 x2 dai Left hand lang lay Left hand lang lay Right hand ordinary lay 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 6577 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 70 Crane operation with main boom when main boom length is 1149 and the reeving is 12 the longest possible hoisting rope is 1508 9 Crane operation w
120. 5Y C 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 A 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 n 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
121. 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 Crane inspections 2222 0066340 200 07Y C 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 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 2 2 2 2 0066340 200 08Y C 8 1 Air conditioning 8 1 1 C
122. 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 A 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 0066340 200 04 4 3 3 Turn power supply Insert ignition key into ignition lock and turn it clockwise to the 1 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 is 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 Oil Fuel Pressure Level Fuel level 10 Engine oil pressure 10 Wind grade 0 0 0 mis 40 Voltage Charge Gradienter 27 6 27 6 96 Inclinometer anemometer voltage 1 Icon Engine oil pressure 2 Icon Fuel level 3 Icon Air filter clog 2 4 Inclinometer 5 Anemometer 6 Voltage 0066340 200 04 1 2 3 4 5 6 7 8 9 Correctly set current work mode load moment limiter otherwise operation is not permitted to be carried out
123. 7 long main boom with 19 8 heavy fixed jib overview G74 G37 G17 0066340 200 05Y C Heavy fixed jib G41 6540mm 21 5 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 view V V 0066340 200 05Y C Component parts of heavy fixed jib front anchoring rods Part Description illustration No 1 Pin spindle Y 2 Retaining pin Kk w Double anchoring 3 rod gos 4 Single anchoring M ES VN FS N rod b MI m B Wi EN T 5 Double anchoring rod M rt Sd 0066340 200 05Y C
124. 8 a 10 8 long double anchoring rod part 1 and 179 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 length of Fixed jib pst Combination of fixed jib front anchoring rods between FA frame to length ft fixed jib anchoring rods ft 394 478 1 4 5 1 6 1 6 7 59 0 66 5 1 4 5 1 2 6 1 6 7 78 8 85 25 1 4 5 1 3 6 1 6 7 98 4 10311 1 4 5 1 4 6 1 6 7 a boo _ 1000 poo 3 80 1224 ale l Boo 1000 000 boo 5421 20260 1 2 sue x n a a iL d D 1224 Jo lt E 1000 1000 Boo poo Boc boo b Fixed jib rear anchoring rods The width of fixed jib rear anchoring rods is 1 8 and the diameter of pin spindle isq1 6 Since the fixed jib can be mounted in the angle of either 10 or 30 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 30 to main boom 0066340 200 05Y C ew Avi awed VA OL
125. 8 C 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 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 Itis 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 au
126. E HASSI JPPORT IRE REEVIN STOP UPESASTD 1 WINCH NN 1 N _ wu nou 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 A 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 A 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 O 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
127. Front 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 0066340 200 04 Setting configuration For the specific methods to set configuration please refer to load moment limiter instructions A CAUTION 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 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 Rocker 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 work range hoisting winch 1 hoisting winch 2 and luffing jib derricking winch and main boom derricking winch a Slow speed loading in fixed position and positioning exactly The switch Rotating switch The middle position of the switch means the automatic Normal speed working speed of the system HiSp When the hoisting win
128. I 91 SI 61 vl l w p ug 9 6 weg 0066340 200 05Y C 5 8 Assembly and dismantling of heavy duty boom S Ay Before assembly or dismantling set the Boom configuration switch to main boom position ote 5 8 1 Preparations for assembly Choose appropriate boom combination and relevant anchoring rods combination according to operational planning and load capacity chart Choose appropriate load hook and rope reeving for load to be lifted Assemble required counterweight plates Make sure that an auxiliary crane is available and operating personnel get full prepared and qualified for operation Change the operating mode into assembly mode A 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 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 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
129. QUY260F 20 CY ZOOMLION Crawler Crane QUY260 QUY260 20 CY QUY260S 20 1 2 ZOOMLION 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 amp Technology Co Ltd QUY260YM 20 1 Contents O Foreword sees hata sao 0066340 200 00Y C 1 Safety 1 1 0066340 200 01Y C 2 Description of the 1 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 0 4 22222 2 0066340 200 03Y C 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
130. Work time 0 hour 2500 atia o AO PW Top L 1 0 MPa 3000 Gradienter x 276 27 6 P w Top 1 0 MPa Speed Water Oil Fuel Engine Temperature Pressure Level Load 20 40 020 PUMP2 9 Mast n 10 0 25 0 0 MPa MPa 0 0 MPa MPa 0 0 MPa 120 5 12 75 20 30 ae 4 6 20 0 0 g 908 60 a om 0 el 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 04 4 2 2 1 Engine information 1000 2000 Work time 500 O hour 2500 67 o 5 3000 Speed Water Oil Fuel Engine Temperature Pressure Level Load 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 A Note The fuel leveland engine load are shown in percentage 0066340 200 04 4 2 2 2 Alarm functions 72 f 74 77 78 79 75 76 45i 297 25i 80 81 Display of alarm function The limit ranges of the working state of crane are
131. Y C 2 1 Product model 2 1 1 Product name plate and its position UJ UJ d 9 vw 2 2 gt UCM 522 5 Trade Mark ZOOMLION aS Mode QUY 260 s Iu Information of storage batter 200 AH 24 V MAME mies Rated Lifting Capacity RINES Engine Model QSL C305 Engine Rated Power 2277W BU V e E Max Design Total Mass IMB RT OX X S Overall Dimensions H RS Serial No Year of Manufactur Y RO BREA AHI Year of first commissioning EN BW reg rh ER 301 S Address No 361 Yin Pen Road Changsha Hunan P R China PRETLTPRARR HARA A ZOOMLION HEAVY INDUSTRY SCIENCE amp TECHNOLOGY DEVELOPMENT CO LTD 0066340 200 02Y C 2 1 2 Engine type and its manufacturer CUMMINS USA QSL C305 2 2 Terminology 2 2 1Boom configuration SFV SF SW SL 0066340 200 02Y C Instructions for boom configuration ae Description
132. a fire e Never spray water on the electric elements and the fittings when washing the machine f Preventa 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 06 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 0 A 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 C and then drain the oil oM iit 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 06 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 1 Pay at
133. a long stretch or at several points then repeat this procedure several times depending on hoist rope length 0066340 200 07 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
134. an 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 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 A Caution 8 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 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 Any other boom configurations and anchoring rod combination that have not been stipulated in
135. 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 06 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 A Caution Switch off engine before checking the fan belt otherwise serious injury may occur 14 Radiator and oil cooler Clean the
136. 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 j 0066340 200 07Y C Excessively worn or damaged tires 7 12 5 Cranes not in regular use Acrane 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 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 b
137. 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 A Note The winding of wire rope should be supervised by a person appointed and no person must stand within danger zone during operation 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 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 A Caution 1 In order to avoid breaking mounting sling the force
138. and oil dirt to keep the crane clean b Retract all the piston rods of the cylinders completely 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 06 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 AlII the safety devices are locked tThe key is taken out from the ignition starter switch to prevent the engine from being switched on by an unauthorized person A Cautio
139. 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 and is approved by ASME sTANDARD B30 5 Distance 5 should be approximately 3xrope diameter or 75mm 3in whichever is less please see the warning in Clause for its use 8 5 LI E zy 23 L2 zx sc2gdsSg 82283282 2 3 5 5 tee a 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 Check that the rotary connection of hook can move easily and the clearance is not too large Check the easy rotation of the hook rotate the hook by hand If it is stiff it indicates that the bearing has been damaged Check the safety catch for completeness and functional work Check the hook for corrosion and wear 5 1 3 3 Checking rope pulleys a b Check rope pulley all around for damage and cracks 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 extens
140. anes 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 7 12 2 Initial inspection Prior to initial use all new and altered cranes shall be inspected to insure compliance with provisions of this section 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 07 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 c
141. anger 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 jib operating mode Load moment limiter in accordance with boom configurations A 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 contr
142. ator 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 A 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 sam
143. b 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 A Caution When main boom angle is 85 the luffing jib angle can be adjusted from 15 to 75 When main boom angle is 75 the luffing jib angle can be adjusted from 15 to 65 When main boom angle is 65 the luffing jib angle can be adjusted from 15 to 55 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 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
144. b 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 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 Clearly define the duty and area of responsibility of all personnel concerned Check whether the crane is adjusted to be horizontal Check whether there is sufficient safety clearance to slopes and trenches 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 Checks that appropriate operating site has been selected so that the crane movements can be performed within maximum and minimum working radius Check whether there are obstacles which will hinder required crane operations Check whether the ground provides adequate load bearing capacity Know clearly about the type of crane operation and working mode Check the distance between the lifting poi
