ZCC800HCG/F20Y

ZOOMLION ® Crawler Crane

ZCC800H
ZCC800HCG/F20Y
 ZCC800HCG/S20Y

CRAWLER CRANE
ZCC800H

ZCC800HCG/20Y

The operating manual is part of the crane！

Always keep on hand！
Comply with road travel and crane operating
regulations！

Zoomlion Heavy Industry Science & Technology Co., Ltd.

 ZCC800HCG/M20Y

Contents

0 Foreword ................................................................................................ 0066305-100-00-20Y

1 Safety instructions ................................................................................. 0066305-100-01-20Y
2 Description of the crane ...................................................................... 0066305-100-02-20Y
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 Crane undercarriage
2.3.2 Crane superstructure
2.3.3 Overall dimensions
2.4 Technical data
2.4.1 Main technical parameters
2.4.2 Type of load hook and selection of rope reeving
2.4.3 Rope reeving and specification of wire rope
2.4.4 Lifting height
2.4.5 Lifting capacity charts
3 Safety guidelines .................................................................................. 0066305-100-03-20Y
3.1 Operational planning
3.2 Safety technical notes
3.2.1 Safety instructions for crane operator
3.2.2 Safety instructions for the rigger
3.2.3 Safety instructions for the signalman
3.2.4 Points for attention for crane operating crew
3.2.5 Points for attention during crane operation
3.2.6 Safety signs
3.3 Slings
3.3.1 Slings introduction
3.3.2 Sling identification tags
3.3.3 Angle of choke
3.3.4 D/d ratio
3.3.5 Load angle factor
3.3.6 Load share
3.3.7 Load angle factor chart
3.3.8 Sling safety
3.3.9 Sling safety guide
3.3.10 Taglines
3.3.11 Load center of gravity
3.4 Requirements for operating site
3.4.1 Selecting an operating site
3.4.2 Slopes and trenches
3.4.3 Permissible ground pressure

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3.4.4 Checking safety measures

3.5 Underground cables
3.6 Checking safety measures
3.7 Crane operation with a load
3.8 Hand signals for controlling crane operations
4 Crane operation ...................................................................................... 0066305-100-04-20Y
4.1 Operating and control instruments
4.1.1 Operator’s cab, overview
4.1.2 Left control lever assy.
4.1.3 Right control lever assy.
4.1.4 Safety control
4.2 Instruction for digital display system
4.2.1 Load moment limiter
4.2.2 Dashboard
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 shut-down button
4.4.2 Load moment limiter
4.4.3 Boom angle indicator
4.4.4 Lowering limiter
4.4.5 Hoisting limiter
4.4.6 Derricking limiter
4.4.7 Anemometer
4.4.8 Inclination display
4.5 Crane operation
4.5.1 Operation of traveling mechanism
4.5.2 Operation of crane winches
4.5.3 Operation of slewing mechanism
4.5.4 Simultaneous operation
4.5.5 Crawler carrier extending & retracting mechanism
4.6 Rope reeving
4.6.1 Hoisting rope guidance and reeving
4.6.2 Derricking rope reeving
5 Assembly & dismantling ........................................................................ 0066305-100-05-20Y
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 rod
5.1.4 Erecting and lowering
5.2 Unloading of basic machine
5.2.1 Checks before operation
5.2.2 Unloading the basic machine
5.3 Fitting and Removal of counterweight
5.4 Available boom configurations for crawler crane ZCC800H

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 ZCC800HCG/M20Y

5.5 Combination of boom frame and anchoring rods

5.5.1 Main boom (S)
5.5.2 Main boom with fixed jib (SF)
5.6 Assembly and dismantling of main boom
5.6.1 Preparation for assemby
5.6.2 Assembly of main boom
5.6.3 Connect the electrics to main boom
5.6.4 Erecting main boom
5.6.5 Lowering and disassembling main boom
5.7 Assembly and dismantling of main boom with fixed jib
5.7.1 Preparations for assembly
5.7.2 Assembly of fixed jib
5.7.3 Connect the electrics to fixed jib
5.7.4 Erecting and lowering main boom with fixed jib
5.7.5 Dismantling main boom with fixed jib
5.8 Assembly and dismantling of tip boom
5.9 Weight and dimensions of main component parts
5.10 Transport means and safety precautions for transport
5.10.1 Transport means and safety precautions for transport
5.10.2 Other requirements
6 Maintenance .......................................................................................... 0066305-100-06-20Y
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
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 6 months or every 600 hours
6.3 Undercarriage maintenance and inspection plan
6.3.1 Maintain and inspect undercarriage every day or every 5 hours
6.3.2 Maintain and inspect undercarriage every month or every 100 hours
6.3.3 Maintain and inspect undercarriage every 3 months or every 250 hours
6.3.4 Maintain and inspect undercarriage every 6 months or every 600 hours
6.4 Boom frame maintenance and inspection plan
6.5 Maintenance and inspection for engine and high-mortality parts
6.5.1 Maintenance and inspection for engine
6.5.2 Maintenance guidelines for high-mortality parts
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

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7 Crane inspections ................................................................................. 0066305-100-07-20Y

7.1 General
7.2 Inspection of steel bearing structures
7.3 Inspection of hosting and derricking 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
7.7.2 Inspection of wire rope
7.7.3 Change of wire rope
7.7.4 Maintenance and care of wire rope
7.8 Inspection of oil and fuel tanks
7.9 Inspection of load bearing components
7.10 Inspection of engine
8 Additional equipment .............................................................................. 0066305-100-08-20Y
8.1 Air conditioning
8.1.1 Control panel for air conditioning
8.1.2 Methods for operating air conditioning
8.1.3 Maintenance of air conditioning system
8.2 Media Player

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 0066305-100-00-20Y

Foreword

Thank you for purchasing ZOOMLION crawler crane produced by Zoomlion Heavy Industry
Science & Technology Co., Ltd. We are glad to provide high-quality and high-efficiency
service for you.
The operating manual is intended to put you in a position to operate the crane safely and
utilize its capabilities to the fullest extent possible.
Certain terms are used in the operating manual, and in order to avoid misunderstandings
while operating, these terms should be used consistently.
Danger:
Only qualified and especially trained personnel are permitted to work on the crane!
If this is not assured, the chance of causing a serious accident is greatly increased!
All regulations and guidelines applicable to the job site, such as accident prevention
regulations and all guidelines and regulations stated in the Operating Manual must be strictly
adhered to.
All accident prevention and operating guidelines and regulations, etc. assume that the crane
is strictly used for lifting and transporting of loads, which are not stuck. Any other application
or use does not constitute specified and proper use.
Any risks associated with unspecified and improper use are the sole responsibility of the
crane’s owner, operator or user.
Using this instruction in the manual:

l makes it easier to become familiar with the crane

l avoids malfunctions due to improper operation

Observing these instructions in the manual:

l increases reliability in operations

l extends the service life of the crane

l reduces repair costs and down-time

Always keep the operating manual handy in the 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. All rights are expressly reserved in accordance with copyright laws.

The content with respect to the safety is marked with “ ”, the safety instructions involved in
the book are only the conventional contents.

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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.
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 devices
The safety devices built into the crane system deserve your special attention. They must
always be checked to see that they are functioning properly. If they do not function or function
incorrectly, the crane may not be operated. Your motto must always be Safety First.
Caution:
When welding work is conducted on crane, the operator should unplug all power
source plugs of controllers, otherwise, he should bear all consequences incurred.

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Chapter 1 Safety instructions
 0066305-100-01-20Y

1.1 Notes

a) Read this manual and familiarize yourself with any associated documentation before
operating this product.
b) Ensure that a copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
Training should be provided to ensure safe working practices.
Initial commissioning and staring must only be undertaken by a competent person who
has read and fully understands the information provided in the manual pack.
c) To avoid the risk of electric shock always isolate this equipment from the supply prior to
carrying out any maintenance adjustment or removing any guards or covers.
d) Always follow the procedures outlined in the operating and maintenance instruction.
e) If in doubt ask, do not take personal risk.
f) Only trained personal can be allowed to install, set, operate, maintain, and decommission
this equipment.

1.2 Alarms and warnings

To assure personnel safety, please observe all the following warnings.

a) You can be injured if you do not obey the safety instructions as indicated on warning
stickers.
b) Ensure that safety instructions and warnings attached to the plant are always complete
and perfectly legible.
c) Keep warnings and instruction labels clean.
d) Replace unreadable or missing labels with new ones before operating the plant. Make
sure replacement parts include warning or instruction labels where necessary.

Note:
For the position of warnings and instruction labels, please see 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.

1.4 Features for operator safety

a) Safety components – crane emergency stop buttons. Ensure all Guards are bolted down.

Steps, handrails, tread plates and fixed guards are provided where personnel are required to climb
on the machine.

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1.5 Environmental safety

1.5.1 It is essential that the service intervals detailed in the maintenance procedures are
followed to ensure that engine emission is kept to a minimum.

1.5.2 Consumable materials

a) Diesel spillages must be dealt with immediately.

b) Only use the Lubricating Oils recommended in the maintenance schedule.
c) Local and National regulations must be observed when disposing of waste.
d) Improperly disposing of waste can threaten the environment and ecology and is illegal.
e) Potentially harmful waste used on this equipment includes such items as oil, fuel, coolant,
filters and batteries, etc.
f) Use leak proof containers when draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them.
g) Do not pour waste onto the ground, down a drain or into any water source.
h) Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact.

1.5.3 Machine disposal. This machine must only be disposed of at a specialist machine
breaker.

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1.6 Personal protective Equipment (PPE)

1.6.1 Loose or baggy clothing can get caught in running machinery.

1.6.2 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.

1.6.3 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.

1.6.4 Always wear correctly fitting personal protective equipment.

1.6.5 Recommended personal protective equipment includes:

a) Hard Hat
b) Safety Glasses/Goggles
c) Hearing Protection
d) Close Fitting Overalls
e) Safety Boots
f) Industrial Gloves
g) High Visibility Vest or Jacket

1.7 Measured Noise Level

The product and local conditions will affect the noise levels.
According to EN13000 Annex G and 2000/14/ EC standards, the sound pressure level and
sound power level are 68.77 dB(A) and 100.87 dB(A) respectively.
The sound pressure level measured using ISO 7731 at the position 1 m away from the
warning device is 105 dB(A).

1.8 Vibration Levels

Suitable seating has been installed to reduce the risk of whole body vibrations, in line with
current industry standards.
According to ISO 2631-1:1997, the crane body vibrations is A(1): 1.4m/s2, A(4): 0.7m/s2, A(8):
0.5m/s2 under normal operating condition.

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1.9 Organizational Safety Measures

a) This vehicle must only be driven and the crane operated by a suitably qualified operative
who holds a current license in line with National/ International legislation.
b) Understand the service procedure before doing work. Keep area clean and dry.
c) Never lubricate, clean, service or adjust machinery while it is moving(excluding central
lubrication).
d) Keep hands, feet and clothing clear of power driven parts and in running nip-points.
e) Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Removed any build up of grease, oil and
debris.
f) Disconnect battery ground cable before making adjustments on electrical systems.
g) Disconnect battery ground cable and ECM connecting cable and unplug all plugs of
controllers before welding on machine.
h) During maintenance only use the correct tool for the job.
i) Never make any modifications, additions or conversions which might affect safety without
the manufacturer’s approval.
j) In the event of safety relevant modifications or changes in the behavior of the machine
during operation, stop the machine and lock out immediately and report the malfunction
to the competent authority/ person.

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.

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1.11 Safety Advice Regarding Specific Operational Phases

1.11.1 Standard operation

a) Take necessary precautions to ensure that the machine is used only when in a safe and
reliable state.
b) 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.
c) Ensure that any local barriers erected to stop unauthorized entry to this equipment are in
place.
d) Before starting the engine ensures it is safe to do so.

1.11.2 Malfunction

In the event of any malfunction or operational difficulty, stop the machine immediately.

1.11.3 Unguarded areas

a) In-running nip points on moving machinery can cause serious injury or even death.
b) Do not reach into unguarded machinery. Your arm could be pulled in and amputated.
c) Switch off the machine before removing any safety devices or guarding.
d) 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 Special Hazards

1.12.1 Electrical energy

1.12.1.1 External considerations and hazards

a) When working with the machine, maintain a safe distance from overhead electric lines.
b) If overhead cables are in the vicinity a risk assessment must be completed prior to
operating this equipment.
c) 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.

1.12.1.2 Machine - Electrical

The electrical equipment of the plant should 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.

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1.12.1.3 Battery

a) Always disconnect battery leads before carrying out any maintenance to the electrical
system.
b) Recharge the battery in a well ventilated area.
c) The battery contains sulphuric acid, an electrolyte which can cause severe burns and
produce explosive gases.
d) Avoid contact with the skin, eyes or clothing.
e) No smoking when maintaining battery.
f) Wear appropriate PPE.

1.12.2 Gas, dust, steam, smoke and noise

a) Always operate internal combustion engines out of doors or in a well ventilated area.
b) If plant is operated for maintenance purposes in an enclosed area, ensure that there is
sufficient ventilation or provide forced ventilation.
c) Observe the regulations in force at the respective site.
d) Dust found on the plant or produced during work on the plant must not be removed by
blowing with compressed air.
e) Toxic dust/ waste must only be handled by authorized persons dampened, placed in a
sealed container and marked, to ensure safe disposal.

1.12.3 Welding or naked flames

a) Welding, flame cutting and grinding work on the plant must only be carried out if this has
been expressly authorized, as there may be a risk of explosion and fire.
b) No welding should be undertaken on this equipment as it will affect its structural integrity.
c) Avoid all naked flames in the vicinity of this equipment.

1.12.4 Hydraulic equipment

a) Work on hydraulic system must be carried out by persons having special knowledge and
experience of hydraulic system.
b) Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury and fire.
c) Always relieve pressure from the hydraulic system before carrying out any kind of
maintenance or adjustment.
d) Depressurize all system sections and pressure pipes (hydraulic system, compressed air
system) to be removed in accordance with the specific instructions for the unit concerned
before carrying out any repair work.
e) Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no
connections are interchanged. The fittings, lengths and quality of the hoses must comply
with the technical requirements.
f) Only fit replacement components of a type provided by the manufacturer.
g) Always practice extreme cleanliness servicing hydraulic components.
h) Hydraulic fluid under pressure can penetrate the skin causing serious injury;
i) Once the fluid is injected under the skin, seek medical help immediately.
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 Description of
Chapter 2
the crane
 0066305-100-02-20Y

2.1 Product model

2.1.1 Product name plate and its position

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2.1.2 Engine type and its manufacturer

QSL9-280, America CUMMINS Engine Co., Ltd.

WP10.270N, Weichai Power Co., Ltd.

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2.2 Terminology

2.2.1Boom configuration

S SF

Instructions for boom configuration

Configuration no. Description Parameters

S Main boom S = 13 – 58 m

SF Main boom with fixed jib S = 37 – 49 m F = 6 – 18 m

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2.2.2 Description of component parts

1.1

1.2
1.4

1.3

1.5

Crane undercarriage

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2.1

2.2

2.3

2.4 2.5 2.6 2.7 2.8

Crane superstructure

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2.7

3.1

3.7 3.2

3.6
3.3

2.6

3.4

2.5

3.5

Overview of crane superstructure from above

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Description of components
Components Names of the Components Names of the Components Names of the
No. components No. components No. components
Additional
1.1 2.1 A-frame 3.1 Slewing motor
support
Crawler Main boom pivot
1.2 2.2 3.2 Fuel tank
carrier section
Undercarriage Main boom
Air-conditioning
1.3 central 2.3 tilting-back 3.3
condenser
section support
Horizontal Rear
1.4 2.4 3.4 Engine
anchoring rod counterweight
Crawler
carrier
Main boom Hydraulic oil
1.5 extending & 2.5 3.5
derricking winch tank
retracting
cylinder
2.6 Hoisting winch 2 3.6 Main valve
Electrical
2.7 Hoisting winch 1 3.7
control box
2.8 Operator’s cab

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2.3 Product description

2.3.1 Crane undercarriage

a) Frame
Self-manufactured and high-rigid welded structure made of high-strength structural steel.
b) Travel gear
Maintenance-free crawler travel gear with flat track pad;
Fitted with track roller, driven sprocket, track-carrier roller and track-carrier plate
c) Drive device
The crawlers driven independently through axial piston motor and planetary reducer at the
rear part of crawler carriers;
High maneuverability;
Traveling movements such as turning on the spot, turning with a crawler and differential
steering
d) Crawler carrier extending/retracting mechanism
The extending and retracting of crawler carrier is controlled by a horizontal cylinder.
The undercarriage control lever and undercarriage control valve are fitted in the front of
undercarriage central section.
After pulling out the undercarriage control lever, actuate the undercarriage control switch, and
then extend support cylinder via undercarriage control valve. After support cylinder is
extended in proper position, extend crawler carrier via horizontal cylinder.

2.3.2 Crane superstructure

a) Slewing table
Self-manufactured and high-rigid welded structure made of high-strength structural steel.
Connected to undercarriage by a 1-row roller slewing ring for 360°continuous rotation.
b) Crane engine
6-cylinder diesel engine, manufactured by Cummins, type QSL9-280, rated power 209 KW at
2000 rpm; maximum torque 1424N.m at 1500 rpm.
6-cylinder diesel engine, manufactured by Weichai, type WP10.270N, rated power 199KW at
2000rpm, maximum torque 1270N.m at 1200 – 1500 rpm.
c) Crane drive device
Driving force, supplied by diesel engine, is transmitted to a variable dual pump and two gear
pumps.
d) Hoisting winches
The crane is fitted with two hoisting winches: hoisting winch 1 and hoisting winch 2. Both of
them consist of hydraulic motor, winch reducer, brake, rope guider, lowering limiter and
hoisting limiter, wire rope as well as main and auxiliary load hooks.