145. 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 04 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 th
146. ble 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 a 0066340 200 01 Y C only properly trained personnel undertake these tasks Isolation When undertaking maintenance and repair work the plant must be first made safe
147. 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 A 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 s
148. ch needs speed higher than Middle speed slow speed shift use middle speed The hoisting movement luffing jib derricking movement High speed and traveling movement will be performed in high speed Left control lever high speed High speed Slew in high speed Right control lever high High speed Raise the hoisting winch and travel in high speed speed switch 1 2 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 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 0066340 200 04 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 0 0 0 0 0 0 0 0 0 0 02 0 0 0 0 0 02 0 M ON 4 ERN ALARME V 07
149. 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 A 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
150. cording to specified requirements A 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 7 207270 14 388080 A 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 r
151. 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 A Note For mobile cranes in assembly operation we normally use the load collective L1 Q1 with the load collective factor km 0 125 Load Load ah Operating time collective Definition collective Graph oe components classification factor Light Drive 10 of the running Km 0 125 Load Q1 device or time at maximum L1 parts load dead load and 100 thereof are 1 1 working load subjected 40 of the running es 40 to time with dead load maximum and 1 3 working 0 0 loading load 50 100 exceptional 50 of the running Running time cases but time only with dead normally load only operate at very light load 0066340 200 07 Medium Drive 1 6 of the running time Km 0 25 Load Q2 device at maximum L2 parts load dead
152. ctions 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 b Check the hook for distortions e g at the hook jaw Inspect all bolts and screws and ensure all cotter pins are complete and opening is stretched Check that the rotary connection of hook can move easily and the clearance is not too large Check the easy rotation of the hook rotate the hook by hand If it is stiff it indicates that the bearing has been damaged Check the safety catch for integrality and functional work Check the hook for corrosion and wear A 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 b Check the rope pulley all around for damage and cracks 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 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 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 Check rope pulley f
153. cylinder 110 Changeover switch RL support cylinder right crawler carrier extension cylinder T 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 A 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 toggle switch 116 to Extend position Note the switch 116 is a self return Front left Switch Release it after the cylinder is extended to prescribed position support Place the switch 109 in FL support cylinder position and then push the cylinder toggle switch 116 to Retract position Note the switch 116 is Retract 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 toggle switch 116 to Extend position Note the switch 116 is a self return Rear left Switch Release it after the cylinder is extended to prescribed p
154. ddle of inspection hole 0066340 200 06 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 Drain oil after removing oil drain Check oil level plug 0066340 200 06 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 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
155. details please refer to section 4 5 3 Turn the switch to left the reeving winch will be spooled up Turn the switch to right the reeving winch will be reeled off 0066340 200 04 Names of the No Remarks components 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 1 In manual accelerator mode the adjuster is used to Manual ACCEL control the engine speed Turn it clockwise to the required 64 Har speed adjuster switch 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 swi
156. ding to difference brands of antifreeze fluid It is recommended to use final antifreeze fluid that has already been matched according to difference temperature Ambient Water Antifreeze fluid temperature condensing 4 C 39 liter 4 liter Coolant 7 C 37 liter 6 liter 13 C 32 liter 11 liter 17 C 30 liter 13 liter 21 C 28 liter 15 liter 25 C 26 liter 17 liter 31 C 24 liter 19 liter 40 C 22 liter 21 liter Fully charge The proportion of electrolyte is more than Battery 1 22 The electrolyte of fully charged battery is anti freezing than that of that of under charged battery in low temperature After adding distilled water run engine to mix it with electrolyte 0066340 200 07 7 1 General Initial Inspection Prior to initial use all new 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
157. during cleaning This equipment must be isolated prior to cleaning Do not direct power washers near or into control boxes and devices 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 2 3 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 Never operate the machine with safety devices and guards removed or unsecured Always report any defects regarding guards safety device or control devices h Safety when refilling Only refuel with diesel from approved storage and supply equipment Diesel fuel is flammable Never remove the filler cop or refuel with the engine running Never add gasoline or any other fuels mixed to diesel because of increased fire or 0066340 200 01 Y 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
158. e Charge o aA PW Top L 1 0 MPa Gradienter X 275 96 27 6 P WV Top 1 0 MPa Display of monitored additional functions No Description Function Display the inclination of crane to the horizontal in longitudinal and lateral direction 82 Crane inclination Note The traveling direction of crane is taken as positive direction Display the current wind speed at boom head detected b 83 Wind speed ind y anemometer 84 Voltage of machine Display the voltage of machine battery 4 2 2 4 Pressure of crane control pumps 85 86 87 20 30 20 30 20 30 a 9 PUMP 50 0 PUMP2 50 0 Mast_L 50 oT 6 0 60 Qe 60 0 0 MPa 0 0 MPa 0 0 MPa 20 30 i 46 20 30 4 0 0 2 8 50 ast R 60 9 A 60 g 10 0 0 MPa 0 0 MPa 0 0 MPa 89 90 Co_ _ 0066340 200 04 Display of pressure of crane pumps No Description 85 Pressure in main pump 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 P Ww Top L 1 0 MPa 91 P Top 1 0 MPa 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
159. e move the right control lever 27 to neutral position to stop the movement of spool the derricking winch A Caution 1 No person may stand underneath A frame as long as A frame is moving otherwise there is a risk of injury 2 Noslack 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 SZOOMLION TE Basic machine in transport position b Swivel the operat
160. e 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 06 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 Serial Inspection Component Item interval No method Pipeline and pipe fittin Leakage d eee 4 inspection 6 3 1 2 ee Visual Every day or Pin anchoring rod and cotter pin Damage and tight fit inspection every 5 hours 7 3 Visual Bolt and nut Tight fit inspection 4 Leakage and Audiovisual Hydraulic motor and reducer 3 2 abnormal sound Inspection 5 Visual Valves Leakage inspection 6 S rt cylinder for basic Visual 6 3 2 T Leakage and damage machine and pin pulling device inspection Every month 7 Visual isua or every 100 Centre revolving joint Leakage inspection hours 8 Listening Slewing ring Abnormal sound and monitoring 9 Tension wear and Visual Crawler inspection 3 Visual i Drive sprocket driven sprocket Tree
161. e 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 amp 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 Ch
162. e basic boom of 65 7 0066340 200 05 Y C Tomain 0 Ne 0066340 200 05 Y C Component parts of main boom anchoring rods Part Description Illustration No 1 Pin spindle 7 2 Cotter pin 1501234 1997 0 4 x3 8 Anchoring rod 3 connected to main 2d 28 M 2 s 2 L2 boom eps 4 4 Pin spindle 5 Retaining pin 2 Single anchoring 3 7 Pin spindle H Double anchoring i rod Single anchoring 0066340 200 05 Y C 9 rod D Double anchoring 10 i rod 11 Coupling link E I 12 Pin spindle UCM Double anchoring 13 E E rod 14 Reducing piece b Er 15 Cotter Pin 1501234 1997 0 48 x4 8 0066340 200 05 Y C rod 16 Pin spindle Double reducing 17 cp Single anchoring 18
163. e 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 07 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 A 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 07 undergoing trial running components of the
164. e 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 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 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 Lattice components which are in contact with the ground during assembly disassembly must be supported by appropriate and stable objects Make sure that no one is standing beneath the lattice boom when the lattice boom is pinned or unpinned 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 1058401 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 ji
165. e interval are shown in following table 0066340 200 06Y C Oil checks and oil change interval Serial Inspected in hour Remarks No Item 5 500 2000 1 Check oil level 2 Clean oil tank Main oil 3 Change Tank 800litre hydraulic oil 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 amp Chemical Character Variation Limitation Inspected item Value L HS NUTO H46 L HV L HM Kinematic viscosity 10 10 10 15 40 C Acid value addition 0 3 0 3 0 3 mgKOH g Moisture 0 1 0 1 0 1 Flash point 60 60 60 Solid grain pollution grade 20 16 20 16 20 16 6 6 1 3 Recommended brand of hydraulic oil used in different ambient temperature The lowest The lowest The lowest The highest Ambient t t t t ki t t mbien emperature emperature working empera Hie yaradi Brand temperature of cold start of cold start temperature of hydraulic without load with load with
166. e 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 i 8 1 FANAANIAN LANA S EET UU 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
167. e 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 7 14 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 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 7 16 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 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 Additional equipment
168. e p rod Sibley _ n 6 Pin spindle 1 t 7 Retaining pin We 4 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 95717 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 5970 fixed jib overview G17 0066340 200 05Y C Fixed jib pivot section G31 198 fixed jib intermediate section G33 6060mm 19 1
169. e 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 Improper method 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 rop
170. e wind speed displayed on the screen 0066340 200 04 4 5 Crane operation a Prerequisites for crane operation 1 The counterweight is fitted and secured according to load capacity charts 2 The crane is horizontally aligned with enough bearing capacity of the ground 3 The diesel engine is running 4 The hook block is properly reeved in accordance with the reeving chart 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 b Checks during crane operation If the crane has been worked for a long time switch on Oil cooling fan switch to cool down hydraulic oil automatically When the engine is running the following icons on the display must not flash 1 Icon Engine oil pressure 2 Icon Water temperature om 3 Icon Air filter clog 4 Icon Oil inlet return pipe clog 5 Icon Upper limit switch on H1 157 6 Icon Lower limit switch on H1 151 7 8 9 0066340 200 04Y C Icon Upper limit switch on H2 257 Icon Lower limit switch on H2 2421 Icon Main boom 85 A ae
171. ead 0066340 200 05Y C Connecting parts of tip boom on main boom head Part No Description illustration 1 Pin spindle x J Y Retaining po E spring us 2 4 1 3 Pin spindle 0066340 200 05Y C Assembly of tip boom on luffing jib head 0066340 200 05Y C Connecting parts of tip boom on luffing jib head Part No Description illustration i 1 Pin spindle 1 NE N 2 Retaining spring ES tud Pin spindle Retaining spring Pin spindle Nu washer 0 64 0066340 200 05Y C 7 Retaining spring ma ud 0066340 200 05Y C 5 14 Transport dimensions and weights of main components All Length values are given in mm Basic machine 10580011 13520mm 44 4 3300mm 10 9 X AT 1 S ZOOMLION ES m 9 Ni i
172. eck 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 A Note Radio or CD DVD player are not the basic allocations of crane Customers can select to assemble according to their different demands Crane inspection log 0066340 200 09 9 1 Crane inspection log 8 pages in total Table 1 No Actions inspection testing maintenance repair Component inspected Date 9 1 Table 2 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date Table 3 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date Table 4 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date Table 5 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date Table 6 1340 000 09 No Actions inspection testing maintenance repair Component inspected Date Table 7 1340 000
173. ed 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 Evaluation of foreign substances found in the oil 1 The maximum permissible quantity of foreign material measured by weight is 0 1596 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 These repairs may only be carried out by specialists with appropriate equipment knowledge f 9 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 Inspection the drive device breaks Check the brakes at the same check the drive devices 0066340 200 07 If the brakes cannot hold the specified test load of 33 tension increase 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 ABS Only qualified personnel with specialized knowledge can
174. ed 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 A Caution Cable plug which is not used should be protected by seal cover Electrical connection to Load Moment Limiter See the Installation Guide amp 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
175. ed 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 04 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 ETF yellow warning and the buzzer sounds meanwhile showing the icon AJ 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
176. el switch operate control lever Do not press this switch when crane winch is operated 1 Put the master lighting M mp working floodlight m on the 274 position before switching on the 0066340 200 04 2 After putting the master lighting switch the 274 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 60 63 0066340 200 04Y C 51 52 53 p Jeden m QD D QD Ce P ORC 201 Y 4 OC UR Ot S05 Manual Throttle Knob Right control panel 55 56 58 59 61 62 64 No 51 52 53 54 0066340 200 04Y C Components on right control panel Names of the components H2 Control Switch Manual automatic accelerator switch 1 Switch Hoisting bypass 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
177. 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 07 Actual used proportion 5 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 1 x 216h 216 h 0 125 Remaining theoretical service life D1 1600 216 1384h 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 2 x192h 384h 0 125 Remaining theoretical service life D2 1384 384 1000h Do the same for the rest calculation 0066340 200 07 7 4 Inspection of load hook The load hook must be inspected annually by a competent inspector These inspe
178. en 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 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 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 A 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 tens
179. ence of Main boom assembly sequence of main boom length ft main boom sections length ft sections 65 7 G11 G12 17310 G114 G144 3xG15 G12 75 5 G11 G13 G12 183 8 911 4 015 G12 85 3 G11 G14 012 1936 G11 G13 4xG15 012 951 G11 G15 G12 2034 G11 G14 4xG15 012 104117 011 G13 G15 012 Q1327 G11 5xG15 G12 1149 G11 G14 G15 G12 223 G11 G13 5xG15 G12 1247 G114 2xG15 G12 232 10 G11 G1445xG154 G12 1345 G114G1342xG154 G12 Q42 8 G1146xG15 G12 144 3 G11 G14 2xG15 G12 252 6 G11 G134 6xG15 G12 15417 G114 3xG15 G12 2624 G11 G14 6xG15 G12 1640 G11 G13 3xG15 G12 272 2 G11 G13 G14 6xG15 G12 Principle for assembling main boom when connecting main boom intermediate sections always bolt the shorter intermediate sections first A 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
180. ent 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 oy eo re rz 5 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 1 oo Connecting parts Part uu f Description Illus
181. ers or the hazardous r 5 0063640 200 03 area is not fenced off 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 All employees shall be kept clear of loads about to be lifted and of suspended loads A 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 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 Shut down the engine and cut off power Check if there is leakage in someplace a
182. ewed 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 A 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 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 A 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 E
183. f hoisting winches oOx High speed switch A 4 Right control lever 5 Hip 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 0066340 200 04
184. 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 A 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 2x depth of trench A2 2xT Hard or grown soil 1xdepth of trench Al 1xT A 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 pressu
185. ffing 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 91 8 a Luffing jib front anchoring rods When main boom is 755 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 ot To luffing jib Ed VER ARE C VET OES Sive NN VVVATIUTO AAAAAA M ni NU i A S fa Wal J AA i Tension force sensor To WA frame 1 0066340 200 05Y C Component parts of luffing jib front anchoring rods Part No Description illustration D 1 Cotter pin 2 1501234 1997 0 24 x3 2 2 Pin spindle 7 3 Anchoring rod eS d 4 Pin spindle DD fec a le owe 5 Coupling link 6 Cotter pin d 1501234 1997 0 4 x3 6 tat 7 Pin spindle 5 8 Double anchori
186. figurations when it is operated on firm and flat ground 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 Clearly define the area of responsibility of all personnel concerned Type of crane operation and required working mode Distance between the lifting points and surrounding buildings Influence of communal facilities including the overhead high low voltage lines and underground gas pipes Space requirements at the work site Movement restrictions due to surrounding structures e g is there another crane nearby in working Number weight dimensions material of load s to be lifted Required lifting height and slewing radius Load bearing capacity of soil or surface to be operated upon Height and widths of thoroughfares leading to the site Other factors affecting the site e g weather live lines etc Communication means adopted between signalman and crane operator Take appropriate measures to keep people unconcerned and equipment away from the working area Eq
187. 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 rows 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 04 Its 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
188. fting 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 2 Detach the load from the hook and set it down the ground if necessary lower the boom frame Apply slewing brake or lock slewing mechanism 422 Apply parking brake Lock traveling mechanism g 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
189. g jib pivot section together with WA frames 1 and 2 from the main boom 0066340 200 05Y C head A 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 main boom sections 4m reducing section luffing jib sections 613 614 615 G29 G22 623 624 G25 0066340 200 05Y C Connecting parts Part No Description illustration Double tapered pin Retaining spring Double tapered pin Retaining spring 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
190. ged 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 x 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 A Note il A general overhaul of the winch is required not later than 10 years after putting the crane into service 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
191. ges roofs or high voltage wiring Incorrect assembly or disassembly of booms 3 2 1 2 Safety instructions for the rigger 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 With crane operation certificate Be qualified with the work in hearing eyesight and reaction ability Be strong enough to carry hook or component Be able to estimate the load balance the load and judge the distance height and clearance correctly Be trained in the skill of handling load Be able to choose proper load handling device and components according to the loading condition Be trained in hand signals for operation and familiar to use them Be able to safely use audio equipment such as interphone to send out oral order exactly and clearly Be capable of conducting the operation of crane to move the load safely 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 a