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e) Main boom derricking winch

Composed of axial concealed piston hydraulic motor, balance valve, reducer and normally
closed brake, derricking pulley block as well as wire rope;
Fitted with a ratchet locking device
f) Slewing mechanism
Composed of axial concealed piston hydraulic motor, planetary gear reducer, slewing brake
valve, brake and pinion gear as well as slewing ring.
The superstructure can carry out 360°slewing motion through pinion gear’s driving slewing
ring.
g) Counterweight
26.8t in total;
Consisting of a 5.2t counterweight base plate, four 3.35t counterweight plates and two 4.1t
central counterweight plates;
h) Crane operator’s cab
Spacious and comfortable, all-steel construction cab, with luxury instrument desk, operating
and control instruments, heating & cooling air conditioning, hydraulic cushioned seat.
Overall of operator’s cab inside (L × W × H): 1850mm×900mm×1650 mm
i) Safety equipment
Many safety and warning equipment, whether mechanically controlled, electronically
controlled or hydraulically controlled, have been fitted into the crane, including but not limited
to the following equipment: load moment limiter, monitor, main boom angle indicator, angle
control device, hoisting limiter, safety catch, balance valves and overflow valves as well as
ratchet mechanism for derricking winch.
j) Electrical system
24V DC, negative ground, 2 batteries of 165 AH each

Note:
The classification group of ZCC800H crawler crane is A1, and the classification groups of
mechanisms are: traveling mechanism (M5), slewing mechanism (M5), hoisting winch (M5)
and derricking mechanism (M5).

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2.3.3 Overall dimensions (unit: mm)

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2.4 Technical data

2.4.1 Main technical parameters

Item Unit Value Remarks

Max. lifting capacity × radius t×m 80×4
Deadweight with basic boom t 72.8
Main boom length m 13 – 58
Fixed jib length m 6 – 18
Max. lifting capacity on fixed jib t 7
Fixed jib angle ° 10, 30
Max. length of main boom with fixed jib m 49＋18
131 (110 during free-fall The 4th rope
Hoisting winch 1 m/min
operation) layer
Max. single
The 4th rope
rope speed Hoisting winch 2 m/min 131
layer
of winches
Main boom derricking The 4th rope
m/min 93
winch layer
Slewing speed rpm 0–2
Traveling speed km/h 0 – 1.67
Gradeability ％ 30
Ground pressure MPa 0.083
With A-frame
and main
Overall dimensions (L×W×H) m 13.5×3.4×3.2
boom pivot
section
Rated power / rotational
kW/r/min 209/2000
speed
CUMMINS
Max. output torque /
Nm/ r/min 1424/1500
rotational speed
Engine
Rated power / rotational
kW/r/min 199/2000
speed Weichai
Max. output torque / Power
Nm/ r/min 1270/1200 – 1500
rotational speed
Crawler
carrier
Distance between track center × crawler 4200×5440×800 extended
mm
contact length × crawler width 2600×5440×800 Crawler
carrier
retracted
Noise level outside
operator’s cab during dB ≤107
Noise operation
Noise level in operator’s
dB ≤79
cab during operation

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2.4.2 Type of load hook and selection of rope reeving

Type of load hook Maximum rope reeving Weight of load hook (kg)
80 t 12 1250
50 t 7 920
30 t 5 600
8t 1 264

Note:
The specification of load hook in above table is not the standard load hook configuration. It is
subject to the contract signed with customer.

2.4.3 Rope reeving and specification of wire rope

2.4.3.1 Rope reeving for different boom lengths

Boom (or jib)

Rated lifting capacity (t) Rope reeving
length (m)
13 80 12
16 66.8 11
19 51.8 10
22 51.7 8
25 41.5 7
28 40.7 6
31 33.8 6
Crane operation with
main boom 34 33.5 5
37 28.4 5
40 23.8 4
43 23.2 4
46 22.6 3
49 17.8 3
52 17.8 3
55 14.3 3
58 14 2
Crane operation with
main boom and fixed 6 – 18 7 1
jib

Note:
(1) If crane is working with rope reeving less than the value listed in the above table, the
single hoisting rope load must be checked to make sure that the max. permissible load of
single hoisting rope is not exceeded.
(2) The maximum permissible lifting capacity of single hoisting rope is 7000kg.
(3) If the maximum tension force of rope is exceeded, there is a risk of breaking off wire rope
and damaging the reducer and motor.

2 - 12
 0066305-100-02-20Y

2.4.3.2 Specification of wire rope

Description and Hoisting rope for Hoisting rope for

Derricking rope
intended use winch1 winch 2
Rotation-resistance
Yes Yes No
or not
Type of rope 35×7IWS-1960 35×7IWS-1960 6T (29) +7×7-20-1910
Nominal rope
24mm 24mm 20mm
diameter
Rope length 240m 160m 150m
Minimum breaking
406KN 406KN 290KN
load
Direction and type Left-hand ordinary Left-hand ordinary
Right-hand lang lay
of lay lay lay
Tensile strength of
1960N/mm2 1960N/mm2 1910N/mm2
wire

2 - 13
 0066305-100-02-20Y

2.4.3.3 Use length of hoisting rope and derricking rope

In transport condition, the longest length of derricking rope is about 138 m.

For S boom configuration: when main boom length is 55 m and the rope reeving is 3, the
longest possible hoisting rope for winch 1 is 226 m.
For SF boom configuration: when main boom length is 49 m and the fixed jib length is 18 m,
the longest possible hoisting rope for winch 2 is 134 m.

2 - 14
 0066305-100-02-20Y

2.4.4 Lifting height

Note:
The main boom lifting height curve is drawn without considering boom deflection.

2.4.4.1 Lifting height on S boom

60

56

52

48

44
Lifting height (m)

40

36

32

28

24

20

16

12

0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
Working radius (m)

2 - 15
 0066305-100-02-20Y

Note:
(1) The horizontal direction indicates working radius (in m) and the vertical direction indicates
lifting height (in m).
(2) For S boom configuration, S= 13m – 58m.

2 - 16
 0066305-100-02-20Y

2.4.4.2 Lifting height on SF boom

68

64

60

56

52

48

44

40
Lifting height (m)

36

32

28

24

20

16

12

0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60

Working radius (m)

Note:
(1) The horizontal direction indicates working radius (in m) and the vertical direction indicates
lifting height (in m).
(2) For SF boom configuration, S= 37m – 49m, F= 6m – 18m, and F-jib angle = 10°.

2 - 17
 0066305-100-02-20Y

64

60

56

52

48

44

40
Lifting height (m)

36

32

28

24

20

16

12

0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64

Working radius (m)

Note:
(1) The horizontal direction indicates working radius (in m) and the vertical direction indicates
lifting height (in m).
(2) For SF boom configuration, S= 37m – 49m, F= 6m – 18m, and F-jib angle = 30°.

2 - 18
 0066305-100-02-20Y

2.4.5 Lifting capacity charts

Note:
The lifting capacity is given in “t”, and “*/*”indicates “lifting capacity/radius”.

2.4.5.1 Lifting capacity on S boom

Unit: t

S-boom length (m)

Radius(m) 13 16 19 22 25 28 31 34 37 Radius(m)
4 80 4
5 68 66.8 5
6 52.3 52 51.8 51.7 6
7 42.3 42 41.9 41.7 40 39.5 7
8 35.5 35.2 35 34.8 34.6 33.97 33.8 33.5 8
9 29.5 29.3 29.2 29.1 29 28.9 28.8 28.6 28.4 9
10 26.7 26.4 26.2 26 25.7 25.3 25 24.8 24.6 10
12 19.5 19.4 19.3 19.2 19.1 19 18.9 18.8 18.7 12
14 17.2 17 16.9 16.6 16.2 16 15.8 15.5 14
16 14.37 14.2 13.9 13.6 13.4 13.1 12.9 16
18 12.2 11.9 11.6 11.4 11.1 11 18
20 10.3 10 9.8 9.7 9.5 20
22 8.5 8.45 8.4 8.3 8.2 22
24 7.7 7.65 7.6 7.5 24
26 6.8 6.75 6.7 26
28 6 5.9 28
30 5.5 5.4 30
32 4.2 32

2 - 19
 0066305-100-02-20Y

Table 1 (continued)

S-boom length(m)
Radius(m) 40 43 46 49 52 55 58 Radius(m)
9 9
10 23.8 23.2 22.6 10
12 18.6 18.6 18.2 17.8 17.8 12
14 15.5 15.2 15 14.75 14.5 14.3 14 14
16 12.8 12.7 12.5 12.3 12.1 12 11.5 16
18 10.9 10.7 10.5 10.3 10.2 10 9.9 18
20 9.4 9.3 9.2 9 8.9 8.8 8.6 20
22 8.2 8.2 8.1 8 7.9 7.7 7.5 22
24 7.45 7.2 7.1 7 6.9 6.8 6.6 24
26 6.6 6.5 6.4 6.2 6 5.8 5.7 26
28 5.8 5.7 5.6 5.55 5.5 5.4 5.1 28
30 5.3 5.2 5.1 5 4.8 4.6 4.5 30
32 4.2 4.2 4.1 4 4 4 3.8 32
34 4.1 4.1 4 3.9 3.8 3.7 3.4 34
36 3.8 3.7 3.5 3.4 3.2 2.9 36
38 3.2 3.1 3.05 3 2.9 2.6 38
40 2.8 2.7 2.6 2.5 2.3 40
42 2.3 2.3 2.2 2 42
44 2 1.8 1.6 44
46 1.6 1.3 46
48 1.5 1 48
50 0.8 50

Note:
The lifting capacities highlighted in grey are determined by the strength.

2 - 20
 0066305-100-02-20Y

2.4.5.2 Lifting capacity on SF boom

Unit: t

S-boom length（m） 37 40 S-boom length（m）

F-jib length（m） 6 12 18 6 12 18 F-jib length（m）
F-jib angle (°)
Radius（m） 10 30 10 30 10 30 10 30 10 30 10 30 Radius（m）
10 7 6 7 10
12 7 6 7 7 6 7 12
14 7 6 7 5.5 7 6 7 5.5 14
16 7 6 7 6 5.5 7 6 7 6 5.5 16
18 7 6 7 6 5.5 7 6 7 6 5.5 18
20 7 6 7 6 5.5 4 7 6 7 6 5.5 4 20
22 7 6 7 6 5.5 4 7 6 7 6 5.5 4 22
24 7 6 7 6 5.5 4 7 6 7 6 5.5 4 24
26 6.7 6 6.7 6 5.5 4 6.4 6 6.1 5.4 5.5 4 26
28 6.1 5.5 6.1 5.5 5.5 3.5 5.5 5.5 5.5 4.8 5 3.7 28
30 5.4 4.8 5.4 4.8 5 3.5 5.2 5 5 4.2 5 3.7 30
32 4.9 4.4 4.9 4.4 4 3.3 4.4 4.3 4.3 4 4 3.5 32
34 4.3 4 4.3 4 4 3.2 4 3.9 3.9 4 4 3.5 34
36 3.9 3.7 3.7 3.2 3.6 3.5 3.6 3.5 3.8 3.3 36
38 3.5 3.4 3.5 3.1 3.1 3.2 3 3.2 3.1 38
40 3.2 3.2 3 2.7 2.7 2.6 2.5 40
42 2.4 2.5 2.3 42

2 –21
 0066305-100-02-20Y

Table 2 (continued)

S-boom length（m） 43 46 S-boom length（m）

F-jib length（m） 6 12 18 6 12 18 F-jib length（m）
F-jib angle (°)
Radius（m） 10 30 10 30 10 30 10 30 10 30 10 30 Radius（m）
12 7 7 12
14 7 6 7 7 6 7 14
16 7 6 7 6 5.5 7 6 7 5.5 16
18 7 6 7 6 5.5 7 6 7 6 5.5 18
20 7 6 7 6 5.5 4 7 6 7 6 5.5 20
22 7 6 7 6 5.5 4 7 6 7 6 5.5 4 22
24 7 6 7 6 5.5 4 6.5 6 7 6 5.5 4 24
26 6.3 5.5 6.3 6 5.5 4 6 5.8 5.9 5.7 5.5 4 26
28 5.5 4.7 5.5 5.4 5.4 4 5 4.9 5 4.9 5 4 28
30 4.8 4.3 4.8 4.7 5 4 4.7 4.6 4.6 4.5 4.8 4 30
32 4.2 4.2 4.2 4.1 4.5 4 4 4.3 4 4 4.4 3.8 32
34 4 4 4 4 4 3.5 4 3.7 4 3.7 3.8 3.5 34
36 3.6 3.6 3.7 3.6 3.6 3.5 3.5 3.5 3.5 3.5 3.5 3.3 36
38 3.3 3.3 3.4 3.4 3.3 3.2 3.2 3.2 3.2 3.2 3.2 38
40 3.1 3 3.1 3.1 2.9 2.9 2.9 3 3 3 40
42 2.7 2.7 2.7 2.7 2.6 2.5 2.6 2.5 2.5 42
44 2.5 2.5 2.5 2.5 2.4 2.4 44

2 –22
 0066305-100-02-20Y

Table 2 (continued)
S-boom length（m） 49 S-boom length（m）

F-jib length（m） 6 12 18 F-jib length（m）

F-jib angle (°)

Radius（m） 10 30 10 30 10 30 Radius（m）

12 7 12
14 7 6 7 14
16 7 6 7 5.5 16
18 7 6 7 6 5.5 18
20 7 6 7 6 5.5 20
22 7 6 7 6 5.5 4 22
24 6.5 6 6.5 6 5.5 4 24
26 5.7 5.5 5.7 5.5 5.5 4 26
28 5.1 5 5 5 4.9 4 28
30 4.5 4.4 4.6 4.4 4.5 4 30
32 4 4 4 4 4 3.7 32
34 4 4 3.6 3.6 3.5 3.5 34
36 3.4 3.3 3.3 3.4 3.2 3.3 36
38 3 3 3 3.2 3 3.2 38
40 2.8 2.8 2.8 2.8 2.8 3 40
42 2.5 2.5 2.5 2.5 2.5 2.7 42
44 2.2 2.2 2.3 2.3 2.3 44
46 1.9 1.9 1.9 1.8 46

Note:
The lifting capacities highlighted in grey are determined by the strength.

2 –23
 0066305-100-02-20Y

Note:
(1) The values in the lifting capacity charts are applicable to 360° working range;
(2) The value in the lifting capacity charts is the rated total lifting capacity of crane, which is
the maximum permissible lifting capacity under various boom configurations. It includes
the weight of load hook and other load handling devices;

Rated lifting
capacity
Rated total lifting capacity =
(Actual load)
+ (Weight of load hook and
other load handling devices)

(3) The radius in the lifting capacity charts is the horizontal distance from central axle of
slewing ring to centerline of hook when crane is loaded;
(4) Crane operation with main boom and fixed jib;
If main load hook is not detached from main boom head, the actual lifting capacity on
fixed jib should be calculated from this formula: rated lifting capacity – main load hook’s
weight – auxiliary load hook’s weight – sling’s weight – wire rope’s weight;
(5) Crane operation with main boom (but some sections of fixed jib are not dismantled): The
actual lifting capacity on main boom is calculated in accordance with following formula;

é L cos(a - b ) ù é L2 ù
G2 = G - G1 ê1 + 2 ú - G3 - G4 ê cos(a - b ) + 1ú
ë 2 L1 û L
4ë 1 û
Where, G= rated lifting capacity
G1= weight of fixed jib head and fixed jib pivot section ＋ weight of 6m fixed jib
intermediate section ×(number of 6m fixed jib intermediate sections) + fixed jib anchoring
rods
G2= actual lifting capacity
G3= weight of FA-frame and tilting-back support of fixed jib
G4= weight of auxiliary load hook and other load handling devices
L1= working radius (or main boom length ×cosα)
L2= fixed jib length
α= main boom angle
β= fixed jib angle (10o or 30o);
2 –24
 0066305-100-02-20Y

(6) The rated total lifting capacity indicates the crane’s lifting capacity under different boom
configurations when it is operated on firm and flat ground.
(7) When tip boom is used, the lifting capacity on the tip boom is the same as that on the
main boom within the same radius, but its max. lifting capacity should not exceed 7 t.
(8) Whether the tip boom is used or not, the lifting capacity on the main boom is the same.
(9) Main boom and tip boom can not work at the same time when main boom is attached
with tip boom.
(10) The maximum in-service wind velocity should not exceed 9.8 m/s during crane operation;
The maximum out-of-service wind velocity should not exceed 21 m/s when crane is only
fitted with main boom;
The maximum out-of-service wind velocity should not exceed 15 m/s when crane is fitted
with main boom and fixed jib.
(11) Crane operation with main boom and fixed jib
The maximum lifting capacity on fixed jib (7 t) includes the weight of auxiliary load hook (8
t) and wire rope (0.6 t). However, the maximum actual lifting capacity should not exceed
6.4 t.
(12) When crane is traveling with load,
– 70% of rated lifting capacity under corresponding working condition should not be
exceeded;
– the boom should be located in the forward driving direction;
– the height of lifted load above the ground should not be more than 500 mm.