192. gulations must be observed when disposing of waste Improperly disposing of waste can threaten the environment and ecology and is illegal Potentially harmful waste used on this equipment includes such items as oil fuel coolant filters and batteries ect Use leak proof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact Machine disposal This machine must only be disposed of at a specialist machine breaker 1 6 Personal protective Equipment PPE a b Loose or baggy clothing can get caught in running machinery 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 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 Always wear correctly fitting personal protective equipment Recommended personal protective equipment includes 1 Hard Hat Safety Glasses Goggles Hearing Protection Close Fitting Overalls Safety Boots 0066340 200 01 Y C 6 Industrial Gloves 7 High Visibility Vest or Jacket 1 7
193. h 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 b After being dismembered the crawler crane be transported by 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 During transportation all component parts should be fixed to prevent them from jostling and sliding 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
194. h 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
195. h will cause damage to coupling A 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 1 Central counterweight plate weight 14600Ib x2 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
196. hium with gun base grease 3 E k ZL 2 lithium Luffing jib main shaft 2272 Inject with gun base grease 4 E k ZL 2 lithi WA frame shaft Inject with gun eek base grease amp th ZL 2 lithi 5 Upper ower pulley very mon ithium block spindle base grease 6 Auxiliary hook swivel Every month ZL 2 lithium Inject with gun spindle base grease 7 Main hook swivel spindle Every month ZL 2 lithium Inject with gun base grease 8 Derricking rope according to ZL 2 lithium working Grease base grease conditions 9 Hoisting rope for winch 1 according to ZL 2 lithium working Grease base grease conditions 10 Hoisting rope for winch 2 according to ZL 2 lithium working Grease base grease conditions A Note oil periodically 5 Switch off engine before lubrication 1 Theoil cup and the surface to be oiled should be wiped clean before adding 2 The sliding surfaces which are not listed in above table must be greased 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 6 Keep ladder platform and guardrail clean and dry When climb the crane tighten safety belt Otherwise the operator may fall down from crane 7T 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
197. hown 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 07 Since 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
198. ifted in advance 1 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 capacitie
199. ight anchoring rods 4 To anchoring rods of heavy duty boom To luffing jib head Combination of light anchoring rods of 3117 light duty boom A 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 zl 7 7 LI d lo zm I Jj To anchoring rods To13 1 reducing section Intermediate tensioners for 3019 and 311 7 long light duty boom To anchoring rods To13 1 reducing section Component parts of intermediate tensioners Component parts of intermediate tensioners Fan Description Illustration No a N 07 SE J 1 Double anchoring O a D rod p Paus 0066340 200 05Y C i 2 Pin spindle 3 Single anchoring rod S E E Y t 01 8 4 Single anchoring ET _ rod 2 N _ 5 Double anchoring SL Ne
200. ime 0066340 200 06Y C Wire rope Clean and lubricate in time 6 6 7 2 Lubrication and maintenance under coast circumstances Item Measures Lubricate all lubricating points and joints which have not been fitted with grease Lubrication 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 When add the oil the Manual for Engine oil of different brands CH 4 CG 4 of API classification or different quality The 25 C 10C 15 C grades can not be ambient 20 C 20 C 40 C mixed The volume of Engine oil temperature all replaced oil is 35 when liter engine starts Viscosity of SAE10W 30 SAE20W 30 SAE15W 40 engine oil Use fuel suitable for following temperature Ambient temperature Type Above 5 C JIS 2 light diesel oil iel Between 5 C and 15 C JIS 3 light diesel oil Below 15 C JIS special 3 light diesel oil Drain water before working and top up oil tank after working 0066340 200 06Y C Make proper proportion of antifreeze fluid to water in accordance with ambient temperature volume of coolant 43 liter Sometimes proportion is different accor
201. ine fuel 700 liter Note The sign X 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 A 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 Coolant checks and coolant change interval No Inspected item in hour Volume 5 100 250 500 1000 Check coolant level 2 Change coolant 43 liter A 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 wa
202. ing up flex fingers in and out as long as load movement is desired USE MAIN HOIST Tap fist on head then use regular signals LOWER BOOM Arm extended fingers closed thumb pointing downward LOWER THE BOOM AND RAISE THE LOAD With arm extended thumb pointing down flex fingers in and out as long as load movement is desired Fig 17 Standard Hand Signals for Controlling Crane Operations SWING Arm extended point with finger in direction of swing of boom TRAVEL Arm extended forward hand open and slightly raised make pushing motion in direction of travel TRAVEL One Track Lock the track on side indicated by raised fist Travel opposite track in direction indicated by circular motion of other fist rotated vertically in front of body For land cranes only 0063640 200 03 CY STOP Arm extended palm down move arm back and forth horizontally DOG EVERYTHING Clasp hands in front of body EXTEND BOOM Telescoping Booms Both fists in front of body with thumbs pointing outward EMERGENCY STOP Both arms extended palms down move arms back and forth horizontally TRAVEL Both Tracks Use both fists in front of body making a circular motion about each other indicating direction of travel forward or backward For land cranes only RETRACT BOOM Telescoping Booms Both fists in front of body with thumbs pointing toward each other Fig 17 Standard Hand Signals for Controlling
203. ing 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 151 or 251 on the main screen of display will flash The icon 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 M 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 V WR c the buzzer will sound continuously and the icon is shown on the display at the same time 0066340 200 04 1 Bypass means when lowering appears 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 need
204. intenance and repair work is performed Check lowering limiter boom angle indicator tilting back supports and other safety devices for functional work Check the load bearing parts carefully such as wire rope hoisting rope derricking rope and sling etc boom frame support cylinders and load hook Check if there are some bolts nuts and pins lost and the components are cracked or damaged 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 Check the fuel lines and the hydraulic oil lines for leakage Check if the values shown on instruments are correct after starting up the engine Check if control mechanisms are working normally 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 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 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 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 holdi
205. ion Installation position 206 anemometer Main boom head 207 Warning lamp 2 Main boom head 208 Main boom junction box Main boom head Control box for Load Moment Main boom head 209 M Limit on luffing jib 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 Roe Hm I p M 213 5 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 Connected with hoisting rope on luffing jib head DIEM Luffing jib head connected with hoisting limit 216 Hoisting limit switch Switch weight 217 Luffing jib junction box Luffing jib head 218 Luffing jib tension force Luffing jib anchoring rod sensor 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
206. ion or provide forced ventilation Observe the regulations in force at the respective site Dust found on the plant or produced during work on the plant must not be removed by blowing with compressed air 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 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 No welding should be undertaken on this equipment as it will affect its structural integrity Avoid all naked flames in the vicinity of this equipment 1 13 4 Hydraulic equipment a b Work on hydraulic system must be carried out by persons having special knowledge and experience of hydraulic system Check all lines hoses and screwed connections regularly for leaks and obvious damage Repair damage immediately Splashed oil may cause injury and fire Always relieve pressure from the hydraulic system before carrying out any kind of maintenance or adjustment 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 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
207. ioned 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
208. isting limiter boom angle indicator tilting back support and other safety equipment for functional work Check the load bearing parts carefully such as wire rope hoisting rope derricking rope and sling etc boom outriggers hook and load handling devices Check if there are some bolts nuts and pins lost and the components are cracked or damaged 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 Check fuel lines and hydraulic oil lines for leakage Check all control mechanisms for functional work after starting up the engine Check all control devices for functional work Check the brakes Test the braking performance by lifting a load away from the ground and suspend it in the air for a moment Check whether lubricating oil grease or anti freeze liquid is sufficient Check for contamination 0063640 200 03 CY The following improper operating errors which are made again and again while operating should be avoided i Slewing too quickly quick braking of the load diagonal pulling of the load to be lifted which is still in contact with the ground Loose wire rope formations overloading or improperly attaching the load driving or slewing too fast with a load or setting up and loading on an uneven surface diagonal pulling breaking away stuck loads swinging of suspended load crashing into brid
209. it downward reel off W1 to lower luffing jib Push it upward slew the superstructure to the left 124 Slewing mechanism switch 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 4 6 Rope reeving 0066340 200 04 Select proper load hook 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 1 N VERON 3 i YO CN AR a n
210. ith 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 A Note The main boom lifting height curve is drawn without considering boom deflection 2 4 4 1 Lifting height on S amp SL boom A Note 1 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 A 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 30 0066340 200 02Y C 2 4 4 3 Lifting height on SFV boom heavy fixed jib combination A Note 1 The horizontal direction indicates working radius in ft and the vertical direc
211. ively checked for damage or cracks 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 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 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 The anchoring rods if removed from boom frame for transportation must be re assembled according to anchoring rods configuration Check the anchoring rods for cracks wear and corrosion 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 scr
212. jib pivot section G27 WA frame 1 G28 WA frame 2 0066340 200 05Y C Connecting parts of luffing jib pivot section to main boom head Part Description Illustrations No T S p 17 Locking plate a g 18 Bolt 1504017 1999 12 1 4 8 8 19 Washer 0 48 20 Pin spindle 1504017 1999 M16x2 2 8 8 22 Washer V 0 64 0066340 200 05Y C 23 Locking plate 24 Pin spindle rJ L pu 25 Retaining spring EST 5 S 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 G21 luffing jib pivot section G23 3m luffing jib intermediate section 0066340 200 05Y C G24 luffing jib intermediate section 25 9 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 Description Illustration No 21 8 Double tapered pin s Retaining 2 4 A spring
213. king winch are limited The tricolor light sends out yellow early warning and red warning continuously The buzzer sounds continuously The ied 5 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 04 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 S and are shown on the display A CAUTION 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
214. 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 A Note boom 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 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 A 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
215. lighting switch Working floodlight 40 5 c4 Control all the working floodlights on the crane switch Cold start on off 41 ve Control the cold start of the engine switch 42 Controller power Control the power supply of PLC controller and supply switch LCD screen Names of the 0066340 200 04 Fecker ewitches The key Remarks Front windshield 43 POEMA Control the front windshield wiper wiper switch E 44 Low speed switch E For details please refer to section 4 5 Automatic eT Lubricate the superstructure lubricating points 45 lubrication system 4 automatically switch Front windshield m 46 PE Control the front windshield washer washer switch Oil cooling NN 47 Pressing this switch can cool the hydraulic oil switch lel 9 y 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 RN 5 the engine can be saved In normal situation Engine shutdown XR 7 48 using the ignition key switch to stop the engine switch M is prohibited Ensure that this switch is not pressed down before engine startup Otherwise the crane cannot be started 49 SETUP switch m For details please refer to section 4 4 To carry out traveling movements the operator must first press the traveling switch and then 50 Trav
216. ll 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 To cable drum y REN Anemoscope hoisting limiter for H2 5E AO c 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 suppor
217. m 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 23172 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 8 9 8 408 s 8 6 8 2 8 9 10 1 9 fr 22 To A frame 6 9 8 6 8 9 8 8 9 8 68 s 9 amp light EN anchoring rods Anchoring rods of heavy duty boom it length is 23172 A Caution For part number of main boom anchoring rods please see Section 5 7 1 3 Combination of anchoring rods of heavy duty boom 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 2820 light duty boom To anchoring een rods of heavy duty boom To luffing head fH 9 12 i 9 2 N10 17 119 2 0066340 200 05Y C Component parts of light anchoring rods Part
218. m 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 Setup 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 06 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
219. m 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 A 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 A 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 the assembly mode will change to operating mode automatically move the left control le
220. 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 A 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
221. me 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 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 Extension torsion in torsion free hoisting rope and its elimination 1 Atorsion 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 07 Caution if this is not observed the 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
222. me 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 rear tilting back support of fixed jib Connecting parts 7 illustrat escription illustration 2 Pin spindle 4 D 3 Cotter pin 1501234 1997 0 32 x2 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 A 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 A Caution The winding of wire rope should be supervised by a person appointed and no person is standing within danger zone during operation f
223. mm 33 5 1180mm 3 10 TN A DRL o _ i 1 WA frame 1 G27 600mm 1 11 10210mm 33 5 s Y Tilting back support of luffing jib G7 1 X Dm LO 9 1 8 8 Tilting back support of WA frame 2 G72 yo 125 Tiling back support accumulator cylinder for WA frame 1 G73 pac 8 8 n 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 assembly sequence of Luffing jib assembly sequence of luffing jib length ft luffing jib sections length ft sections 90 21 024 2 625 022 sion 21 3 025 022 m G214623 3x625 622 21 024 3 025 022 m G21 G29G24 3xG25 G22 108 3 G21 3xG25 G24 G24 G22 118 1 G21 G23 G24 G24 3xG25 G22 1277117 G21 G23 2xG25 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 lu
224. movements of main boom derricking winch Description 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 Right control lever boom Return to neutral Main boom derricking winch stops working position 0066340 200 04Y C 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 E M Y A Ay Ay S 5 B 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 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 Right control lever Boos Return to neutral Main boom derricking winch stops working position 0066340 200 04Y C 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 lowe
225. n Failing to observe this regulation may result in death or serious injury 6 1 1 1 Basic requirements for crane maintenance The maintenance worker should wear specified clothes during maintenance The crane should be set up on level and firm ground where a warning board marked Inspection is placed around the crane Use ladder and safety belt when working in high position 2m above the ground When there is a need to move the crane for maintenance the operator must operate the crane according to the signals When inspecting or maintaining the hydraulic system dust and impurities are not allowed to enter into the system If several parts need to be repaired and adjusted please repair and adjust them immediately If the crane needs to be repaired the customer must contact a local service station of Mobile Crane Branch Company of Zoomlion In order to ensure the performance of the crane please use the accessories and lubricating grease specified by Zoomlion The expendable parts such as filter cartridge must be changed in time to avoid the malfunction If uncertain failure is found during inspection or maintenance please contact a local service station of Mobile Crane Branch Company of Zoomlion 0066340 200 06 Place crane where it will cause the least interference with other equipment operations in the area 1 Set all controls in the off position and ensure all operating features are secured fro
226. n 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
227. nation of main boom anchoring rods is shown in following diagram 44m 38m 23m 20m 5700 300 2700 300 2700 0066340 200 05Y C il mam 2900 oe 6 600 5700 3 2700 00 5700 300 5700 300 2700 oL 5700 fao 2700 300 2700 400 i200 1100 420 360 300 3 6 8 9 8 9 8 6 3 9 8 6 3 9 8 9 0 13 600 5700 300 2700 300 2700 300 5700 300 2700 300 5700 300 2700 300 2700 400 420 1200 p A 420 360_ 300 38100 3 6 9 8 6 8 9 8 6 8 9 8 9 10 13514 07 570 300 2700 5700 300 2700 570 300 2700 300 2700 1 4001 420 oo 300 L 35100 3 6 8 9 8 6 8 6 8 9 8 9 10 11 13 14 17 18 300 2700 400 420 1200 Pm 1100 15 11001420 360 500 19 88 22 eoo 5700 300 2700 300 5700 300 5700 300 2700 32100 1420 560 500 55 56 2180278 ay 262 248 6 8 9 8 9 10 1 13 14 17 18 19 22 600 5700 300 2700 300 2700 300 570 2700 2700 400 420 mo xx so 1100 420 360 500 29100 3 6 6 9 9 10 15 eoo 5700 300 2700 300 5700 500 2700 300 2700 400 420 1200 300 300 1100 420 360 300 3 6 8 9 6 8 9 100 1 13 14 17 18 19 M 22 0 1 5700 oo 42 200 500 300 11
228. nd repair it if necessary Clean such components as movable parts and exposed part of the piston rod of cylinder 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 Record the operating conditions and abnormal symptoms Check if the quantity of tools and accessories meet specified requirements Lock the operator s cab or safety devices Take precaution measures against storm or lightning strikes Take precaution measures against frostbite in winter 0063640 200 03 CY A 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 A 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 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 per
229. nds are fixed on the left side plate of bottom section of A frame 0066340 200 05 Y C Quick release coupling Mounting plate for quick release coupling Fit together the protective covers of the hydraulic couplings and hydraulic connectors A 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 05 Y C A 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 exampl
230. ner 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 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
231. ng L d rod Reducing piece single 0066340 200 05Y C 10 1501234 1997 0 4 x4 8 11 Pin spindle Reducing piece 12 double Single anchoring 4 gt 13 4 b p rod WI o d d 14 Coupling link o 15 Pin spindle 16 Retaining pin lt H 0066340 200 05Y C N for LIN 7 pi K E ly Double anchoring rod l ds 228 18 Single anchoring DN Qu eee ENDE 2 a rod cd FUT 1 62 19 Single anchoring Ke m li v rod ll 4 20 Single anchoring C e l rod f f it 21 Double anchoring S L rod 22 Single anchoring rod uten NE o 70 M Ne d 23 Double anchoring oe rod 0066340 200 05Y C Dp i N 24 Single anchoring L M 4 rod 1 i 22 qu dis ER 25 Double anchoring