2 –25
 0066305-100-02-20Y

2.4.5.3 Lifting capacity on main boom under SF boom configuration (fixed jib attached with
a load hook)

37m main boom

S-boom length (m)

37

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

9 26.87 26.74 26.69 26.43 26.51 26.11

10 23.08 22.97 22.91 22.69 22.74 22.41

12 17.69 17.60 17.54 17.35 17.38 17.11

14 14.00 13.93 13.85 13.70 13.71 13.48

16 11.41 11.34 11.27 11.14 11.12 10.94

18 9.51 9.46 9.38 9.28 9.24 9.09

20 7.92 7.87 7.79 7.70 7.66 7.52

22 6.62 6.59 6.50 6.42 6.37 6.26

24 5.53 5.50 5.40 5.34 5.28 5.19

26 4.73 4.70 4.61 4.56 4.49 4.42

28 3.93 3.91 3.81 3.77 3.69 3.64

30 3.23 3.22 3.12 3.09 3.00 2.96

32 2.74 2.73 2.62 2.60 2.51 2.48

2 –26
 0066305-100-02-20Y

40m main boom

S-boom length (m)

40

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

10 22.29 22.18 22.13 21.90 21.97 21.63

12 17.50 17.40 17.35 17.15 17.19 16.90

14 14.01 13.93 13.87 13.71 13.72 13.49

16 11.32 11.25 11.18 11.06 11.05 10.87

18 9.42 9.37 9.29 9.19 9.17 9.01

20 7.93 7.88 7.80 7.71 7.68 7.54

22 7.03 6.99 6.91 6.83 6.79 6.67

24 5.93 5.90 5.82 5.75 5.70 5.61

26 5.13 5.11 5.02 4.97 4.91 4.83

28 4.34 4.32 4.23 4.18 4.11 4.05

30 3.84 3.82 3.73 3.70 3.62 3.57

32 3.34 3.33 3.23 3.21 3.13 3.09

34 2.64 2.63 2.54 2.52 2.43 2.41

36 2.55 2.54 2.44 2.43 2.34 2.32

2 –27
 0066305-100-02-20Y

43m main boom

S-boom length (m)

43

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

10 21.69 21.58 21.54 21.31 21.39 21.04

12 17.10 17.01 16.96 16.77 16.82 16.52

14 13.71 13.64 13.58 13.42 13.45 13.21

16 11.22 11.16 11.09 10.96 10.97 10.77

18 9.23 9.17 9.11 9.00 8.98 8.82

20 7.83 7.79 7.71 7.62 7.60 7.46

22 6.83 6.80 6.72 6.64 6.61 6.49

24 5.74 5.70 5.63 5.56 5.52 5.41

26 5.04 5.01 4.93 4.87 4.82 4.74

28 4.24 4.22 4.14 4.09 4.03 3.95

30 3.54 3.52 3.44 3.40 3.34 3.28

32 3.25 3.23 3.15 3.11 3.04 3.00

34 2.65 2.64 2.55 2.52 2.45 2.41

36 2.35 2.34 2.25 2.23 2.15 2.13

38 1.75 1.75 1.66 1.64 1.56 1.54

40 1.55 1.55 1.46 1.44 1.36 1.34

2 –28
 0066305-100-02-20Y

46m main boom

S-boom length (m)

46

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

10 21.10 20.98 20.95 20.72 20.80 20.45

12 16.71 16.61 16.57 16.37 16.43 16.14

14 13.52 13.44 13.39 13.23 13.26 13.03

16 11.03 10.96 10.91 10.78 10.79 10.59

18 9.03 8.97 8.91 8.80 8.80 8.63

20 7.74 7.69 7.62 7.53 7.51 7.37

22 6.64 6.60 6.53 6.45 6.42 6.30

24 5.64 5.61 5.54 5.47 5.43 5.33

26 5.05 5.01 4.94 4.88 4.84 4.74

28 4.15 4.12 4.05 3.99 3.94 3.86

30 3.65 3.63 3.55 3.51 3.45 3.39

32 3.15 3.13 3.05 3.02 2.96 2.90

34 2.55 2.54 2.46 2.43 2.36 2.31

36 2.26 2.24 2.16 2.14 2.07 2.03

38 1.76 1.75 1.66 1.65 1.57 1.54

40 1.56 1.55 1.47 1.45 1.38 1.36

2 –29
 0066305-100-02-20Y

49m main boom

S-boom length (m)

49

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

12 16.31 16.21 16.18 15.98 16.04 15.74

14 13.28 13.20 13.15 12.99 13.03 12.79

16 10.83 10.76 10.71 10.58 10.59 10.39

18 8.84 8.78 8.73 8.61 8.61 8.44

20 7.54 7.49 7.43 7.33 7.32 7.17

22 6.54 6.50 6.44 6.35 6.34 6.21

24 5.55 5.51 5.44 5.37 5.34 5.23

26 4.75 4.72 4.65 4.58 4.55 4.45

28 4.15 4.12 4.06 4.00 3.96 3.87

30 3.65 3.63 3.56 3.51 3.47 3.39

32 3.06 3.04 2.96 2.92 2.87 2.81

34 2.56 2.54 2.47 2.43 2.38 2.32

36 2.06 2.04 1.97 1.94 1.88 1.83

38 1.76 1.75 1.67 1.65 1.59 1.55

40 1.26 1.25 1.18 1.16 1.09 1.06

42 1.06 1.06 0.98 0.96 0.89 0.87

2 –30
 0066305-100-02-20Y

2.4.5.4 Lifting capacity on fixed jib under SF boom configuration (main boom attached with
a load hook)

37m main boom

S-boom length (m)

37

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

10 6

12 6 5.1 6.2

14 5.9 5.1 6.1 4.8

16 5.9 5.1 6.1 5.3 4.8

18 5.9 5 6.1 5.3 4.8

20 5.9 5 6.1 5.3 4.7 3.5

22 5.9 5 6.1 5.2 4.7 3.4

24 5.9 5 6.1 5.2 4.7 3.4

26 5.6 5 5.8 5.2 4.7 3.4

28 5 4.4 5.2 4.7 4.7 2.8

30 4.3 3.7 4.5 3.9 4.2 2.8

32 3.8 3.3 3.9 3.5 3.2 2.6

34 3.2 2.9 3.3 3.1 3.2 2.5

36 2.9 2.8 2.9 2.5

38 2.5 2.5 2.7 2.3

40 2.3 2.3 2.2

2 –31
 0066305-100-02-20Y

40m main boom

S-boom length (m)

40

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

10 6

12 6 5.1 6.2

14 5.9 5.1 6.1

16 5.9 5 6.1 5.3 4.8

18 5.9 5 6.1 5.3 4.7

20 5.9 5 6.1 5.2 4.7 3.5

22 5.9 5 6.1 5.2 4.7 3.4

24 5.9 5 6.1 5.2 4.7 3.4

26 5.3 5 5.2 4.6 4.7 3.3

28 4.4 4.4 4.9 3.9 4.2 3

30 4.1 3.9 4 3.3 4.2 3

32 3.3 3.2 3.3 3.1 3.2 2.8

34 2.9 2.8 2.9 3.1 3.1 2.8

36 2.5 2.4 2.6 2.6 2.9 2.5

38 2 2.2 2.1 2.3 2.3

40 1.7 1.8 1.7 1.7

42 1.4 1.6 1.5

2 –32
 0066305-100-02-20Y

43m main boom

S-boom length (m)

43

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

12 5.9

14 5.9 5.1 6.1

16 5.9 5 6.1 5.3 4.7

18 5.9 5 6.1 5.3 4.7

20 5.9 5 6.1 5.2 4.7 3.5

22 5.9 5 6.1 5.2 4.7 3.4

24 5.9 5 6 5.2 4.7 3.4

26 5.2 4.4 5.3 5.2 4.7 3.3

28 4.4 3.6 4.5 4.5 4.6 3.3

30 3.7 3.2 3.8 3.8 4.1 3.3

32 3.1 3.1 3.2 3.2 3.6 3.3

34 2.9 2.9 3 3.1 3.1 2.7

36 2.5 2.5 2.7 2.7 2.7 2.7

38 2.2 2.2 2.3 2.5 2.5 2.5

40 2.1 2.1 2.2 2.3

42 1.7 1.7 1.8 1.9

44 1.5 1.6 1.7

2 –33
 0066305-100-02-20Y

46m main boom

S-boom length (m)

46

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

12 5.9

14 5.9 5.1 6.1

16 5.9 5 6.1

18 5.9 5 6.1 5.3

20 5.9 5 6.1 5.2 4.7

22 5.9 5 6 5.2 4.7 3.4

24 5.4 5 6 5.2 4.7 3.4

26 4.9 4.7 4.9 4.8 4.6 3.3

28 3.9 3.8 4 4 4.1 3.3

30 3.6 3.5 3 3.6 3.9 3.3

32 2.9 3.2 3 3.1 3.5 3.1

34 2.9 2.6 3 2.8 2.9 2.7

36 2.4 2.4 2.5 2.6 2.6 2.5

38 2.1 2.1 2.2 2.3 2.3 2.4

40 1.8 1.8 1.9 2 2.1 2.2

42 1.5 1.5 1.6 1.6 1.7

44 1.5 1.5 1.6

2 –34
 0066305-100-02-20Y

49m main boom

S-boom length (m)

49

F-jib length (m)

Radius (m)
6 12 18

F-jib angle (°)

10 30 10 30 10 30

12 5.9

14 5.9 5.1

16 5.9 5 6.1

18 5.9 5 6.1 5.3

20 5.9 5 6 5.2 4.7

22 5.9 5 6 5.2 4.6 3.4

24 5.4 5 5.5 5.2 4.6 3.4

26 4.6 4.4 4.7 4.6 4.6 3.3

28 4 3.9 4 4.1 4 3.3

30 3.4 3.3 3.6 3.5 3.6 3.3

32 2.9 2.9 3 3.1 3.1 3

34 2.9 2.9 2.6 2.7 2.6 2.7

36 2.3 2.2 2.3 2.5 2.3 2.5

38 1.9 1.9 2 2.3 2.1 2.4

40 1.7 1.7 1.8 1.8 1.9 2.2

42 1.3 1.4 1.5 1.5 1.6 1.9

44 1.1 1.2 1.3 1.4 1.5

46 0.9 0.9 1 1

2 –35
0066305-100-02-20Y

2 –36
Chapter 3 Safety guidelines
 0066305-100-03-20Y

3.1 Operational planning

In addition to a perfectly working crane and a well-trained crew, operational planning is an

important precondition for safe and reliable crane operation.
The crane operator must obtain or receive the necessary information (familiarize himself with
the operating manual, basic knowledge about pneumatic, electrical and hydraulic drive, and
notes for safe operation as well as operating environment) before starting the crane operation,
in particular:
a) Clearly define the area of responsibility of all personnel concerned.
b) Type of crane operation and required working mode;
c) Distance between the lifting points and surrounding buildings;
d) Influence of communal facilities（including the overhead high/low voltage lines and
underground gas pipes）;
e) Space requirements at the work site;
f) Movement restrictions due to surrounding structures (e.g. is there another crane nearby
in working);
g) Number, weight, dimensions, material of load(s) to be lifted;
h) Required lifting height and slewing radius;
i) Load-bearing capacity of soil or surface to be operated upon;
j) Height and widths of thoroughfares leading to the site;
k) Other factors affecting the site (e.g. weather, live lines, etc.);
l) Communication means adopted between signalman and crane operator;
m) Take appropriate measures to keep people unconcerned and equipment away from the
working area;
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
– Counterweight

Caution:
(1) A correct and complete operational planning is vital for safe and problem-free operation
of the machine. The operation planner must plan a safe and reliable operational planning
by obtaining and analyzing all necessary information about the operation and considering
all the factors that may impair safety of crane operation;
(2) If the crane operator does not possess all necessary and required information, it may
prove impossible to carry out the intended work and accidents may be the result!

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3.2 Safety technical notes

3.2.1 Safety instructions for crane operator

The crane operator’s primary responsibility is to control, operate and adjust the crane in a
manner that is safe for both himself and others. Therefore the crane operator should meet the
following requirements.
a) The operator must be familiar with the operating manual for the crane, and know the
working principle, structure performance and the safety devices’ function, as well as
master the operation essentials and maintenance skills.
b) The operator should inspect brake, load hook, wire rope and safety devices 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. Stop
the crane immediately if somebody is found climbing the crane.
d) Operator who is in low spirits or poor healthy is not allowed to operate the crane.
e) Crane operator and slinger/banks man should be familiar with safety rules, signals and
symbols. Prohibit drinking and driving.
f) Be qualified with the work in hearing, eyesight and reaction ability; be strong enough to
operate safely, and has the ability to estimate distance, height and clearance correctly.
g) Be familiar with the usage of fire extinguisher and be well trained; know how to survive
under emergent conditions.
h) Make sure that only authorized personnel are allowed to operate the crane.
To make sure that the crane is kept in good working order, the crane operator should perform
the following checks before operating the crane:
a) Check the daily record of work to ensure that all regular inspections, maintenance and
repair work is performed.
b) Check the hoisting limiter, boom angle indicator, tilting-back support and other safety
equipment for functional work;
c) Check the load-bearing parts carefully, such as wire rope (hoisting rope, derricking rope
and sling etc.), boom, outriggers, hook and load handling devices;
d) Check if there are some bolts, nuts and pins lost, and the components are cracked or
damaged.
e) Ensure that no modification has been made to the crane without permission, e.g.,
increase or decrease in counterweight plate and improper repair of boom frame.
f) Check fuel lines and hydraulic oil lines for leakage.
g) Check all control mechanisms for functional work after starting up the engine.
h) Check all control devices for functional work.
i) Check the brakes. Test the braking performance by lifting a load away from the ground
and suspend it in the air for a moment.
j) Check whether lubricating oil, grease or anti-freeze liquid is sufficient.
k) Check for contamination.
The following improper operating errors, which are made again and again while operating,
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should be avoided.
a) Slewing too quickly;
b) Quick braking of the load;
c) Diagonal pulling of the load to be lifted which is still in contact with the ground;
d) Loose wire rope formations;
e) Overloading or improperly attaching the load;
f) Driving(or slewing) too fast with a load, or setting up and loading on an uneven surface;
g) diagonal pulling, breaking away stuck loads;
h) swinging of suspended load, crashing into bridges, roofs or high voltage wiring;
i) Incorrect assembly or disassembly of booms.

3.2.2 Safety instructions for the rigger

The rigger is responsible for ensuring that the load is slung or released safely and carefully.
Therefore, he only uses suitable, undamaged lifting and slinging equipment to prevent the
load from either slipping or falling. If no signalman is available, the rigger works directly with
the crane operator.
Qualifications for rigger:
a) With crane operation certificate;
b) Be qualified with the work in hearing, eyesight and reaction ability;
c) Be strong enough to carry hook or component;
d) Be able to estimate the load, balance the load and judge the distance, height and
clearance correctly;
e) Be trained in the skill of handling load;
f) Be able to choose proper load handling device and components according to the loading
condition;
g) Be trained in hand signals for operation and familiar to use them;
h) Be able to safely use audio equipment (such as interphone) to send out oral order exactly
and clearly;
i) Be capable of conducting the operation of crane to move the load safely;
j) Make sure that only authorized personnel are allowed to carry out work.

3.2.3 Safety instructions for the signalman

The main job of signalman is to assist crane operator to carry out safe operation. Potential
damage to property or personal injury could be avoided if the crane operator carries out the
crane movement following the signals given out by appointed signalman. However, only one
signalman may work with the crane operator at a time.
Qualifications for signalman:
a) Familiar with the lifting task so as to cooperate with crane operator and other workers;
b) Make sure that only authorized personnel are allowed to carry out work;
c) Be qualified with the work in hearing, eyesight and reaction;
d) Be able to estimate the distance, height and clearance correctly;
e) Be trained in hand signals for operating and familiar to use them;
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f) Use standard hand signals for crane operation. If necessary, use a radio device to send
out correct and clear order;
g) Be capable of conducting the operating of crane to move the load safely;
h) Position himself in a safe location from where he can see the whole process of operation
and be seen clearly by the crane operator.

Warning:
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.

3.2.4 Points for attention for crane operating crew

a) Any unsafe operation must be corrected or any dangerous situations must be reported to
supervisor.
b) All the persons in vicinity of crane must observe the acoustic warning signals of the
machine so as to ensure himself and others safety.
c) All the worker must know about the content of task and working sequence;
d) Check whether dangerous situations occur during operation of the machine, and inform
crane operator and signalman of the unsafe factors such as high-voltage power line,
unauthorized persons, obstacles and poor ground conditions.
3.2.5 Points for attention during crane operation

Note:
Observe the rated lifting capacity of crane and working radius specified in load capacity
charts.

Caution:
(1) The crane is not allowed to work at working radius less than the value in load capacity
charts, which is also applicable to the condition that the load is not attached to the load
hook. If not, there is a risk of accident.
(2) Check that the number of wire rope reeving specified in load capacity charts matches
with the maximum lifting capacity of crane. If not, the wire rope may be broken and the
accident may occur.
(3) Slowly activating and braking all crane movements can prevent load from swinging. If the
wire rope on the winding drum is unwound to the last layer, an operator must check the
drum to see if there are three windings of wire rope left on the drum. If less than three
windings of wire rope remains on the drum, the serious accident may occur.
(4) Do use appropriate load hook whose lifting capacity matches the actual load to be lifted.

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3.2.6 Safety signs

1. Danger: snagging /dragging

2. Company identity

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3. Warning: Dragging / entanglement

4. Note: Lift point

5. Prohibited: No access for unauthorized personnel

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6. Warning: Risk of falling

7. Crushing / collisions

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8. Prohibited: Naked flames

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9. Safety sign

10. Safety sign

11. Safety sign

12. No standing under the boom

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13. Prohibited: Access prohibited

14. Danger: Risk of burn

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15. Safety sign

16. Note: First aid kit

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17. Note: Fire extinguisher

18. Danger: Crush hazard

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19. Safety sign

20. Be careful in the working radius

As to the position of safety signs, please see following diagrams.

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12

11

10

2 3 4 5 6 7 5 8
Safety signs position diagram 1

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8 1 13

15

13

14 8 8
Safety signs position diagram 2

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16 17 7 6 5 4 3

Safety signs position diagram 3

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 0066305-100-03-20Y

18 19 20

Safety signs position diagram 4

Note:

(1) When the safety sign is damaged or illegible, please order it from appointed
service supplier.

(2) It is forbidden to cover or take off safety signs casually.

(3) If the safety sign is covered with dust, clean it in time.

(4) The operator’s cab should be equipped with an emergency hammer which can
be used to smash the window in an emergency so that operator can run away
from the cab.