232. ng brake will work automatically when energy supply is switched off 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 5 Pressure testing joint Pressure testing joint 2 Toolbox assembly 3 Load handling device Flexible belt with two 10 11 13 1 a BEI UD E EMEN NE EN NN EE NN NEN NN ae ee IRL oe E CX NN pup 4 DE 2 5 009 5T 10000 ends fastening 6 2 Superstructure maintenance and inspection plan 0066340 200 06Y C Maintenance Serial Serncnent TM Inspection interval No method 1 Fuel pipe or hydraulic pipe Damage Visual inspection Visual 2 A frame Deformation and crack inspection Start up leakage Start up 3 Engine noise audiovisual inspection 4 Slewing brake Functional work Operation 5 Slewing lock Functional work Operation Operation and 6 Horn lamps and wiper Functional work visual inspection eee Visual 7 Air filter Blockage inspection 8 Pin Sneton rod and cotter Damage and tight fit usual pin inspection 6 2 1 9 Bolt and nut Tight fit inspection Every day or STE avery 5 10 Hoisting limiter Functional work Operation 11 Derricking limit switch Functional work Operation
233. nly 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 Reeve SYNC Nest E SYNC Up Most Down 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 e 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 0066340 200 04 After the A frame reaching the required position turn the synchronisation switch to neutral position 2 Operation of
234. nts and surrounding buildings Check influence of communal facilities including the overhead high low voltage lines and underground gas pipes Check movement restrictions due to surrounding structures e g is there another crane nearby in working Check number weight dimensions material of load s to be lifted Check required lifting height and slewing radius Check heights and widths of thoroughfares leading to the site Communication means must be agreed upon by both the signalman and crane operator Take appropriate measures to keep people unconcerned and equipment away from the working range A 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
235. 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 Connecting diagram of luffing jib rear anchoring rods Combination of luffing jib rear anchoring rods 00691 m 00 4 Tort 00 4 Toor 0081 Tort 00 0 Too 07 We it 8 7 94 z Hd 7 00561 00077 00 2 00 2 Toot 00 2 Toot 0281 Toor 00 2 Toor Tozer 9c Zt 91 Z 91 27 9 C Hg 27 CU 00522 00077 00 2 Tort 0022 Toot 00 5 07 0781 roo 00 7 Toor WC Th 9 91 2 vi 91 Z8 Let 0022 Tort 00 7 Tort 00 5 7 0072 Torr weer totoz Toor Tots We TL 91 Z 91 Z GI 91 Zl 7 9i EE 00582 00077 00 7 Tort 00 7 Tort 00 6 Tow 0072 Foo 0012 Toor 0781 Too T oo Too Toz WG epp gt z 9 Z 27 4 27 9 Hg 67 9 EE 0061 00077 00 2 Tort 00 2 Tort 00 5 Toot 00 2 Toot 00 5 Tort 0281 00 2 Toor Tozer Wee it 8 27 94 SI 7 9 2 707 27 Cw 0066340 200 05Y C b rear anchoring rods ing ji Connecting diagram of luffi ooste 0077 00 0 foo i 00 8 r 00 0 r 00 5 oor T 00 0 r 0081 foo oor 2 Lu 91 9I 91 SI 91 vl 91 l 00G 00077 00127700277 owz o T 0015 Foo ow
236. oad Push right control lever backwards the mounting cylinder will be retracted to lift the load 0066340 200 04 Extend mounting cylinder Right control lever etract mounting cylinder Operation of mounting cylinder When operating self assembly amp dismantling mechanism turn the W1 winch Assembly switch to right 4 5 10 Emergency control box Luffing Winc 0066340 200 04Y C Description of switches on emergency control box No Names of the switches Operation 117 Reserved Push it upward spool up 1 to lift main load hook 118 Hoisting winch 1 H1 switch 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 Push it upward main pump 1 is selected 120 Main pump switch Push it downward main pump 2 is selected 121 Emergency stop button 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 derrick boom and suspended ballast switch Push it downward reel off E to lower main boom or raise derrick boom when crane is operated with derrick boom and suspended ballast Luffing jib derricking winch Push it upward spool up W1 to raise luffing jib W1 switch Push
237. ocket and driven sprocket 2 lt 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 A 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 Ibs 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 A 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 Serial Inspection i Component Item interval No method 1 Upper amp lower pulley Deformation and crack Visual block inspec
238. ol 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 A 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 0066340 200 05Y C 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
239. om 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 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 07 It is recommended that the old should be removed prior to fitting a new rope If the old rope is used as a lead rop
240. ombination of light anchoring rods of 291 11 light duty boom A 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 Tensioning rope Part 10 of light anchoring rods single anchoring rod Part 17 of light anchoring rods Double anchoring rod EM ASIF B 7 N 7 g V x 131 reducing Section Connecting position between tensioning and light anchoring rods 8 10 y 19 To anchoring rods of heavy duty boom nm To luffing j FU jib head pe 420 L 1160 420 300 1400 500 4000 Combination of light anchoring rods of 301 9 light duty boom A 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 long light duty boom 3117 long light duty boom Part 10 of light anchoring Tensioning rope P NI 7 Part 17 of light anchoring ro rods Double anchoring rod 131 reducing Section Connecting position between tensioning rope l
241. on 32 9 6659 1 G12 Main boom head 32 9 7452 9 G13 Main boom intermediate 9 10 1587 6 section G14 Main boom intermediate 19 8 2646 0 section G15 Main boom intermediate 29 6 3924 9 section G17 A frame 6923 7 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 9 10 705 6 section G24 Luffing jib intermediate 19 8 1323 0 section G25A Luffing jib intermediate 29 6 1764 0 section G25 Luffing jib intermediate 29 6 1323 0 section G27 WA frame 1 3351 6 G28 WA frame 2 3836 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 273 3 section G37 FA frame 1653 8 G70 Titling i itling back support of main boom G71 titing Back SUpport of T lufffing jib G72 Rear unig support of TT luffing jib G74 Front tilting back support of fixed jib G75 Rear tilting back support of fixed jib A 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 ri
242. on 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 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 When the upper angle between main boom and luffing jib is more than 10 and less than 15 the luffing jib will move slowly 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 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 04 4 4 6 Lowering limiter Lowering limiter In order to prevent wire rope from be
243. ontrol 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 b Deformed cracked or corroded members the crane structure and boom Loose bolts or rivets Cracked or worn sheaves and drums ee Worn cracked or distorted parts such as pins bearings shafts gears rollers and locking devices e Excessive wear on brake
244. ontrol 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 00 20 Foreword Thank you for purchasing ZOOMLION crawler crane produced by Changsha Zoomlion Heavy Industry Science amp 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
245. ook 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 h 0063640 200 03 CY Stop the crane immediately if somebody is found climbing the crane Operator who is in low spirits or poor healthy is not allowed to operate the crane Crane operator and slinger banks man should be familiar with safety rules signals and symbols Prohibit drinking and driving 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 Be familiar with the usage of fire extinguishing equipment and be well trained know how to survive under emergent conditions 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 b Check the daily record of work to ensure that all regular inspections maintenance and repair work is performed Check the ho
246. ope guidance and reeving Derricking pulley in A frame To balance beam Derricking pulley at the tail end of slewing table Derricking pulley 2 Main boom at the tail end of or 2 derricking winch Main boom derricking winch slewing table 0066340 200 04Y C 4 6 6 luffing jib derricking rope guidance and reeving WA frame 1 WA frame 2 Hoisting winch 1 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 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 Counterweight plates must be fitted according to load capacity chart 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 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 Assembly of the boom must be done over th
247. ope pulleys K E n 0339363299 Rope pulleys OOS T 0 2 Qi AN i Si Reeving winch O Winch 1 573300 Ib load hook rope reeving 14 0066340 200 05Y C Attach the two ropes together R I I Hoisting winch 1 ope pulleys eecbeocpoc pulleys GOERS 1 eeepc Rope pulleys ODIO 2 32 AN Reeving winch O Winch 1 573300 Ib load hook rope reeving 12 the two ropes together WOR R lleys I Hoisting winch 1 2 5 Rope pulleys Rope pulleys y Reeving winch 0 5 A Caution 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 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 A 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 203 202 201 X15 X16
248. operly because seized therefore closed exhaust flaps during operation will cause increases in temperature and considerable overheating 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 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 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 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 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 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 cr
249. or s cab from transport position to working position and then secure it with fixing pin for swivel arms Fixing for le swivel arm Er Fi Slewing table pala irection J eee on 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
250. or tight fit and shakes loose and shaken rope pulley means that the bearing and bearing bush is damaged A 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 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 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 Enamel coating The anchoring rod coating must be inspected
251. oring rods Part T No Description illustration Double 7 anchoring rod NES d D zi D Nek J ps de Pat 2 Pin spindle Y E NUM 9 Retaining pin Reducing _ 4 double anchoring rod E E 2 j Reducing g 5 single anchoring rod f 0066340 200 05Y C 1749 d 18 5 ing e q GM um i Y 6 i 72 7 des m TZ 7 Double H H anchoring rod T E BU 8 Cotter pin 1501234 1997 0 4 3 6 1 9 Pin spindle io ij A 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 1 6 When fixed jib is 394 long the corresponding front anchoring rods is 49 0 long When fixed jib length increases by 19
252. osition support Place the switch 110 in RL support cylinder position and then push the cylinder Retract toggle switch 116 to Retract position Note the switch 116 is self return switch Release it after the cylinder is retracted to prescribed position Place the switch 111 in FR support cylinder position and then push the Front toggle switch 116 to Extend position Note the switch 116 is a self return right Paena switch Release it after the cylinder is extended to prescribed position support 0066340 200 04Y C cylinder Place the switch 111 in FR support cylinder position and then push the toggle switch 116 to Retract position Note the switch 116 is etrac 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 toggle switch 116 to Extend position Note the switch 116 is a self return Rear right Switch Release it after the cylinder is extended to prescribed position support Place the switch 112 in RR support cylinder position and then push the cylinder Retract toggle switch 116 to Retract position Note the switch 116 is etrac 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
253. ould 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 A 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 ca
254. ound 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 Coe EE D 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 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
255. 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 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
256. plete 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 06 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
257. 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 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 relia
258. 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 A 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 dr
259. re Soil type 107 back filled not naturally compacted ground LO MERI B Natural soil apparently undisturbed 21 0063640 200 03 CY 1 mud peat marshy soil 3 non cohesive sufficiently compactly layered soil Fine to medium grained sand From coarse grained sand to gravel 3 cohesive soil loamy soft Stiff Semi solid hard rock with few fissures in healthy un weathered condition and in a favorable location In cohesive layer order In massive or column style shape C artificially compacted ground 1 asphalt 5 15 3 concrete concrete group l 50 250 Concrete group II 350 550 A 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 360 deg See Note 1 9 i a idler tumbler Drive tumbler
260. rection cylinder 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 amp dismantling the A frame erecting mechanism serves as a mounting crane whose maximum lifting capacity is 55125lb 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
261. red via hoisting winch 1 or luffing jib derricking winch Crane operation with main boom with luffing jib A 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 0066340 200 04 Raise lower boom WI Winch Assenbl 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 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 Right control lever 9 boom Return to neutral Main boom derricking winch stops working position 0066340 200 04 Note Under crane operation with main boom with luffing jib main boom must be fixed at 65 75 or 85 position
262. 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 He 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 ln Reeve Winch Lut Turn the reeving winch switch to left then the reeving winch is spooled up 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 4 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 0066340 200 04 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
263. requirements Only fit replacement components of a type provided by the manufacturer Always practice extreme cleanliness servicing hydraulic components Hydraulic fluid under pressure can penetrate the skin causing serious injury Once the fluid is injected under the skin seek medical help immediately 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 01 Y 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 Description of the crane 0066340 200 02
264. rs Positioned by the upper limit plate of crawler carrier and undercarriage centre section 2 arate Upper limit plate of crawler of undercarriage ___ centre section A PRINS __ T Bolting tl cylinder A 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 e
265. s 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 2 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 A 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
266. s 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 A 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 01 Y C b Steps handrails tread plates and fixed guards are provided where personnel are required to climb on the machine 1 5 Environmental safety It is essential that the service intervals detailed in the maintenance procedures are followed to ensure that engine emission are kept to a minimum a b Consumable materials Diesel spillages must be dealt with immediately Only use the Lubricating Oils recommended in the maintenance schedule Local and National re
267. s 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
268. scripti illustrati m escription illustration 1 sleeve 5 2 2 Cotter pin 3 1501234 1997 0 16 x1 2 3 Nut 1504032 1999 M20 8 4 Bolt H 1504014 1999 M20x 8 8 8 Anchoring rod an oh 01 0 Single anchoring d p rod us Double anchoring i ET 4 P unu s DR Z 0066340 200 05Y C 8 Pin spindle l 9 Retaining pin UT 10 Single anchoring 7 rod _ 4 01 6 ns 11 Coupling link 12 Double anchoring rod 13 Reducing piece PS or gt 14 Pin spindle 0066340 200 05Y C 15 Cotter pin 2 1501234 1997 0 4 x3 6 Reducing double mu B anchoring rod A 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
269. 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 L 477 i Pull the lever upwards the front of the seat is raised up Pull the lever upwards the rear of the seat is raised up Press your back gently against the backrest Pull the lever upwards The backrest tilts backwards pull the lever downwards The backrest automatically tilts forwards 0066340 200 04 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 A 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 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
270. 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 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 crane is properly supported and level b The counterweight plates have been attached in accordance with the lifting capacity charts c Select appropriate boo
271. sist 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 irc Wire Main boom derricking winch Derricking crown block Derricking mechanism 0066340 200 04 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 A 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 F ule _ 2 Switch off traveling switch prior to operating crane winches 0066340 200 04 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
272. sk of accidents 0066340 200 05 Y 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 G17 0066340 200 05 Y C Main boom pivot section G11 eS oJ 5 i y Main boom head G12 LE 9 10 main boom intermediate section G13 1 a ST Iz 1 19 8 boom main intermediate section G14 29 6 main boom intermediate boom section G15 0066340 200 05 Y 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 assembly sequ
273. sonnel 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 0 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 Aninsulator is required at all times between the crane load hook and tackle It is strictly prohibited to remove this insulator 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 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
274. spectively 0066340 200 04 When front windshield needs to 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 put the master lighting switch on the 274 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 2 position then the engine is started Start the engine 0066340 200 04 1 When ambient temperature is higher than or equal to 10 C 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 999 will flash After the engine is preheated it will go out 3 When ambient temperature is lower than 10 C the operator must actuate engine cold start device first and then start the engine When engine cold start device i
275. spector The diagrams are only examples and are not necessarily 100 complete Welding joints on main boom lt lt 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 07 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 o Every 1000 operating hours at least once a year annually 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 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 Checking for foreign substances This inspection should be carried out in a qualifi
276. st 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 section of crawler when crawler crane is traveling over Remove the undulation Gentle slope Slope treating diagram A 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 0066340 200 04 Traveling with suspended load The crane can travel with suspended load providing that the following precautions are taken 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 crane can travel with a load of
277. sting 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 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 rear tilting back support of fixed jib 0066340 200 05Y C Connecting parts da Description Illustration No P 2 Pin spindle Y 3 Cotter pin 1501234 1997 0 32 x2 4 A 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
278. t a time Qualifications for signalman a b Familiar with the lifting task so as to cooperate with crane operator and other workers Make sure that only authorized personnel are allowed to carry out work Be qualified with the work in hearing eyesight and reaction Be able to estimate the distance height and clearance correctly Be trained in hand signals for operating and familiar to use them Use standard hand signals for crane operation If necessary use a radio device to send out correct and clear order Be capable of conducting the operating of crane to move the load safely Position himself in a safe location from where he can see the whole process of operation and be seen clearly by the crane operator A 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 All the persons in vicinity of crane must observe the acoustic warning signals of the machine so as to ensure himself and others safety All the worker must know about the content of task and working sequence Check whether dangerous situations occur during operation of the machine and inform crane operator and signalman of the unsafe
279. t cylinder Right counterweight Push up Right counterweight cylinder extends Lis 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 m switch Push down Lower A frame Its function is the same as that of emergency shut down 105 Emergency stop switch button on the right control panel 0066340 200 04 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 ic N Push down Reel off reeving winch Its function is the same as that of Reeving winch rotary Switch on the right control panel A 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 109 113 110 111 112 Qutlrigger utTrigger right back 114 115 116 0066340 200 04Y C Description of switches on the undercarriage remote control box No Description 109 Changeover switch FL support cylinder left crawler carrier extension