3.3 Slings

3.3.1 Slings introduction

The predominant characteristics of a sling are determined by the components of that

sling. For example, the strengths and the weaknesses of a wire rope sling are
essentially the same as the strengths and the weaknesses of the wire rope from
which it is made.
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Slings are generally one of six types:

a) Chain

b) Wire rope

c) Metal mesh

d) Natural fiber rope

e) Synthetic fiber rope

f) Synthetic web

Usage and inspection procedures tend to place these slings into three groups with
each type having its own particular advantages and disadvantages:

a) Chain

b) Wire and mesh rope

c) Fiber rope web

Factors that must be taken into consideration when choosing the best sling for the job
include:

a) Size

b) Weight

c) Shape

d) Temperature

e) Sensitivity of the material to be moved

f) Environmental conditions that the sling will be used

3.3.2 Sling identification tags

All slings should be labeled with identification tags.

The Information required to be on the identification tags is as follows:

a) Manufacturer’s name or trademark

b) Diameter or size of sling

c) Sling type of material

d) Rated load for the types of hitches used

e) Lift angle the load rating is based

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3.3.3 Angle of choke

The angle used on the choker hitch reduces the sling capacity.

Angle of choke Sling rated capacity (%)

90° - 120° 87%

60° - 90° 74%

30° - 60° 62%

0° - 30° 49%

3.3.4 D/d ratio

Depending on the hitch used, wire rope capacity will experience an efficiency loss
when bent. To determine the D/d ratio, divide the diameter of the wire rope sling into
the diameter of the load. A good rule to follow is to keep at least a 6:1 ratio which
results in an 80% efficiency of the sling. A 1:1 ratio results in only a 50% efficiency of
the sling and cannot be used.

D/d ratio Efficiency（%）

40 95

30 93

20 92

15 89

10 86

8 83

4 75

2 65

1 50

3.3.5 Load angle factor

Increasing the number of sling legs on a load helps ensure better control of the load
and helps distribute the weight of the load among more slings legs. Slings are at their
greatest strength on a straight pull. By having the slings pull at an angle, added stress
is placed on the sling. The capacity of a multiple leg sling is directly affected by the
angle of the sling leg with the vertical. As the angle formed by the sling leg and the
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horizontal line decreases, the rated capacity of the sling also decreases.

The smaller the angle between the sling leg and the horizontal, the greater the stress
on the sling leg and the smaller or lighter the load, the sling can safely support. The
smaller the angle, the greater bending forces are imposed on the load.

The capacity can be readily determined by multiplying the sling’s vertical capacity by
the appropriate load angle factor.

3.3.6 Load share

For symmetrical loads with 2 legs:

To calculate the load for each sling leg, use the following formula:

L ÷H = Load Angle Factor

Multiple the Load Angle Factor by the load weight.

Divide the answer by the number of legs.

This equals the load share of each sling leg.

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3.3.7 Load angle factor chart

When the load angle factor (LAF) has been determined, refer to the chart listing the
corresponding sling angles measured in degrees. All safety standards recommend
safe lifting angles to be 60°or more, and do not recommend angles lower than 45°
be used.

Sling angle Load angle factor

Following angles are not recommended
90° 1.000
when rigging
85° 1.004

80° 1.015 40° 1.555

75° 1.035 35° 1.742

70° 1.064 30° 2.000

65° 1.104 25° 2.364

60° 1.155 20° 2.924

55° 1.221 15° 3.861

50° 1.305 10° 5.750

45° 1.414 5° 11.49

3.3.8 Sling safety

a) Before making a lift, check to be certain that the sling is properly secured around
the load and that the weight and balance of the load have been accurately
determined. If the load is on the ground, do not allow the load to drag along the
ground. This could damage the sling.

b) Position the hook directly over the load and seat the sling squarely within the
hook bowl. This gives the operator maximum lifting efficiency without stressing
the sling.

c) Make sure that the load is not lagged, clamped, or bolted to the floor.

d) Guard against shock loading by taking up the slack in the sling slowly.

e) Apply power cautiously so as to prevent jerking at the beginning of the lift, and
accelerate or decelerate slowly.

f) Check the tension on the sling. Raise the load a few inches, stop, and check for
proper balance and that all items are clear of the path of travel. Never allow
anyone to ride on the hook or load.

g) Keep all personnel clear while the load is being raised, moved, or lowered. Crane
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or hoist operators should watch the load at all times when it is in motion.

Caution:

Never allow anyone to ride on the hook or load.

3.3.9 Sling safety guide

a) Sling must not be shortened with knots, bolts, or other makeshift devices.

b) Sling legs cannot be kinked.

c) Slings cannot be loaded in excess of their rated capacities.

d) Slings used in a basket hitch can have the loads balanced to prevent slippage.

e) Slings must be securely attached to their loads.

f) Slings must be padded or protected from the sharp edges of their loads.

g) Suspended loads must be kept clear of all obstructions.

h) All employees must be kept clear of loads that is about to be lifted and of
suspended loads.

i) Hands or fingers cannot be placed between the sling and its load while the sling
is being tightened around the load.

3.3.10 Taglines

The safest method for a rigger to control a load suspended from a hook is with a
tagline:

a) Taglines are used to control load spin.

b) Keep the tagline away from the center of gravity.

c) Never wrap the tagline around your body or any limbs.

d) Tail the load, never stand directly underneath a load.

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3.3.11 Load center of gravity

a) The center of gravity of an object is the point at which the weight of the object
acts as though it were concentrated. It is the point at which the object may be
completely supported or balanced by a single force.

b) The center of gravity of a regularly shaped object may be estimated fairly

accurately by determining its approximate center.

c) Finding the center of gravity of irregularly-shaped objects can be more difficult,

but it is necessary. A load will always hang from its attachment point through the
center of gravity. It is important to visualize this before making a lift.

d) All loads to be lifted must be rigged above the center of gravity in order to
prevent tipping and possible hazards to equipment and workers. The lifting force
must always be located above the center of gravity and exert a straight vertical
pull to prevent swinging of the load.

e) In all crane lifts, the center of gravity must remain below the hook and below the
point of attachment for any rigging.

f) A center of gravity above the hook is unstable and will cause the load to flip as
the load will attempt to ‘find’ center gravity. Similarly, loads which are not
balanced horizontally can slip from the rigging.

g) The overall stability of the load is a combination of balance with respect to center
of gravity, distribution of weight, and proper rigging practices.

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3.4 Requirements for operating site

3.4.1 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;

b) no obstacles hinder necessary movements;

c) the ground an the operating site is able to support expected loads;

Note:

The most essential requirement for safe crane operation is working on firm ground
with the capacity to support you loads.

3.4.2 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.

Caution:

Safety distance is measured from the foot of the trench and is:

Soft or backfilled soil = 2× depth of trench (A2 = 2×T)

Hard or grown soil = 1×depth of trench (Al = 1×T)

Caution:

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.

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 0066305-100-03-20Y

3.4.3 Permissible ground pressure

Soil type 10-1MPa

A) Back-filled, not naturally compacted ground 0 － 1

B) Natural soil, apparently undisturbed

1. Mud, peat, marshy soil 0

2. Non-cohesive, sufficiently compactly layered
soil:
1.5
Fine to medium grained sand;
2.0
From coarse-grained sand to gravel
3. Cohesive soil:
Loamy; 0
Soft; 4
Stiff; 1.0
Semi-solid; 2.0
Hard 4.0
4. Rock with few fissures, in healthy,
un-weathered Condition and in a favorable
location:
15
In cohesive layer order
30
In massive or column-style shape
C) Artificially compacted ground

1. Asphalt; 5 － 15

2. Concrete Concrete group B I; 50 － 250

Concrete group B II 350 － 550

Note:

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.

3.4.4 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

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crane;

e) Check whether there are obstacles which will hinder required crane operation.

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.

3.5 Underground cables

With special equipment (for example: a hanging leader), the equipment can also be
used for underground working.

With underground working, it is possible to damage:

a) Underground electric cables

b) Gas pipes

c) Telephone, TV, and data cables

d) Sewage pipes, district heating supply, etc.

Warning:

If a live underground cable is damaged, lives are at risk from electric shock.
There is an extreme danger of explosion and fire in the vicinity of a damaged gas
pipe.

3.5.1 Measures to be taken during operational planning

The construction company doing the work is responsible for gathering accurate
information about possible underground cables within the working area of the
equipment so that work can be done safely:

a) Obtain the relevant information from the relevant utility companies.

b) Examine the "as completed" plans of:

1) Utility companies (electricity, gas or water)

2) Cable users (telephone companies, factories, transport companies)
3) Building authorities.

c) Only use the latest, up-to-date plans.

d) If there are any deviations or extensions to a project, initiate new inquiries.

e) If in doubt, localize the underground cables around the site using a locating
device via search slots or test digs.
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 0066305-100-03-20Y

f) The relevant utility companies, cable users and public authorities:

1) Must be informed in good time about the start of the work.

2) Must be asked for written approval for the civil engineering work to be done.

g) When several construction companies are involved, their activities must be

coordinated. All companies must have the same up-to-date information on
underground pipes, etc. on the construction site.

3.5.2 Safety precautions and protective measures when operating the equipment
near underground cables

a) Do not start work until you have obtained all the approvals from the utility
companies and the cable users.

b) The equipment operator must obtain all relevant information about the exact
location of all underground cables before starting work. These plans must be
readily accessible at the construction site.

c) Operate the equipment with particular care near underground cables, all
applicable national safety guidelines as well as the special guidelines and safety
measures of the utility companies must be noted and obeyed.

d) In the event of any unexpected encounters with underground cables or

associated warning tapes and protective coverings, cease working with the
equipment immediately and inform the appropriate superiors.

e) It is prohibited to uncover underground cables with the equipment, the

underground cables must only be uncovered manually by the appropriate
personnel who is responsible for the cables.

f) Secure, support, or prop up all exposed underground cables so that they cannot
sway, slide, or become deformed.

g) Stabilize the cable ducts and trenches and secure the edges to prevent caving.

3.5.3 What is to be noted in connection with gas pipes?

a) Whenever the position of the gas pipe casing changes or the casing is damaged,
report this to the appropriate gas company. The gas pipe can only be backfilled
after inspection, repair, and approval by specialist personnel from the gas
company.

b) All devices of the gas supply network around the site must remain accessible
(fittings, valve boxes, manhole covers, etc.). Existing markings and information
signs must not be covered, rearranged or removed.

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3.5.4 What happens if a gas pipe is damaged?

The escaping gas:

a) Forms an inflammable gas-air mixture around the affected area.

b) Can strike personnel or equipment if escaping from gas supply pipes is under
high pressure.

c) Not only endangers personnel and equipment on the site, but also passers-by
and residents in the neighborhood.

A gas fire can develop in seconds and spread explosively. In a conventional supply
pipe with a leak of 50 mm (2"), for example, the flames can be up to 10 m (33 ft) high
if the gas is escaping at a pressure of 1 bar (14.5 psi). The equipment and
surrounding construction equipment will quickly be burned.

Even a minor change in position of the gas pipe can result in damage to other
sensitive points of the gas network, for example connection points or house feeder
pipes. Leaks and small leaks that are not immediately detectable are very dangerous
if gas is allowed to escape over a lengthy period of time and penetrate along the gas
pipe network into the surrounding buildings. An explosive gas-air mixture is formed
considerably quicker in enclosed areas than in the open air. Every source of ignition,
such as On /Off switches on electrical equipment or the turning on of a light, can
trigger an explosion.

Corrosion can cause leaks to form within 5 -10 years of minor damage to the casings
of metal gas pipes.

3.5.5 What must the equipment operator do if a gas pipe is damaged and gas
escapes, or a leak is suspected?

a) Stop work immediately.

b) Leave the equipment after shutting down the engine and all additional fuel
powered units.

c) Alert all site personnel, avoid producing any sparks and maintain a strict
no-smoking policy.

d) Switch off all construction equipments and shut down the engine nearing the
construction equipments.

e) Clear the danger area and secure a wide area with barriers. Do not allow access
by an unauthorized personnel.

f) Inform the relevant gas company of the following:

1) The extent of the damage

2) The exact location of the site
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3) The exact circumstances of the accident

4) How long ago the accident occurred
5) A name and telephone number for a return call.

g) If there is the slightest suspicion that gas can be leaking into a building, alert the
local occupants by knocking or calling. Do not ring the door bell or call them by
telephone, as this may trigger an explosion.

If the odor of gas is present in the building, especially around the area where the
gas pipe is known to enter the house; do not operate any electrical systems or
equipment. Open all doors and windows widely for ventilation purposes and
leave the building immediately.

h) In the event of major damage, evacuate the occupants of all the surrounding
buildings with the cooperation of the police or fire department.

i) Building site personnel:

1) Must assist all specialist personnel from the gas company during the repair
work.
2) Can only leave the building site with the consent of the specialist personnel.
j) Work on the building site can only begin again if authorization has been given by
the relevant gas company.

Note:

Extinguishing a gas fire requires specialist knowledge.

A gas fire that has already been extinguished can flare up again if more gas escape
and break out in an unexpected spot.
Precautions:
(1) Alert the local fire department to fight the fire.
(2) Do not attempt to put out the fire before the fire department arrives unless lives
are in danger or there is risk of major damage to property.
(3) If the gas fire is not causing any immediate danger, it is sometimes better, in
certain circumstances, to let the gas burn. As soon as the gas company shuts off
the gas pipe, the fire will extinguish itself.

3.6 Checking safety measures

Before beginning any work, the crane operator must be convinced that the crane is in
safe operating condition. All safety devices, such as load moment limiter, hoist limiter
switches, brakes, etc., are in good working order.

a) The load moment limiter must be set according to the current crane
configuration.

b) The load capacities as given in the load lifting capacity tables must be adhered to.
The loads given in the load lifting capacity tables must not be exceeded.

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c) The crane operator must know the weight and dimensions of the load before
operating the crane.

d) Load handling devices, lifting equipment and tackle must be in accordance with
specified requirements.

e) It must be ensured that the weight of the hook block and the weight of the tackle
are subtracted from the load given in the lifting capacity table.

Example:
Maximum permissible load according to table 27t

Weight of the hook block 0.38t

Weight of the slinging rope 0.04t

Actual useful load of the crane 26.58t

Note:

In this case, the load to be lifted may no exceed 26.58t.

3.6.1 Counterweight

The required counterweight should be installed prior to operation according to

specified requirements.

Caution:

If the counterweight is not installed according to the lifting capacity table, there is a
danger of the crane toppling over.

3.6.2 Hoisting winch, 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 winch is able to pull.

If the load to be lifted is heavier than the hoisting winch 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. (As to detailed
hoisting rope reeving, refer to Section 2.4.3 in Chapter 2.)

When reeving, ensure that the data given in the load capacity table and operating
manual are observed and adhered to. (For details, see Section 4.6 in Chapter 4.)

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Caution:

If the maximum tensile force is exceeded, the wire rope may snap or the winch motor
may be damaged.

3.6.3 Electromagnetic influences

Strong electromagnetic fields are likely to be present if the construction site is close to
a transmitter.

Caution:

These electromagnetic fields can pose direct or indirect danger to persons or objects,
for example:

(1) Effect on human organs due to temperature increase.

(2) Danger of burns or inflammation due to temperature increase.

(3) Spark or electric arc formation.

In any case, before working with the crane near transmitters, contact Zoomlion
representative. In addition, consult a high frequency specialist.

a) Every crane must be “totally” grounded. Check visually or with a simpler tester to
ensure that ladder, cab and cable pulleys are grounded.

b) All personnel working on the crane or with large metal objects must protect
themselves from burns by wearing non-conductive gloves and suitable clothing
while working.

c) 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”.

d) The temperature of objects affected by high frequency radiation depends on their

‘size”. Cranes, carriers and coverings, for example, are “hooter”.

e) 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.

f) An insulator is required at all times between the crane load hook and tackle. It is
strictly prohibited to remove this insulator.

g) The ropes may not be touched above the insulator. This is strictly prohibited!

h) Crane with attached loads may not be touched by any unprotected parts of the
body after the load has been lifted or set down.
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 0066305-100-03-20Y

i) Do not work with a bare upper torso or in short pants, this is prohibited.

j) To minimize absorption of high frequency radiation, large loads should be

transported horizontally if possible.

k) Loads must be grounded, or additional insulation used (rubber material between

the object and gloves) when manual work is required.

l) To avoid accidents, use a safety belt when working on components that are high
off the ground.

m) 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.

n) Any accidents and unexpected events must immediately be reported to the local
construction supervisor and the safety engineer.

3.7 Crane operation with a load

3.7.1 Operating conditions

a) All components of crane are in running-in state at the initial operating period. So,
for the first 100 operating hours, the working load should not be too great and the
working speed should not be too high. The maximum lifting load can not exceed
80% of its rated load. And the maximum working speed is forbidden.

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 0066305-100-03-20Y

b) The ground on jobsite should be firm and flat and the gradient should not be
greater than 1/100. The complete vehicle should be level and the supporting
ground should not give away during operating. If the ground is soft, a steel plate
should be placed under the track shoe.

c) The permitted temperature range for crane’s operation is -20℃ – 40℃. Humidity
should not exceed 85%; however, high humidity up to 100% is only permitted for
a short period of time. The crane should be operated and supported on a ground
lower than 1000m above seal level.

d) The maximum in-service wind velocity should be not more than 9.8m/s during
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 0066305-100-03-20Y

operation; the maximum out-of-service wind velocity should be no more than

21m/s when only main boom is assembled, and no more than 15m/s when fly jib
is assembled.

Note:

Before beginning any work, the crane operator must receive information on the
expected wind velocity from the responsible meteorological authorities.

If impermissible wind velocity is forecasted, lifting a load is prohibited.

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
Wind direction is shown only by observing the
1 Light air 0.4 - 1.4 trail of smoke, not by the wind sock
Light Wind can be felt on the face, the leaves rustle,
2 1.6 - 3
breeze wind sock moves slightly
Gentle Leaves and thin twigs move. Wind extends a
3 3.4 - 5.3
breeze small breeze flag.
Moderate Swirls up dust and loose paper, moves twigs and
4 5.5 - 7.8
breeze thin branches
Fresh Small deciduous trees begin to sway, foam forms
5 8 - 10.6
breeze at sea.
Strong Thicker branches move; telephone lines begin to
6 10.8 - 13.7
breeze whistle, umbrellas are difficult to use
7 Stiff wind 13.9 - 17 Entire trees swaying; difficult to walk into wind
Gale force
8 17.2 - 20.6 Breaks twigs off trees, walking becomes difficult
wind
Minor damage to property(chimney tops and
9 Gale 20.8 - 24.5 roofing tile are blown off)
Severe Trees are uprooted, significant damage to
10 24.7 - 28.3
gale property

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 0066305-100-03-20Y

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:

The safe clearance from high-voltage power lines:

Output voltage of
high-voltage power V≤1 1< V ≤15 15 <V ≤40 40<V≤100 100<V≤200

line V, kV
Safe clearance 1.5 3 4 5 6
m

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.

Caution：

Not observing above points can lead to (fatal) accidents and damage!

f) Only the crane without fault is allowed to work.

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 0066305-100-03-20Y

3.7.2 Instructions for Safety Operation

a) No person is allowed to stand under boom when crane is operated.

b) No person is allowed to stand on slewing table during operation.

c) It is forbidden to lift load over people.

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 0066305-100-03-20Y

d) It is forbidden to lift the load when someone is standing on it.

e) Overloading operation and lifting staggered load is prohibited. Never pull load
obliquely.

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 0066305-100-03-20Y

f) It is forbidden to lift load hidden in the ground or frozen on the ground.

g) The crane can travel with a load of 70% of the rated load. In this case, the ground
should be firm and its gradient should not be more than 5/1000. The driving
speed must be less than 0.5km/h. The boom frame must be located in the driving
direction.

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h) If the crane is operated in the vicinity of transmission systems (e.g. transmitters),

strong electromagnetic field will be generated there, so measures should be
taken to protect the crane against high frequency interference and all workers
who stand on large metal plate should wear special isolating gloves and clothes
to avoid being burnt.

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.

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 0066305-100-03-20Y

k) When a load is suspending in the air, the operator is not allowed to leave the cab.

l) Operation should be carried out stably and gently. Never operate control lever
jerkily and carry out switchover operation abruptly.

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 0066305-100-03-20Y

m) When actual load reaches 90% of the rated one, the load moment limiter will
sound an alarm, to which high attention should be given.

n) Getting on and off the crane should be careful to avoid casualty.

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 0066305-100-03-20Y

o) It is prohibited to make any modifications to the crane without permission;

otherwise you should take the consequences.

p) Stop the crane operation if one of the following conditions occurs:

1) The crane is overloaded or the weight of load is uncertain;

2) Load’s binding or hanging is not good or load may fall due to imbalance;

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3) No protective mat is added between the edges of load and wire rope;

4) In case of poor visibility and /or darkness, it is difficult to identify load or

conduct signal;

5) There is defect or damage of configuration or components which will impair

safe operation, for example, the brake and safety equipment fail, or the wire
rope is damaged etc.

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q) Anyone is not permitted to climb on the load hook, slings or load.

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.

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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) 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.

u) It is more dangerous that two cranes carry out lifting operations together.
Therefore, a careful calculation must be made before commencing the work, and
following import requirements for this type of operation must be observed.

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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.

v) When you leave the machine in an emergency, you are putting your lift at risk.
Therefore, you must take following measures prior to leaving the machine.

1) Detach the load from the hook and set it down on the ground; if necessary,
lower the boom frame;
2) Apply slewing brake or lock slewing mechanism;
3) Apply parking brake;
4) Lock traveling mechanism;
5) Cut off power supply or switch off engine;

w) 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.

x) Do not stop crane near the bank which is possible to collapse or on low-lying
land that may be washed down by water.

y) Take away the key when machine remains idle. In this way, the unauthorized
person can not start the machine without permission.

z) Unqualified person is forbidden to repair crane and change parts.

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3.7.3 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 boom frame 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.

k) Estimate the weight and dimensions of load to be lifted in advance.

l) Crane operation can be carried out within minimum working radius. No obstacles
hinder the necessary movements. The ground at the operating site is able to
support expected loads.

m) Ensure that no obstacles are within working radius and operator can see the load
clearing from the cab. Check if the communication between operator and
signalman is kept smooth so as to ensure safe crane operation.

n) Determine the load-bearing capacity of ground to be operated upon. Ensure that

crane is supported properly and never operate the crane on the soft and uneven
surface or on the ground of high water content or covered with frozen soil. If
crane is set up close to trenches, reinforce the trenches to avoid landslide. If the
ground does not have adequate load-bearing capacity, the crane is liable to
turnover. In this case, crosstie, steel plates should be padded underneath the
crawler to distribute load so that the load-bearing capacity of the ground will not
be exceeded; make sure that the crane is leveled.

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3.7.4 Notes for crane operation

a) Estimate the weight and dimensions of load to be lifted in advance.

b) Use load handling devices (wire rope or chain) correctly. Make the vertical line of
hook pass through center of gravity of load.

c) If any part of crawler crane or load handling devices come in contact with
high-voltage line, or emergent situation occurs, the operator should stop the
vehicle at once.

d) The load capacities as given in the load lifting capacity tables must be adhered to.
The loads given in the load lifting capacity tables must not be exceeded. Driving
(or slewing) too fast with a load, or setting up and loading on an uneven surface,
and swinging of suspended load should be avoided.

e) Diagonal pulling of the load to be lifted which is still in contact with the ground is
prohibited.

f) It should be avoided that the load or auxiliary lifting device collides with structural
members of crawler crane.

g) If crane gets caught in a thunderstorm during operation, following measures

should be taken at once:

1) Stop work on the crane immediately

2) Always set down the load and boom frame on the ground.
3) Apply brake or lock winch and slewing gear
4) Switch off the crane engine and cut off the power of load moment limiter and
limit switch
5) Ask all crane workers to leave away.

h) If the crane is struck by thunderbolt, following checks should be performed:

1) Check whether there are burnt or damaged components

2) Check the performance of electrical parts and load moment limiter
3) Check the associated components for functional work.

i) If earthquake occurs when crane is operated, following measures should be

taken immediately:

1) Stop work on the crane immediately

2) Always set down the load and boom frame on the ground.
3) Apply brake or lock winch and slewing gear
4) Switch off the crane engine and cut off the power of load moment limiter and
limit switch
5) Ask all crane workers to leave away.

After earthquake, following checks should be performed prior to crane operation:

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 0066305-100-03-20Y

1) Check the performance of electrical parts and load moment limiter

2) Check the associated components for functional work

j) If any part of crawler crane or load handling device is in contact with high-voltage
lines, the best way to guarantee the personal safety of operator is to stay in
operator’s cab until the danger is obviated. If operator must leave the crane, he’d
better jump rather than climb down the cab.

k) The operator’s cab should be equipped with an emergency hammer which can
be used to smash the window in an emergency so that operator can run away
from the cab.

l) The load moment limiter, once be triggered, should be kept in that state until the
crane is not overloaded.

m) If the load moment limiter is not set to the actual configuration status of the crane,
it can not fulfill its function as a safety device.

n) Examine if the angle indicators and the strain gauges are in function.

o) The crane may topple over backwards if a load is suddenly freed since the
tension created in the boom can cause it to jerk back violently.

p) Make sure that the loads and working radius contained in the lifting capacity
tables are not exceeded.

q) When working in the vicinity of power cables, a sufficient safety clearance must
be maintained, if the cables are not isolated by electricity engineers or the
hazardous area is not fenced off.

r) For all crane movements, the crane operator must always keep the load, as well
as the crane hook or loading equipment when the crane is not loaded, in his field
of vision. If this is not possible, the crane operator may only operate the crane
according to instructions given to him by a signalman. These instructions may be
given in the form of hand signals or over a two-way radio. Whatever method is
used, precautions must be taken to eliminate the risk of misunderstanding.

3.7.5 Checks after operation

a) When crawler crane and auxiliary lifting device are in non-working condition,
never park the vehicle near the embankment liable to collapse or low-lying land
subject to be washed by water.

b) Set down the load on the ground, and if necessary low the boom frame to some
extend; lock the slewing gear and traveling gear and apply the brake.

c) Shut down the engine and cut off power.

d) Check if there is leakage in someplace and repair it if necessary.

e) Clean such components as movable parts and exposed part of the piston rod of
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 0066305-100-03-20Y

cylinder.

f) Check if bolts and nuts are fitted tightly. Any defects found should be eliminated
at once. It is prohibited to operate the crane with fault.

g) Record the operating conditions and abnormal symptoms.

h) Check if the quantity of tools and accessories meet specified requirements.

i) Lock the operator’s cab or safety devices.

j) Take precaution measures against storm or lightning strikes.

k) Take precaution measures against frostbite in winter.

Note:

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.

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3.8 Hand signals for controlling crane operations

1) Preparation

Arm stretched out over the head, palm of the

hand facing forwards.

2) Use main hoist

Tap fist on the safety helmet; then use

regular signals.

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3) Use auxiliary hoist

Bend one hand and hold it upward, tap the elbow

with the other hand; then use regular signals.

4) Hoist

With forearm vertical, palm of the hand facing

forwards, move hand in small horizontal circle.

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5) Lower

With arm extended downwards with a 30° angle to the

body，palm of the hand facing inwards, move hand in
small horizontal circle.

6) Raise load slowly

With forearm vertical, palm of the hand facing

upwards, wave hand up repeatedly.

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7) Rotate

Turn left: With right forearm vertical, the palm of the hand facing outwards,
lower the forearm sideways horizontally, fingers pointing in the direction of
rotation.

Turn right：With left forearm vertical, the palm of the hand facing outwards,
lower the forearm sideways horizontally, fingers pointing in the direction of
rotation.

8) Lower load slowly

With arm extended downwards with a 30°

angle to the body，palm of the hand facing
downwards, wave hand down repeatedly.

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 0066305-100-03-20Y

9) Rotate slowly

Turn left：With right forearm vertical, the palm of the hand facing
outwards, move forearm horizontally and repeatedly, fingers pointing
in the direction of rotation.

Turn right：With left forearm vertical, the palm of the hand facing
outwards, move forearm horizontally and repeatedly, fingers pointing
in the direction of rotation.

10) Indicate load lowering position

Extend the fingers to point at the position the

load should fall on.

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11) Raise boom

With arm stretched sideways horizontally, thumb pointing

upwards, the remaining fingers closed, wave forearm up.

12) Lower boom

With arm stretched sideways horizontally, thumb

pointing downwards, the remaining fingers
closed, wave forearm down.

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13) Raise boom slowly

Bend one hand with thumb pointing upwards; place other

hand motionless above hand moving up and down.

14) Lower boom slowly

Bend one hand with thumb pointing downwards;

place other hand motionless below hand moving
up and down.

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15) Stop

Arm extended, the palm facing downwards,

move the arm back and forth horizontally.

16) Emergency stop

Both arms extended, palms facing downwards,

move arms back and forth horizontally.

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17) End of a movement

With fingers extended, cross both hands before

the forehead.

Note:

(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.

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Chapter 4 Crane operation
 0066305-100-04-20Y

4.1 Operating and control instruments

4.1.1 Operator’s cab, overview

3 4 5

1 2 3—5

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 0066305-100-04-20Y

Components in crane operator’s cab

Names of the
No. Position and (or) function
components
The upper one is the LCD screen of load moment limiter, and
1 Digital display system the lower one is the dashboard. (For the detailed information,
please see Section 4.2)
LCD screen of winch Monitor the condition of crane winches and rear side of the
2
monitoring system crane.
Press the free-fall switch, and then depress the free-fall pedal,
3 Free-fall pedal
the free-fall operation can be performed.
Travel gear pedal (with
4 Control the movements of left and right crawlers.
hand lever)
5 Accelerator pedal Control the engine speed.
Central unit of air At the rear side of operator’s cab. (For the detailed
6
conditioning information, please see Section 8.1)
It is adjustable. (For the detailed information, please see
7 Operator’s seat
Section 4.3.1)
Control the movement of slewing mechanism. (For the
8 Left control lever assy.
detailed information, please see Section 4.1.2)
Control the movements of hoisting winch 1 (H1), hoisting
9 Right control lever assy. winch2 (H) and main boom derricking winch (E). (For the
detailed information, please see Section 4.1.3)

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4.1.2 Left control lever assy.

3
2

4—9

4 5 6

9 8 7

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 0066305-100-04-20Y

Components of left control lever assy.

Names of the
No. Position and function
components
Control the movement of slewing mechanism.
Left control lever
Push it forwards, the superstructure will slew to the right;
1 (slewing control
Push it backwards, the superstructure will slew to the left.
lever)
(For the detailed information, please see Section 4.1.2.1)
Power control
2 Push it forwards, the control system will be electrified.
lever
Cigarette lighter is heated after pressing it. Pull it out to light a
cigarette when you need to use.
3 Cigarette lighter Note:
Never keep the cigarette lighter pressed for more than 10 seconds.
Otherwise, it is overheated.
Emergency As soon as this emergency shutdown button is pressed, the power
4
shutdown button supply of machine will be cut off and the engine will shut down.
5 Switch Not assigned
It is recommended to use this switch if the ground is even. When it
Slewing stable
6 is turned to ON position, the slewing movement will be performed
button
more stably.
Protect the lifting boom against damage by reducing the side force
“Swing free acting on the boom.
7 running on/off” Note:
button It should be avoided to swing the load heavily due to stopping the
slewing motion suddenly.
8 Switch Not assigned
When load hook runs against hoisting limit switch or there are only
three windings of wire rope left on winch, the crane movement is
Derricking bypass
9 cut off by the control system. At this moment, turning the derricking
switch
bypass switch clockwise can bypass this cutoff, and the speed of all
movements will be reduced to 25% of original speed.

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 0066305-100-04-20Y

4.1.2.1 Left control lever (slewing control lever)

2
1

Components of left control lever

Names of the
No. Position and function
components
Press the left side of slewing brake switch, the crane can carry out
Slewing brake
1 slewing movement.
switch
Press its right side, the slewing movement of crane is prohibited.
Actuate the horn
Caution:
2 Horn switch
The horn is only used in emergency situation to warn the
person in vicinity of crane.

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4.1.3 Right control lever assy.

1 2
3

5—17
5 6 7 8 9 10 11 12

17 16 15 14 13

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 0066305-100-04-20Y

Components of right control lever assy.

Names of the
No. Position and function
components
Main boom Control the movement of main boom derricking winch.
1 derricking winch Push it forwards, main boom will be derricked down;
control lever Push it backwards, main boom will be derricked up.
Control the movement of hoisting winch 2.
Hoisting winch 2
2 Push it forwards, hoisting winch 2 will be reeled off;
control lever
Push it backwards, hoisting winch 2 will be spooled up.
Control the movement of hoisting winch 1.
Hoisting winch 1
3 Push it forwards, hoisting winch 1 will be reeled off;
control lever
Push it backwards, hoisting winch 1 will be spooled up.
Turn this switch to the 2nd position, the power supply will be
switched on;
Turn this switch to the 3rd position, the engine will be started up.
Note:
Ignition starter (1) Before restarting the engine each time, turn the ignition starter
4
switch switch to initial position, and then start the engine.
(2) Compared with routine conditions, it takes longer time to
preheat the engine automatically in cold temperature. This is a
normal phenomenon.
Turn the switch clockwise, the manual accelerator mode is
Manual selected. The engine speed in this condition is controlled by
5
accelerator switch manual ACCEL adjuster (No. 17 in above figure). At this time, the
accelerator pedal is disabled.
Control the movement of hoisting winch 2 at high speed.
High-speed rotary Turn it anti-clockwise completely, the working speed of hoisting
6 knob for hoisting winch 2 is not increased;
winch 2 Turn it clockwise completely, the working speed of hoisting winch 2
will reach the maximum value.
“Controller on/off”
7 Switch on or off the power supply of the whole control system.
switch
Micro-positioning Press this switch, the speed of all crane movements will be
8
switch reduced 25% of original speed.
Press this switch, the clutch of hoisting winch 1 is disengaged;
9 Free-fall switch Depress the free-fall pedal (No.3 in figure of Section 4.1.1);
At this time, the free-fall operation can be performed.
“Derricking ratchet
10 Switch on or off the derricking ratchet [see Section 4.5.2.2.(d)]
on/off” switch
11 Switch Not assigned

12 Switch Not assigned

Shut down the engine
Note:
(1) When the engine is shut down, release ignition starter switch
Engine shutdown to initial position after 30s. Otherwise, the work hour of engine
13
switch for this time can not be saved.
(2) The engine shutdown switch must be switched off before
restarting the engine.
“Oil cooling fan Switch on the oil cooling fan to cool down the oil when oil
14
on/off” switch temperature is too high.
When the load reaches 100% - 110% of the rated load, or main
15 SetUp switch
boom is lowered to minimum angle position (30°), the dangerous

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 0066305-100-04-20Y

Names of the
No. Position and function
components
crane movements are switched off by the control system. At this
time, press SetUp switch, the switch-off can be bypassed, and the
movement speed will be reduced 25% of original speed. (For the
detailed information, see Section 4.1.4)
Control the movement of hoisting winch 1 at high speed.
High-speed rotary Turn it anti-clockwise completely, the working speed of hoisting
16 knob for hoisting winch 1 is not increased;
winch 1 Turn it clockwise completely, the working speed of hoisting winch 1
will reach the maximum value.
In “manual accelerator mode”, the adjuster is used for controlling
Manual ACCEL
17 engine speed. Turn it clockwise, the engine speed is increased
adjuster
gradually.