280. t of luffing jib socket 2 pin not assigned Hoisting limit switch for 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 A caution Cable plug which is not used should be protected by seal cover c Electrical connection to Load Moment Limiter See the Installation Guide amp 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 scre
281. tch 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 0066340 200 04 4 2 Instruction for digital display system 66 L Digital display system Function No Description Display the current working condition of crane Display of load moment limiter Display of control system 65 66 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 ty ah wo 151 194 25T 251 Ae 10 ES we 10 2000 Wind grade 0 Bee Voltage Charge
282. ted to stop slewing movement or change slewing direction jerkily 4 Longer boom slower slewing speed 5 Heavier load slower slewing speed 6 Itis not permitted to slew the superstructure on the trailer 7 n 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 Winch Left control lever left and right right control 1 lever forwards and backwards 2 Slewing mechanism and Left control lever left and right right control derricking mechanism lever left and right 3 Slewing mechanism and winch Operate the left control lever in 20 70 2 range 4 Winch 1 and derricking Operate the right control lever in 20 70 mechanism range 5 Winch 2 and derricking Left control lever forwards and
283. tention 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 3 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 Unauthorized personnel are prohibited to maintain the crane and replace the parts 0066340 200 06 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 b Check the daily record of work to ensure that all regular inspections ma
284. ter tank A 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 A 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 t
285. th 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 06 All rope which has been idle for a period of a month 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 Rotation resistant rope shall be given special care during installation as it is easily damaged 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 com
286. thorities 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 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 ll operational aids and alternative measures Operational aids listed in this paragraph that are not working properly must be repaired no later than 3
287. ting 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 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 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
288. tion 2 Load hook and safety Damage and tight fit Visual catch inspection 3 Deformation damage and Visual Rope support wear inspection 4 Deformation damage and Visual Rope pulley wear inspection 5 Main boom and Deformation and damage inspection Every day or 6 Connecting pin Damage and tight fit Visual every 5 anchoring rod and lock inspection hours pin 7 Tight fit Visual Bolt and nut f SS inspection 8 Tilting backsuiagert Deformation and damage inspection 9 Deformation and damage Visual A frames inspection 10 Deformation damage and Visual Wire rope inspection 11 ond od ando The SONNE that may Vispa impair safety inspection Note The serial number in above table should be consistent with that in the following context 1 Upper amp lower pulley block Check upper amp lower pulley block for deformation and crack A Note It is prohibited to touch wire rope with bare hands Otherwise the operator will be injured by rope s convex section Keep yourself away from rotary drum and running wire rope Failure to observe this regulation may result in death or serious injury 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 06
289. tion 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 A 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 A 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 ifting Weight of load hook Capacity i 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 con
290. tion of crane winches A 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 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 0066340 200 04 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
291. tration No 1 Pin spindle 2 Cotter pin ES 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 c er 77 SCRA See nm TED ARN OTE Connecting parts Part f Description Illustration No 1 Locking bolt 2 Pin spindle 0066340 200 05Y C 3 Retaining pin i H 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 appropriat
292. uipment 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 A Caution 1 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 Ifthe 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 ina 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 h
293. uld 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 A A SS 22 222 i 2 ES SSS Proper method improper method The wire rope can be unwound fr
294. um 2 main boom pivot section 204 Main boom tension force anchoring rods of A frame sensor 205 Luffing jib derricking winch main boom pivot section optional 206 Main boom junction box Main boom head 207 Control box for Load Moment Main boom head Limit on luffing jib 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 Eidistinig Riincswiteh 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 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 warning hoisting mier for HI CN 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 us
295. unctional work Operation mechanism 6 2 3 27 Engine oil Change Every 3 28 Engine oil filter Change months or 29 Engine oil separator filter Change every 250 30 Filter cartridge of fuel fine filter Change hours 31 Filter cartridge of coolant filter Change 6 2 4 Visual 32 Slewing table Damage and crack Every 6 inspection months or 600 ond 33 Engine air filter Change hours 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 A 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 A 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
296. unning 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 The permitted temperature range for crane s operation is 20 C 40 C 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 No wind smoke rises straight up 22 Wind direction is shown only by observing the trail of PUT smoke
297. ver 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 A Caution 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 HI 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 A 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 co
298. vers 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 flow L min gpm at specified pressure psi and speed 2 285 L min 0066340 200 02Y C 2 3 3 Overall
299. vot 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 A Caution Cable plug which is not used should be protected by seal cover C Electrical connection to Load Moment Limiter See the Installation Guide amp 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
300. wards switch to the right then the cab will tilt forwards After it tilts to proper position turn the switch to neutral position Up Cabin Down 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 0066340 200 04 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 amp dismantling operation The functions of switches on it are shown in following figure 101 102 103 104 ERE AME Ft RES i RH LeftCountenweight Up RightCountdrweight Up CounterWeight Pin Out Mast Up at 4 gt ENE LeftCounterweight Down _ gt ARE M KEH f RightCounterweight Down Counter eight Pin In Mast Dom BRA Boom Pin Out Reeve Winch In FARIA Boom Pin In Reeve Winch Out 105 106 107 108 Auxiliary remote control box Instructions for switches on the auxiliary remote control box NO Name of switch Operation Function Counterweight left lifting Push up Extend left counterweight cylinder m cylinder switch Push down Retract left counterweigh
301. weight plates is carried out in the reverse order to assembling A 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 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 Inthe process of self assembly amp 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 G12 G15 G15 S Heavy duty boom SL light duty boom 0066340 200 05Y C G15 G15 SF Fixed jib on heavy duty boom SFV Heavy fixed jib on heavy duty boom 0066340 200 05Y C G11 G70 SW luffing jib on heavy duty boom G22 0066340 200 05Y C Description of part number of boom configuration Part number Description Length ft Weight Ib G10 Tip boom on main boom 441 0 head G11 Main boom pivot secti
302. witch Release it after the cylinder is extended to crawler i prescribed position carrier E E Place the switch 110 in Right crawler carrier extension cylinder position 2 and then push the toggle switch 116 to Retract position Note the switch cylinder Retract 116 is a self return switch Release it after the cylinder is retracted to prescribed position 0066340 200 04 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 Up Mast 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 amp dismantling refer to section 5 2 2 Operation of mounting cylinder on A frame v Winch Assenbly 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 l
303. 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 Reeve SYNC MasttE SYNC Turn synchronization switch to the left Reeve SYNC gear which is described as above 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 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 0066340 200 04 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
304. wlers 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 le
305. 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 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 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 01 Y C 1 13 2 Gas dust steam smoke and noise Always operate internal combustion engines out of doors or in a well ventilated area If plant is operated for maintenance purposes in an enclosed area ensure that there is sufficient ventilat
306. y of the rope is protected Improper methods gt N TERRAM Sa ot m 7 4 Ny m Proper methods MIT MM 0066340 200 07 7 7 2 Inspection of wire 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 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
307. 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 0066340 200 01 Y 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 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 instruction
308. ze 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 A 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 2 LEFT AST DUNTERWETCHT IGHT COUNTERWEIGHT D DUNTERWETCHT 1 21 Jl it EVERG

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