4.1.4 Safety control

Table 1 Warning limit movements and their bypass methods
Warning Limited
Bypass methods Remarks
situations movements
1. Press Setup switch, the
switch-off can be bypassed
The load after icon or
Spool up
reaches 100% - appears on screen of load 1. Pressing the Setup switch
hoisting
110% of the moment limiter; one time can bypass the
winch 1 or
rated load, or 2. Turn derricking bypass switch-off. If turn it again,
hoisting
main boom is switch clockwise, the bypassing the switch-off is
winch 2,
lowered to switch-off of derricking invalid;
derrick
minimum angle boom up can be bypassed 2. If the switch-off is
boom down
position bypassed on time, and
after icon appears
on screen of load moment there is a need to bypass
limiter. the switch-off again, the
Spool up Setup switch should be
hoisting Turn bypass key switch pressed again;
winch 1 or clockwise, the switch-off can be 3. When the crane is
Overload（above overloaded, if press the
hoisting bypassed after icon
110%）
winch 2, appears on screen of load SetUp switch, icon
derricking moment limiter. appears. When main
boom down boom is lowered to
Spool up minimum angle position, if
hoisting press the SetUp switch,
winch 1 or 1. Turn derricking bypass icons and
Over-hoisting hoisting switch clockwise (No. 9 in occur together;
winch 2, figure of Section 4.1.2), the 4. Turning the bypass key
derricking switch-off can be bypassed; switch one time can
boom down 2. Turn bypass key switch bypass the switch-off. If
Reel off clockwise and release it, turn it again or stop the
hoisting the switch-off can be engine, bypassing the
winch 1 or
bypassed after icon switch-off is invalid. After
hoisting
Overlowering appears on screen of load turn the bypass key
winch 2,
moment limiter. switch, the bypass is valid
derricking
in thirty minutes.
boom down

Main boom is Derrick Bypassing the switch-off is

raised to 80° boom up prohibited.

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 0066305-100-04-20Y

Warning Limited
Bypass methods Remarks
situations movements
position

Note:
(1) The bypass key switch can bypass all the switch-off crane movements except main boom
raised to 80° position, the speed of movement is reduced 25% of original speed after
bypassing the switch-off.
(2) In non-working angle, the speed of movement is not changed after bypassing the
switch-off (except bypassing the switch-off by bypass key switch); In working angle, the
speed of movement is reduced 25% of original speed after bypassing the switch-off.
(3) The “bypass” mentioned in above table refers to bypass the crane movements towards
dangerous direction temporarily by pressing the relevant bypass switches after the
warning is sent out and the motions are switched off. However, the safety alarm is not
relieved.
(4) When the above one or more warning situations occur, never carry out slewing
movement if the slewing limit switch in electrical control box at the rear side of slewing
table is activated.
(5) All switches are self - reset switches except slewing limit switch. The bypass key switch
and slewing limit switch are installed in electrical control box at the rear side of slewing
table. (For the detailed information, see Section 4.1.4.1.

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 0066305-100-04-20Y

Table 2 Tricolor light warning logic

Gree
Yellow Red
n Buzzer
light light
light
Before
○ √ √ √
bypass
0%< Load
moment
√ ○ ○ ○
percentag
Crane is
e <90%
overloaded
90%≤Loa
or main In
d moment Intermittentl
boom is workin ○ √ ○
percentag y
lowered to After g
e ≤100%
minimum bypass angle
100%<
angle
Load
position
moment ○ √ √ √
percentag
e ≤110%
In non-working Intermittentl Intermittentl
○ ○
angle y y
Before
○ √ √ √
Over-hoistin bypass
g After Intermittentl
○ ○ √
bypass y
Before
○ √ √ √
Overlowerin bypass
g After Intermittentl
○ ○ √
bypass y
Bypassin
When main g the
boom is switch-off
○ √ √ √
raised to is
80° position prohibite
d.
In any case,
bypass key
Intermittentl
switch is in ○ ○ √
y
functional
work.
When 90%≤
Load
Intermittentl
moment ○ √ ○
y
percentage
≤100%

Note:
(1) The “bypass” mentioned in above table refers to bypass the crane motions towards
dangerous direction temporarily by pressing the relevant bypass switches after the
warning is sent out and the motions are switched off. However, the safety alarm is not
relieved.
(2) In above table, sign “○” indicates that the warning light is off or the buzzer does not
sound; sign “√” indicates that the warning light is on or the buzzer sounds continuously;
the word “Intermittently” indicates that the warning light flashes and the buzzer sounds
intermittently.

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 0066305-100-04-20Y

4.1.4.1 Electrical control box

1
2

3 4

Components of electrical control box

Names of the
No. Position and function
components
Turn it to left, the slewing limit is disabled;
Turn it to right, the slewing limit is functional.
Slewing limit
1 If any warning situation occurs, the slewing movement of crane is
switch
prohibited automatically even though the slewing limit switch is
triggered.
Turn it clockwise, the switch-offs can be bypassed except main
boom raised to 80° position.
2 Bypass key switch Caution:
It is only permitted to use the bypass key switch during assembly,
commissioning, maintenance or in emergencies.
Push it upwards, the idle speed will be increased;
Idle speed Push it downwards, the idle speed will be decreased.
3 adjusting switch for Note:
Cummins engine Push it upwards or downwards one time, the idle speed will be
increased or decreased by 50r/min.
Engine diagnostic It is a diagnosis interface for service personnel from engine
4
socket manufacturer.

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 0066305-100-04-20Y

4.2 Instruction for digital display system

No. Description
1 LCD screen of load moment limiter
2 Dashboard

4.2.1 Load moment limiter

As to detailed operation, refer to Load Moment Limiter Operating Manual.

Caution:
Observe safety regulations for crane operation and rated lifting capacity charts when
adjusting the load moment limiter.

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 0066305-100-04-20Y

4.2.2 Dashboard

It can display the working status of crawler crane in real time. Various kinds of information can
be displayed on the dashboard, including engine speed, total engine operating hours, water
temperature, oil pressure, oil level, pump pressure and so on. When abnormal conditions
occur, the corresponding icons on the dashboard will flash.
1

4 5

Components of dashboard
Names of the
No. Function
components
Display engine information and various warning alarms.（For
Engine instruments and
1 the detailed information, see components of instruments and
warning icons
warning icons）
Oil pressure gauge for
2 Display the working pressure of main pump I.
main pump I
Oil pressure gauge for
3 Display the working pressure of main pump II.
main pump II
Oil pressure gauge for
4 Display the working pressure of slewing pump.
slewing pump
Oil pressure gauge for
5 Display the working pressure of control pump.
control pump

Caution:
When crane movement “spool up / reel off hoisting winch 1” or “left crawler forwards /
backwards” is carried out, main pump I works; when crane movement “spool up / reel off
hoisting winch 2 or main boom derricking winch or right crawler forwards/backwards” is
carried out, main pump II works; when crane movement “slew to the right/left” is carried out,
slewing pump works.

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 0066305-100-04-20Y

12 3 4 5 6 7

15 8

14 9

13 12 11 10

Components of engine instruments and warning icons

Names of the
No. Icon Function
components

1 Icon “Oil filter clog” When oil filter is clogged, this icon will flash.

Icon “Water When water temperature exceeds 96℃, this icon will
2
temperature” flash.

3 Power indicator If vehicle power is switched on, this indicator will be on.
Display the current engine speed and total engine
4 Tachometer
operating hours.
5 Icon Not assigned

6 Icon Not assigned

7 Icon Not assigned

Engine oil pressure
8 Display current engine oil pressure.
gauge
9 Icon Not assigned

10 Icon Not assigned

11 Icon Not assigned

Icon “Engine oil If engine oil pressure is lower than 0.06MPa, this icon
12
pressure” will flash.
If fuel level is lower than 10% of fuel tank, this icon will
13 Icon “Fuel level”
flash.
Water-temperature
14 Display engine water temperature.
gauge
15 Fuel gauge Display current fuel quantity in percentage.

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 0066305-100-04-20Y

4.3 Startup of crane

4.3.1 Adjustment of crane operator’s seat

4.3.1.1 Vertical adjustment of headrest

The height of headrest is adjusted manually.

4.3.1.2 Adjustment of armrest

The height of armrest can be adjusted by adjusting knobs.

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 0066305-100-04-20Y

4.3.1.3 Horizontal adjustment of seat

Pull the lever upwards;

Move the seat to required position;
Release the lever.

4.3.1.4 Adjustment of the height of seat

There are two levers to adjust the height of the seat. The front lever adjusts the height of the
front of the seat, and the rear lever adjusts the height of the rear of the seat.

Pull the lever upwards, the front of the seat is raised up.

Pull the lever upwards, the rear of the seat is raised up.

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 0066305-100-04-20Y

4.3.1.5 Adjustment of backrest

Press your back gently against the backrest;

Pull the lever upwards;
The backrest tilts backwards;
Pull the lever downwards;
The backrest automatically tilts forwards.

4.3.2 Checks before startup

Following checks should be performed before startup of engine.

4.3.2.1 Check oil filter and oil level

a) Oil level of diesel engine;

b) Oil level of hydraulic oil tank;
c) Oil filter on hydraulic oil tank.

4.3.2.2 Check fuel level

Check fuel level shown on the fuel gauge in the operator’s cab.

4.3.2.3 Check coolant level

Add coolant to the rim on the filling nozzles.

Warning:
Never check the coolant level before the engine is cooled down. Otherwise, you may get
scalded.

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 0066305-100-04-20Y

4.3.2.4 Check the general conditions of crane

Before starting up the crane, the operator must ensure that the following conditions are
fulfilled:
a) Check the daily record of work to ensure that all regular inspections maintenance and
repair works are performed.
b) Check the boom limit switch, 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.
k) Estimate the weight and dimensions of load to be lifted in advance.
l) Crane operation can be carried out within minimum working radius. No obstacles hinder
the necessary movements. The ground at the operating site is able to support expected
loads.
m) Ensure that no obstacles are within working radius and operator can see the load
clearing from the cab. Check if the communication between operator and signalman is
kept smooth so as to ensure safe crane operation.
n) Determine the load-bearing capacity of ground to be operated upon. Ensure that crane is
supported properly and never operate the crane on the soft and uneven surface or on the
ground of high water content or covered with frozen soil. If crane is set up close to
trenches, reinforce the trenches to avoid landslide. If the ground does not have adequate
load-bearing capacity, the crane is liable to turnover. In this case, crosstie, steel plates
should be padded underneath the crawler to distribute load so that the load-bearing
capacity of the ground will not be exceeded; make sure that the crane is leveled.

Caution:
Before carrying out any boom movement, make sure that there are no loose parts on the
boom. Otherwise, the falling parts may hit the persons or other objects.

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 0066305-100-04-20Y

4.3.3 Turn on power supply

4.3.3.1 Insert ignition key into ignition lock and turn it clockwise to the 2nd position, then
the power supply is turned on.

Turn on the
power supply

4.3.3.2 Operation of air conditioning of crane operator’s cab

(For the detailed information, refer to Section 8.1 in Chapter 8.)

The control panel for air conditioning is located at the top right side of operator’s cab.

Control panel for air

conditioning

a) Heating:
1) Turning cooling/heating selective switch downwards;
2) Turn on switch behind the electrical control box for slewing table;
3) Turn air volume rotary switch to adjust the temperature inside operator’s cab.
b) Cooling:
Turn air volume rotary switch and temperature control rotary switch to adjust the wind
speed and temperature inside operator’s cab.

4.3.3.3 Startup of front/roof windshield wiper

In case of rainy day, press front windshield wiper switch on the control panel at the top right
side of operator’s cab, then the front windshield wiper is turned on;
The roof windshield wiper switch is located above the operator’s seat. To turn on the roof
windshield wiper, the operator only needs to press this switch.

Roof windshield
wiper switch

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 0066305-100-04-20Y

4.3.3.4 Horn

Check if the horn is working properly with horn switch (see No. 2 in figure of Section 4.1.2.1)
before work.

4.3.3.5 Illumination

When crane works at night, the operator can turn the master lighting switch on the control
panel at the top right side of operator’s cab to,
1) 1st position: the LED on the switches of control panel will light up;
2) 2nd position: all the working floodlights will light up.
Press working floodlight switch, the working floodlight on the slewing table will light up.

Master lighting
switch

4.3.4 Start engine

After the power supply is turned on, continue to turn ignition key clockwise to start the engine.

Start engine

Note:
(1) Compared with routine conditions, it takes longer time to preheat the engine
automatically in cold weather. This is a normal phenomenon.
(2) The crane engine can not work with full load until running temperature is reached.
(3) Do not use accelerator when starting engine.
If the engine fails to start after approx. 5s, slowly depress the accelerator pedal all the
way down.
If the engine can not be started within 5-10s, give up the starting attempt and wait approx.
1 minute before trying again.
If the engine still can not be started for three times, stop starting engine at once and
check it for fault.
If the temperature of engine is high, do not depress accelerator pedal when starting
engine to avoid black smoke discharging.
After engine starts, release ignition key at once to let it return to initial position, and check
the parameters of engine at the same time.

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 0066305-100-04-20Y

4.4 Safety devices

The crane operator must check all safety devices for functional work before every crane
operation.

Danger:
Operating crane with faulty safety devices is prohibited!

4.4.1 Emergency shut-down button

As soon as this emergency shut-down button is pressed, electrical system and diesel engine
is switched off, all crane movements stop immediately.

Danger:
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.

4.4.2 Load moment limiter

Load moment limiter is a computer for monitoring and controlling crane. It can display the
basic parameters of crawler crane under various working conditions at any time.
When the actual lifting capacity reaches 90% of rated lifting capacity, the forewarning signal
will be given out; when the actual lifting capacity reaches or exceeds the rated lifting capacity,
the warning signal will be sent out and all the dangerous movements “Derrick boom up/down”
will be switched off. Under this situation, only operation towards safe direction is permitted.
The load moment limiter can prevent crane from toppling over, boom buckling and personnel
injuries during operation, and thus ensure normal and safe operation of crane.
When crane is overloaded, the load moment limiter will send out warning signal and cut-off
signal. However, this cut-off signal can not switch off dangerous motions directly, which can
only be cut off by crane’s electrical system and hydraulic system.
When actual lifting capacity reaches 90% to 100% of the rated lifting capacity, the indicator
light will turn yellow, the buzzer will sound the alarm intermittently.
When actual lifting capacity exceeds 100% of the rated lifting capacity, the indicator light will
turn red, and the buzzer will sound the alarm continuously. Such dangerous movements as
derricking boom up/down and lifting the hook are switched off via PLC controller. For methods
to bypass the switch-off of overload, see Section 4.1.4.

Caution:
It is only permitted to bypass the switch-off of overload by specialist personnel in
commissioning and maintenance conditions or it is carried out to avoid other accidents.

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 0066305-100-04-20Y

4.4.3 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 operator’s cab), thus the operator, even in the operator’s cab, can clearly read the
boom angle shown on the indicator.

4.4.4 Lowering limiter

In order to prevent wire rope from being wound in the opposite direction after it is unwound
completely, the lowering limit switches fitted on winch 1 and 2 are triggered when there are
only 3 windings of wire rope left on the drums. Under this condition, the buzzer in operator’s
cab will sound continuously and the icons or will flash, the red part and
yellow part of tricolor light outside operator’s cab will be on synchronously. At this time, the
movement “reel off winch” is switched off, and only the movement “spool up winch” can be
carried out. For methods to bypass the switch-off of reeling off winch, see Section 4.1.4.

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 0066305-100-04-20Y

Caution:
The derricking bypass switch or bypass key switch is only used in commissioning and
maintenance conditions or it is used to avoid other accidents

4.4.5 Hoisting limiter

The hoisting limit switch is installed to prevent the hook block from colliding with the boom
head.
If the load hook comes into contact with hoisting limit switch weight during its upward
movement, the hoisting limit switch is triggered, the buzzer sounds, and the crane movement
“spool up winch” is switched off. At this moment, only crane movements “Reel off winch” and
“Derrick boom up” are permitted. For methods to bypass the switch-off of spooling up winch,
see Section 4.1.4.

Danger:
During crane operation, bypass the hoisting limit switch only with derricking bypass switch or
bypass key switch if someone is monitoring the distance between hook block and boom head.
He must contact the crane operator directly.
Carry out any hoisting movement with great caution and at minimum speed.

Caution:
The derricking bypass switch or bypass key switch is only used in commissioning and
maintenance conditions or it is used to avoid other accidents.

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 0066305-100-04-20Y

4.4.6 Derricking limiter

It is used to detect main boom angle in real time according to the data collected by angle
sensors. Once the detected angle exceeds safe angle range, an alarm will be sent out and all
dangerous movements will be switched off so as to ensure safe crane operation.

4.4.6.1 For “main boom” configuration

The max. main boom angle is 80°.

When main boom is raised to 78° position, the alarm will be sent out, but the movement of
derricking boom up is still permitted.
When main boom is raised to 80° position, the alarm will be sent out, and the movement of
derricking boom up will be switched off automatically. At this time, only derricking boom down
is permitted. Under this condition, the main boom can not be raised any more even though
any bypass methods are adopted.

4.4.6.2 For “main boom with fixed jib” configuration

The requirements for main boom angle in this configuration are the same as that in “main
boom” configuration. The fixed jib can be fitted in the angle of 10° or 30° to main boom.

4.4.7 Anemometer

The anemometer should be installed on boom head. It is used to detect the wind speed on
boom head. The wind speed will be shown on LCD screen of load moment limiter.

Caution:
The maximum in-service wind velocity should be not more than 9.8m/s during operation; the
maximum out-of-service wind velocity should be no more than 21m/s when only main boom is
assembled, and no more than 15m/s when fly jib is assembled.

4.4.8 Inclination display

The inclinometer is fitted on crawler crane to measure the inclination of the whole crane.

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 0066305-100-04-20Y

4.5 Crane operation

4.5.1 Operation of travel gear

4.5.1.1 Travel gear components

The travel gear comprises drive sprocket, driven sprocket, track-carrier roller, track roller and
crawler, crawler carrier, traveling motor as well as traveling reducer. Both the right crawler
carrier and the 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
block I, main valve block II and central revolving joint.

1 2 3 4 5 6 7 8

Traveling mechanism

No. Description

1 Drive sprocket

2 Track-carrier roller

3 Track roller

4 Track pad

5 Track-carrier roller

6 Crawler carrier

7 Track-carrier plate

8 Driven sprocket

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 0066305-100-04-20Y

4.5.1.2 Operation of travel gear

The travel movements are controlled by left and right travel gear pedals or left and right hand
levers. The movements “left crawler forwards” and “left crawler backwards” are controlled by
left travel gear pedal or left hand lever, and the movements “right crawler forwards” and “right
crawler backwards” are controlled by right travel gear pedal or right hand lever. In a word, the
crane can carry out such movements as traveling straight ahead/backwards, steering during
traveling and turning on spot. The travel alarm device at the bottom of operator’s cab will
sound the alarm during traveling.

Right crawler forwards

Left crawler forwards

Right crawler backwards

Left crawler backwards

Left travel gear Right travel gear

pedal pedal

Danger:
The crane operator must make sure that there are no persons or obstacles within the danger
zone before operation. He must give a warning signal before starting crane movement.

Note:
Always operate the hand lever slowly and carefully, which can not only extend the service life
of crane but also avoid accidents.

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 0066305-100-04-20Y

4.5.1.3 Traveling on level road

a) Traveling straight ahead:

Push the two hand levers forwards at the same time.
b) Traveling straight backwards:
Push the two hand levers backwards at the same time.
c) Turning to left with a crawler:
Push the right hand lever forwards.
d) Turning to right with a crawler:
Push the left hand lever forwards.

Turning to left with a crawler Turning to right with a crawler

e) Differential steering to left:

Push right hand lever forwards heavily, while pushing left hand lever forwards slightly to
make the speed of right crawler faster than that of left crawler.
f) Differential steering to right:
Push left hand lever forwards heavily, while pushing right hand lever forwards slightly to
make the speed of left crawler faster than that of right crawler.

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 0066305-100-04-20Y

Differential steering to left Differential steering to right

Caution:
The operator can infinitely push the hand levers, and thus make crawlers on both sides drive
forwards at different speed. In this way, the steering radius can be changed infinitely.
g) Turing to right on the spot:
Push right hand lever backwards heavily, then right crawler will turn to left; Push left hand
lever forwards heavily, then left crawler will turn to right.
h) Turing to left on the spot:
Push left hand lever backwards heavily, then left crawler will turn to right; Push right hand
lever forwards heavily, then right crawler will turn to left.

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 0066305-100-04-20Y

Caution:
(1) When there is a need to stop traveling or steering, return the hand lever to neutral (zero)
position, the traveling brake will be activated automatically.
(2) When crane is traveling with a load, it can only travel forwards with boom located straight
ahead. In traveling condition, the suspended load should not exceed 70% of the rated
lifting capacity.
(3) When crawler crane is traveling for a long distance, ensure that the traveling motor is
behind the slewing table.

4.5.1.4 Traveling on slope

Make crawler crane travel forwards, and place the left control lever (slewing control lever) in
neutral (zero) position. When crawler crane is traveling uphill, the engine speed must be
controlled 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.

a) Traveling crawler crane with attachments on uphill slope

The maximum climbing ability of a crawler crane is limited by following criteria:
1) The center of gravity of the whole crane;
2) The friction coefficient between roadway and track pad;
3) The transfer between the horizontal and the incline;
4) The maximum gradient of 30º.

Caution:
To travel crawler crane uphill, following conditions must be observed:
(1) The ground must be able to take on the ground pressure, which will occur.
(2) The friction coefficient between roadway and track pad must be large enough to take on
any drive forces which will occur. Slippery ground can cause crane to slip sideways and
to move into an impermissible side incline position. There is a danger of accidents!
(3) The slewing table must be aligned parallel to the crawler carriers and must be secured to
prevent it from turning.
(4) The maximum permissible wind velocity is 9m/s.
(5) Side incline is not permitted!

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 0066305-100-04-20Y

(6) Travel slowly, and perform all acceleration and deceleration motions with utmost caution.
(7) The transfer from the horizontal to the incline and from the incline to the horizontal must
be made very evenly, which means there may be no edges over which the crane tips.
The change of gradient must be continuous.
b) Turning on the slope
If crawler crane needs to turn on the slope when it is traveling downhill, some treatments
should be taken to the undulations to form a gentle slope curve (see following diagram),
which can prevent crane’s center of gravity from deviating and load from concentrating
on a section of crawler when crawler crane is traveling over undulations.

Remove the undulation

Gentle slope

Slope treating diagram

Note:
(1) When crawler crane is traveling from the horizontal ground to the slope, if its center of
gravity deviates forwards, the crane should be stopped to adjust the center of gravity.
(2) When the slope is short and there is no barrier in front, or when the roadway is very
narrow because some plates are placed on the slope for crawler crane traveling, the
crane may skid. At this time, do not stop the crane and travel it forwards directly.

Caution:
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.

4.5.1.5 Travel movement 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;
c) Only minimum traveling speed is permitted;
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.

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 0066305-100-04-20Y

4.5.2 Operation of crane winches

4.5.2.1 Hoisting winch

a) Hoisting winch components

The hoisting winch consists of hydraulic motor, winch reducer, brake, rope guider,
lowering limiter, hoisting limiter, wire rope, main load hook and auxiliary load hook etc..
The lifting speed of load can be changed by adjusting inclination angle of control lever. The
angle can vary from -26.5° to 26.5°. The bigger the inclination angle is, the quicker the
lifting speed is. The control lever will blocked automatically after it is pushed
forwards/backwards completely.
b) Operation of hoisting winch
The crane is fitted with two hoisting winches: hoisting winch 1 and hoisting winch 2. The
structure of winch 1 is the same as that of winch 2, but their positions and functions are
different. Winch 1 is required for crane operation with main boom, and winch 2 is required for
crane operation with main boom and fixed jib, or crane operation with main boom and tip
boom.
1) Operation of hoisting winch 1
Main boom derricking winch control lever
Hoisting winch 2 control lever
Forward direction Hoisting winch 1 control lever

Spool up winch 1: push hoisting winch 1 control lever backwards;

Reel off winch 1: push hoisting winch 1 control lever forwards.
2) Operation of hoisting winch 2
Spool up winch 2: push hoisting winch 2 control lever backwards;
Reel off winch 2: push hoisting winch 2 control lever forwards.
3) High-speed operation of hoisting winches
Both hoisting winch 1 and 2 have high-speed load lifting and lowering functions. Turn
high-speed rotary knob for hoisting winch 1 or high-speed rotary knob for hoisting
winch 2 (see No. 6,16 in figure of Section 4.1.3), the main load hook or auxiliary load
hook can be lifted or lowered at higher speed.
4) Micro-positioning function
Both hoisting winch 1 and 2 have micro-positioning function. Press this switch (see
No.8 in figure of Section 4.1.3), the movement speed will be reduced 25% of original
speed.

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 0066305-100-04-20Y

Note:
(1) Choose proper rope reeving in accordance with boom length.
(2) Under any conditions, there must be at least three windings of wire rope left on the
winding drum.
(3) When a load is lifted away off 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 lift the load with boom if the load is still in contact with the ground.
(4) Do not change 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
machine will be damaged.
(5) The hoisting mechanism has good micro-positioning function. In micro-positioning
operating condition, the engine should run at fixing speed a little faster than the idle
speed. Never change accelerator arbitrarily, otherwise the unstable hoisting speed and
vibration of lifting load will occur.
(6) In micro-positioning operating condition, the engine should run at 1500r/min.
(7) The hoisting winch 1/2 high-speed rotary knob is only used when crane is working
without a load or with a light load.
(8) If the main boom length is extended in “main boom” configuration, the lifting height of the
crane will increase accordingly, which will therefore make the wire rope not be 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.
(9) When 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 the alarm will be
given out.

Caution:
When system sounds the alarm, the operator should operate crane towards safe directions. If
it is necessary to operate crane towards dangerous directions, the operator can refer to
Section 4.1.4 safety control. Any operation to bypass the switch-off is only carried out by
specialist personnel in commissioning and maintenance conditions or it is carried out to avoid
other accidents.

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 0066305-100-04-20Y

4.5.2.2 Operation of derricking mechanism

a) Derricking mechanism components

Through changing the length of wire rope reeved between derricking pulley blocks
(includes derricking crown block and derricking traveling block), the derricking
mechanism, via derricking winch, can adjust boom angle so as to change the working
radius. We can use A-frame and boom frame to carry out derricking motion. During
derricking, the derricking crown block is located at the top of A-frame, while the traveling
block is on the other end of anchoring rod, so the boom angle can be changed with the
variation in the length of wire rope between the derricking pulley blocks.

1
6

3
5
4

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 0066305-100-04-20Y

Derricking mechanism

No. Description

1 Derricking traveling block

2 Derricking crown block

3 A-frame assy.

4 Derricking rope

5 Tilting-back support of main boom

6 Boom frame

7 Anchoring rods

b) Operation of derricking mechanism

Derrick boom down: push main boom derricking winch control lever forwards;
Derrick boom up: push main boom derricking winch control lever backwards;
Stop derricking motion: return main boom derricking winch control lever into neutral
position.

Main boom derricking winch control

lever
Forward direction

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 0066305-100-04-20Y

4.5.2.3 Functions of crane winches for various boom configurations

a) Main boom (S)

Main boom angle can be changed from 0° to 80°.
Hoisting winch 1 — lift/lower main load hook;
Derricking winch—derrick main boom up/down.

b) Main boom with fixed jib (SF)

The fixed jib can be assembled in the angle of 10° or 30° to main boom.
Note: The angle must be set in advance. It can not be changed during operation.
Hoisting winch 1— lift/lower main load hook;
Hoisting winch 2 —lift/lower auxiliary load hook;
Derricking winch—derrick main boom up/down.

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 0066305-100-04-20Y

c) Ratchet mechanism
The derricking winch is fitted with brake and ratchet mechanism, which can lock
derricking winch so as to make boom stop at any position in case crane does not work for
a long time.

When pressure oil passes through the brake valve, press ratchet switch and hold it until
ratchet pawl is disengaged from ratchet wheel completely. Once ratchet mechanism is
activated, the ratchet pawl can be disengaged from ratchet wheel all the time even
though the ratchet switch is released.
If derricking mechanism does not work for a long time, the brake must be actuated and
the brake valve should not be electrified. At this time, press ratchet switch and hold it until
ratchet pawl engages with ratchet wheel teeth.

Note:
(1) Derricking operation should be performed stably. When crane is lifting a load, jerky
operation will bring great impact on the crane.
(2) When crane is lifting a load, the operator should not derrick boom towards dangerous
directions. Otherwise, crane may topple over.
(3) Before derricking mechanism is operated, first derrick boom down a little, and then
operate ratchet mechanism according to the correct methods mentioned above. In this
way, ratchet pawl can be disengaged from ratchet wheel successfully.
(4) Before switch off the derricking mechanism, press the ratchet switch and hold it till the
ratchet pawl engage with the ratchet tooth.
(5) If ratchet pawl is not disengaged from ratchet wheel completely, derricking winch is only
permitted to reel off.

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 0066305-100-04-20Y

4.5.3 Operation of slewing mechanism

4.5.3.1 Slewing mechanism components

The slewing mechanism consists of piston hydraulic motor, planetary gear reducer, slewing
brake valve, brake, drive gear and slewing ring, etc. The superstructure can carry out 360°
continuous rotation via the slewing ring which is driven by drive gear. The slewing speed can
be adjusted by changing the inclination angle of control lever.
An independent closed piston pump is applied to hydraulic system to supply oil. The slewing
valve is load sensitive proportioning valve, which can adjust the slewing speed accurately.

4.5.3.2 Operation of slewing mechanism

The slewing alarms on the both sides of rear counterweight will send out acoustical signal
during slewing operation.
a) Slew to right: press the left side of slewing brake switch on left control lever (slewing
control lever) and push left control lever forwards at the same time ;
b) Slew to left: press the left side of slewing brake switch on left control lever (slewing
control lever) and push left control lever backwards at the same time;
c) Stop slewing: return left control lever in neutral position.

Slew to right Slew to left

Forward direction
Left control lever

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.
(3) Before carry out slewing movement, an acoustic signal should be given.

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 0066305-100-04-20Y

4.5.3.3 Fixing device for slewing table

Procedure for fixation of slewing table:

a) Slew superstructure to front position;
b) Pull out fixing pin for slewing table;
c) Rotate fixing pin for 180°;
d) Insert fixing pin.

Assembly of fixing pin

Note:
(1) The fixation of slewing table can be deactivated in reverse order.
(2) Pull out fixing pin before slewing and lifting operation; insert it well before traveling, and
when machine is in transport condition or it does not work for a long time.

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 0066305-100-04-20Y

4.5.3.4 Swing free running

If load hook is not positioned vertically over the load’s center of gravity before lifting operation,
the operator should operate hoisting winch control lever and turn the “Swing free running
on/off” button clockwise (No.7 in figure of Section 4.1.2) at the same time. At this moment, the
boom will enforce the slewing table, under the influence of side force of wire rope, to rotate
toward the direction of load’s center of gravity till the hoisting wire rope is vertical. In this way,
the boom can be protected against damage due to side force.

Note:
(1) When carrying out the movement “Swing free running”, operate control lever to lift hook
at the same time. In this way, a side force will be produced on the wire rope to make load
hook vertical to boom.
(2) Ensure 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, and apply the
brakes. It is prohibited to stop slewing movement or change slewing direction jerkily.
(4) Longer boom - slower slewing speed;
(5) Heavier load - slower slewing speed;
(6) It is not permitted to slew the superstructure on the trailer.
(7) In order to ensure safe operation, the user 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.

Caution:
(1) When operator has to leave the machine in traveling or transport condition, never rely
solely on the slewing brake to lock the slewing mechanism.
(2) Activating slewing brake switch to lock slewing mechanism abruptly should be avoided,
since it may cause damage to the superstructure.

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 0066305-100-04-20Y

4.5.4 Simultaneous operation

4.5.4.1 Main boom (S)

a) Simultaneous operation of slewing mechanism and derricking mechanism

Operate left control lever and main boom derricking winch control lever at the same time.

b) Simultaneous operation of derricking mechanism and hoisting winch 1

Operate main boom derricking winch control lever and hoisting winch 1 control lever at
the same time.

c) Simultaneous operation of slewing mechanism and hoisting winch 1

Operate left control lever and hoisting winch 1 control lever at the same time.

d) Simultaneous operation of hoisting winch 1 and hoisting winch 2

Operate hoisting winch 1 control lever and hoisting winch 2 control lever at the same
time.

e) Simultaneous operation of slewing mechanism and travel gear

Operate left control lever and depress travel gear pedal at the same time.

f) Simultaneous operation of hoisting winch 2 and derricking mechanism

Operate hoisting winch 2 control lever and main boom derricking winch control lever at
the same time.
4.5.4.2 Main boom with fixed jib (SF)

a) Simultaneous operation of slewing mechanism and hoisting winch 2

Operate left control lever and hoisting winch 2 control lever at the same time.

b) Simultaneous operation of slewing mechanism and derricking mechanism

Operate left control lever and main boom derricking winch control lever at the same time.

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 0066305-100-04-20Y

4.5.5 Crawler carrier extending & retracting mechanism

4.5.5.1 Components of crawler carrier extending & retracting mechanism

Crawler carrier extending & retracting mechanism consists of additional supports, crawler
carrier extending & retracting cylinder, crawler carrier, anchoring rods and inserting pin etc..
This mechanism is connected to undercarriage central section through additional supports.
The extending and retracting of crawler carrier is achieved by the hydraulic cylinder.

4.5.5.2 Procedure for extending crawler carrier (see following figure)

a) After basic machine arrives at jobsite, pull out inserting pin manually.

Undercarriage central section

Crawler carrier extending &

retracting cylinder

Inserting pin

b) Pull out the undercarriage control lever.

Note:
The ground which supports the crane must be even and flat. And no obstruct is within the
working radius.
c) Pull out pin spindle on the anchoring rods before extending crawler carrier.
Note:
Insert the pin spindle after crawler carrier extending & retracting cylinder is extended or
retracted to proper position, or before traveling.

Note:
The retracting of crawler carrier should be carried out in reverse order.

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 0066305-100-04-20Y

Note:
(1) In any conditions, crawler carrier must be extended/ retracted by more than two
operators. When extend or retract the cylinder, one operates the control valve, and the
other checks whether the outrigger and crawler carrier have extended/retracted to proper
position.
(2) Connect outrigger to frame with inserting pin before extending crawler carrier.
(3) Insert the inserting pin after the horizontal cylinder is extended / retracted completely or
before machine travels.
(4) It is forbidden to extend/ retract crawler carrier when the crane is equipped with boom
and counterweight or when it is lifting a load.
(5) The engine speed must be controlled within middle-low speed (about 1000 -1500 rpm)
when crawler carriers are extended/retracted.
(6) The extending or retracting of crawler carrier should be carried out on firm and even
ground. Much attention should be given to the level state of machine during operation.
(7) Do not lift a load until two crawler carriers are extended completely!

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 0066305-100-04-20Y

4.6 Rope reeving

As to detailed rope reeving and specification, see Section 2.4.3 in Chapter 2.

4.6.1 Hoisting rope guidance and reeving

4.6.1.1 Prerequisite:

a) The crane is properly supported and aligned horizontally;

b) An assistant is present to guide the hoisting rope.

4.6.1.2 Assembly procedure:

a) Place required hook block under the pulley head of boom;

b) On the hook block, remove the retaining springs and pull out rope guard tubes;
c) Switch on crane engine;
d) Lay the hoisting rope over the upper rope pulley and reeve it between the pulley head
and the hook block (for details, see Section 4.6.1.3);
e) Reinsert the rope guard tubes and then secure them with retaining springs.

Warning:
When the assistant guides the hoisting rope to the pulley head, the crane operator must
operate the winch. This procedure must be done in such a manner that the rope does not
slacken up on the winding drum.

Warning:
(1) Complete the assembly operation on a stable area! If it is unavoidable that the rope must
be hand-guided over the boom to the pulley head, proceed with great caution when
walking on the boom.
(2) There is a great danger of causing a serious accident if the crane function is not operated
properly and the person guiding the rope slips on the boom.

4.6.1.3 Reeving the load hook

a) Number of rope pulleys

– 80t load hook, 6 rope pulleys;
– 50t load hook, 3 rope pulleys;
– 30t load hook, 2 rope pulleys;
– 8t load hook without rope pulley
b) Reeving the load hook
As to rope reeving corresponding to different load hook, please see Section 2.4.3.1 in
Chapter 2.

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 0066305-100-04-20Y

– 80t load hook, rope reeving of 12, 10, 8;

WⅡ WⅠ WⅡ WⅠ

×12 ×10

WⅡ WⅠ

×8

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 0066305-100-04-20Y

– 50t load hook, rope reeving of 7, 6, 5;

×7 ×6

WⅡ WⅠ WⅡ WⅠ

×5

WⅡ WⅠ

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 0066305-100-04-20Y

– 30t load hook, rope reeving of 4, 3;

×4 ×3

WⅡ WⅠ WⅡ WⅠ
– 6t load hook, rope reeving of 1;

×1

WⅡ WⅠ

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 0066305-100-04-20Y

4.6.1.4 Fixation of rope end point

a) Insert wire rope into rope lock; (figure 1)

b) Put wire rope around rope thimble and then insert them together into rope lock again;
(figure 2)
c) Pull the wire rope tightly to make it fixed between rope thimble and rope lock closely;
(figure 3)
d) Fix wire rope with two rope clamps; (figure 4)
e) Fix rope lock on the boom head or hook block with pin and secure it with retaining spring.

Warning:
The pin must always be inserted from the inside to the outside and secured from the outside
to prevent hoisting rope from rubbing against the pin or the retaining spring.

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 0066305-100-04-20Y

4.6.1.5 Attach the hoisting limit switch weight, figure 5

a) Fix the rope connected to weight with rope clamp;

b) Attach hoisting limit switch weight to the hoisting rope;
c) Secure weight and rope with fixing pin and retaining spring.

Caution:
Risk of injury to feet!
The hoisting limit switch weight consists of two interconnected parts.
When detaching or attaching the weight, make sure that both parts remain inserted in each
other and that weight does not fall down.

Warning:
Accident hazard!
Incorrect reeving or incorrect number of reevings can lead to accidents.
Make sure that the reeving process has been done properly and that the overload protection
has been correctly set.

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 0066305-100-04-20Y

4.6.2 Derricking rope reeving

1
2

3 4, 5, 6 7

Components of derricking rope

No. Code Description Quantity Weight

1 00663000100001210 Pin spindle 1 0.9kg

Retaining spring
2 006340000001 1 0.053kg
(D40,45)
3 00663002100001140 Washer 1 0.12kg

4 1090100446 Rope lock 20 1 8.156kg

5 1090100453 Rope thimble 1 1.513kg

6 1090100001 Rope clamp 2 0.624kg

7 00663022100001021 Derricking rope 1 264kg

The method for fixing derricking rope end point is the same as that for hoisting rope end point.

Warning:
(1) There must be no persons in the area around the hook block.
(2) When derricking winch spools up, the wire rope can lash out like a whip. Therefore,
ensure that there is no loose rope on the winch.

Caution:
When wire rope is spooled onto the winch, at least 2m long rope should remain, and the rope
end point should be fixed.
Never wind rope end point onto the winch!

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0066305-100-04-20Y

4 - 50
Chapter 5 Assembly &
dismantling
 0066305-100-05-20Y

5.1 Safety-technical notes

5.1.1 Notes on assembly

- Make sure that the crane complies with operating requirements. Then check the positions
of A-frame, anchoring rod, FA-frame and sequence of boom intermediate sections one by
one according to combination mode of boom length.
- Reeve the hoisting rope between the rope pulleys on the boom head and hook block in
accordance with the corresponding hoisting rope reevings.
- Assemble counterweight according to relevant requirements.
- 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.
- While erect boom from the ground after it is assembled, it must be placed pointing at the
straight front/rear direction of crane. According to this requirement, attention should be
given to choose flat ground to support the crane.
- Assemble the fixed jib strictly in accordance with the maximum permissible boom length.
Reeve the hoisting rope in accordance with rope reeving.
- Protective mattress should be used between lifting chain, load hook, hoisting rope and
chords, web members; or attach fibre lifting chain to the lifting eye on boom frame prior to
lifting operation.
- Lattice components which are not 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.

Caution:
(1) For assembly work on the crane, a safety assembly support or working platform should
be used. Improvisations are prohibited. Otherwise, there is a danger of falling down;
(2) Before operate the slewing mechanism, the slewing fixing pin must be unpinned,
otherwise, the buzzer will sound all the time and the slewing movement can not be
carried out.

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 0066305-100-05-20Y

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.
- Check whether an appropriate operating site has been selected so that the crane
movements can be performed within maximum and minimum working radiuses.
- Check whether there are obstacles which will hinder required crane operation.
- Check whether the ground provides adequate load-bearing capacity.
- Know clearly about the type of crane operation and operating mode.
- Distance between the lifting points and surrounding buildings.
- Influence of communal facilities on crane operation (including the overhead high/low
voltage lines and underground gas pipes).
- 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.
- Heights and widths of thoroughfares leading to the site.
- Check the use of radios adopted by signalman and crane operator.
- Take appropriate measures to keep people unconcerned and equipment away from the
danger area of the crane.

Note:
To master the actual condition of lifting operation accurately and ensure safe operation, the
safety measures mentioned above should be checked and a proper operational planning
should be carried out.

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 0066305-100-05-20Y

5.1.3 Inspection of wire rope, load hook, rope pulley and anchoring rod

5.1.3.1 Checking wire rope

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.

Note:
The ropes must be removed immediately if any of the following damage is detected:
– Breakage of a strand;
– Wire breaks;
– Broken wire nests;
– Reduction in the rope diameter by more than 10% of the nominal size;
– Rope deformation.
The replacement rope must comply with the original rope’s specifications, including length,
diameter and strength rating. The lowering limit switch must be readjusted if a new hoisting
rope is used.

Caution:
Worn rope pulley must be repaired or changed prior to fitting a new hoisting rope. If this is not
done, the new hoisting rope will be damaged.
For the detailed information about wire rope inspection and maintenance, please refer to
Maintenance Manual.

5.1.3.2 Checking load hook

- Check load hook for distortions, e.g., at the hook jaw.

- Inspect all bolts and screws, and ensure all cotter pins are complete.
- Check that the rotary connection of load hook can move easily, and the clearance is not
too large.
- Check the easy rotation of load hook: Rotate load hook by hand. If it is stiff, it indicates
that the bearing has been damaged.
- Check safety catch for completeness and functional work.
- Check load hook for corrosion and wear.
For the detailed information about load hook inspection and maintenance, please refer to
Maintenance Manual.

5.1.3.3 Checking rope pulley

- Check rope pulley 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 pulley has
been worn down more than 1/4 of the rope diameter.

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 0066305-100-05-20Y

- 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. Loose and shaken rope pulley indicates that the bearing
and bearing bush are damaged.
For the detailed information about rope pulley inspection and maintenance, please refer to
Maintenance Manual.

5.1.3.4 Checking anchoring rod

- During transportation, the anchoring rods should be secured firmly on the boom frame;
- The anchoring rods should be re-fitted to boom frame according to the assembly diagram,
if they were disassembled during transportation;
- Check the anchoring rods for cracks, wear and corrosion;
- The anchoring rods should be checked regularly.
For the detailed information about anchoring rod inspection and maintenance, please refer to
Maintenance Manual.

5.1.4 Erecting and lowering

Before erecting or lowering a boom combination, ensure that the following prerequisites are
met:

- The crane is properly supported and level.

- The counterweight plates have been attached on slewing table as specified in Section 5.3
of Chapter 5.
- The main boom and fixed jib have been attached in accordance with the lifting capacity
chart and operating instructions.
- All limit switches have been correctly fitted and are fully operational.
- All pinned connections have been secured.
- The hoisting rope has been correctly placed in the rope pulleys and prevented from
jumping out (from rope groove) using rope guard tubes.
- There are no loose parts on main boom or fixed jib.
- In winter, the main boom, fixed jib and associated components (limit switches, rope drums,
solar lamp, anemometer etc.) must be kept free of ice and snow.

Danger:
Incorrectly fitted or faulty limit switches and falling parts (pins, retaining spring, ice etc.) can
cause injury.

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 0066305-100-05-20Y

5.2 Unloading of basic machine

According to certain disassembly principles and methods, crawler crane ZCC800H can be
divided into several parts for transport. The basic machine includes main boom pivot section,
undercarriage central section, slewing table, crawler carrier, A-frame and derricking pulley
block and its gross weight is 42t.

5.2.1 Checks before operation

5.2.1.1 Jobsite
- The ground on the jobsite must be firm and flat. If necessary, steal plate should be
padded.
- It should be large enough for trailer traveling and auxiliary crane operation.

5.2.1.2 Operating procedure and safety regulations

All operators should be familiar with operating procedure and safety regulations and clear
about their areas of responsibility before operating.

5.2.1.3 Checks before operation

Check the basic machine before operation.

5.2.2 Unloading the basic machine

- After the basic machine reaches the jobsite, remove fixing devices and the package.

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 0066305-100-05-20Y

- Drive the basic machine down off the low-loader; or lift the basic machine with a track
crane to make it not contact with the low-loader, and then drive the low-loader away.

- Extend the outrigger and crawler carrier. For detailed operation, please refer to Section
4.5.5 in Chapter 4.

Danger:
During transportation, the traveling switch must be always in “ON” position. Otherwise, the
hoisting rope may be damaged.

Caution:
(1) Before transportation, retract the crawler carrier, lay down the A-frame and place boom
pivot section flatly, and finally lock the slewing mechanism by slewing fixing pin.
(2) When drive the basic machine off or onto to the low-loader, a steel plate (with an
inclination less than or equal to 8°to the ground) should be used to connect the
low-loader to the ground. The inclination angle of main boom pivot section should be less
than 30° in order to protect crane against overturning.
(3) The slewing fixing pin must be unpinned prior to operating the slewing mechanism;
otherwise, the buzzer will sound all the time and the slewing movements can not be
carried out.

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 0066305-100-05-20Y

5.3 Fitting and removal of counterweight

The weight of all counterweight plates is 26.8t, including 1 counterweight base plate of 5.2t, 4
counterweight plates of 3.35t each and 2 central counterweight plates of 4.1t each.
During working, all counterweight plates should be fixed at the tail end of superstructure.
Before fitting the counterweight, make sure that the crawler carrier is extended completely.
When fitting the counterweight, you should unload the counterweight plates via an auxiliary
crane from transport vehicle and place them on flat ground.
After that, lift two counterweight plates in turn and place them in the specified positions, next
secure the counterweights with pin spindles.
The removal of counterweight is carried out exactly in the reverse order.
Description of counterweight

Name and ID code Weight Height

Outline dimensions Qty.
of counterweight (t) (mm)

Counterweight base
plate 5.21 1 605
1090900075

Counterweight plate
3.35 2 560
1090900079

Counterweight plate
3.35 2 560
1090900078

Counterweight plate
4.1 2 560
1090900080

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 0066305-100-05-20Y

Name and ID code Weight Height

Outline dimensions Qty.
of counterweight (t) (mm)

Locking bolt
28.3kg 2 —
00663024900200000

Plate
1.32kg 3 —
00663024900001010

Nut Specification: M30-8

0.277kg 3 —
1040200272 GB/T56-1988

Washer Specification: 30
0.011kg 3 —
1040300010 GB/T93-1987

Pin spindle
3.78kg 2 —
00663024900001020

Retaining spring
0.185kg 2 —
00663300100001090

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 0066305-100-05-20Y

Vertical view

Caution:
(1) Distinguish the front counterweight from the rear one;
(2) It is prohibited to fit and remove counterweights when crawler carriers do not extend
completely (The distance between crawler center is 4.2m when two crawler carriers
extend completely.);
(3) In any condition, the fitting & removal of counterweight should be done by more than two
persons; one person is not permitted to perform this operation.

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 0066305-100-05-20Y

5.4 Available boom configurations for crawler crane ZCC800H

S SF
Instructions for boom configuration

Configuration no. Description Parameters

S Main boom S = 13m - 58m

S = 37m - 49m
SF Main boom with fixed jib
F = 6m - 18m

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 0066305-100-05-20Y

5.5 Combination of boom frame and anchoring rods

5.5.1 Main boom (S)

5.5.1.1 Components of S boom

The main boom, whose length varies from 13m to 58m, comprises basic boom and an
optional number of main boom intermediate sections.
The basic boom is 13m long, including main boom pivot section, main boom head and tip
boom.
There are three types of main boom intermediate section: 3m main boom intermediate
section, 6m main boom intermediate section and 9m main boom intermediate section.

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 0066305-100-05-20Y

12 G12

11
13

G10

G15 10
4

G14

5
4
G13
3
4 6、7

G11

14

8
2
9

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 0066305-100-05-20Y
Component parts of main boom
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

1 00663000100001031 Pin spindle 28 2.12kg

Retaining spring
2 006340000001 56 0.053kg
(D40, 45)

3 00663020100001010 Pin spindle 2 1.1kg

4 00663300100001230 Retaining pin 50 0.1kg

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 0066305-100-05-20Y
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

5 00663000100001162 Pin spindle 2 2.32kg

6 1090100448 Rope lock 2 4.58kg

7 1090100455 Rope thimble 2 2.38kg

8 00663020100001040 Pin spindle 2 1.87kg

5-14
 0066305-100-05-20Y
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

9 1090100022 24（GB5976-1986） Rope clamp 4 1.25kg

10 00663020100001050 Nylon plate 23 1.62kg

11 1040300094 GB/T96.1-2002（ISO7093-1-2000） Washer 8-140HV 46 0.006kg

12 1040100069 GB/T70.1-2000（ISO4762-2004） Screw M8×20-8.8 46 0.015kg

13 00663020101400000 Rope support 1 10.84kg

14 00663300102200000 Angle indicator 1 2.57kg

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 0066305-100-05-20Y

5.5.1.2 Method and principle of assembling and dismantling main boom

When different length of main boom is required, the crane operator only needs to disconnect
main boom pivot section from main boom head, and install main boom intermediate sections
between them. In this way, main boom can be assembled to required length.
Principle of assembling: always bolt on the shorter intermediate sections first!
Main boom assembly table
Main boom length Assembly sequence of Main boom length Assembly sequence of
(m) main boom sections (m) main boom sections

13 6.5+6.5 37 6.5+6+9+9+6.5

16 6.5+3+6.5 40 6.5+9+9+9+6.5

19 6.5+6+6.5 43 6.5+3+9+9+9+6.5

22 6.5+9+6.5 46 6.5+6+9+9+9+6.5

25 6.5+3+9+6.5 49 6.5+9+9+9+9+6.5

28 6.5+6+9+6.5 52 6.5+3+9+9+9+9+6.5

31 6.5+9+9+6.5 55 6.5+6+9+9+9+9+6.5

34 6.5+3+9+9+6.5 58 6.5+3+6+9+9+9+9+6.5

Description of component parts of main boom

Part No. Name of the part Length (m) Weight (t)

G10 Tip boom 1.2 0.12

G11 Main boom pivot section 6.5 0.95

G12 Main boom head 6.5 1.2

Main boom intermediate

G13 3 0.255
section
Main boom intermediate
G14 6 0.44
section
Main boom intermediate
G15 9 0.63
section

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 0066305-100-05-20Y

According to the assembly principles stated above, main boom can be assembled as follows:

G10

G10

G12
G10

G12
G10
G12

G12
G15
G14
G13

G11 G11 G11 G11

13m 16m 19m 22m

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 0066305-100-05-20Y

G10

G10

G10 G12

G10 G12

G12
G15
G12
G15

G15
G15
G14 G15

G14
G13 G13 G13

G11 G11 G11 G11

25m 28m 31m 34m

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 0066305-100-05-20Y

G10

G10

G10 G12

G10 G12

G12
G15
G12

G15
G15

G15 G15

G15

G15

G15
G15
G15

G15
G14 G14
G13

G11 G11 G11 G11

37m 40m 43m 46m

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 0066305-100-05-20Y

G10
G10

G10 G12

G10
G12

G12
G15
G12 G15

G15

G15 G15

G15

G15
G15
G15

G15

G15

G15 G15

G15

G15
G14
G15
G14
G13 G13

G11 G11 G11 G11

G11

49m 52m 55m 58m

Caution:
(1) Different main boom sections should be pinned strictly in accordance with main boom
assembly table;
(2) While the boom sections are assembled, no person is allowed to stand inside or beneath
it.

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 0066305-100-05-20Y

Description of component parts of main boom

Part No. ID code Outline dimensions (unit: mm) Name of the part Quantity Weight

G10 00663050100600000 Tip boom assy. 1 0.12t

Main boom pivot

G11 00663020100200000 1 0.93t
section

G12 00663050100400000 Main boom head 1 1.2t

3m main boom
G13 00663020100800000 1 0.26t
intermediate section

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 0066305-100-05-20Y

Part No. ID code Outline dimensions (unit: mm) Name of the part Quantity Weight

6m main boom
G14 00663020101000000 1 0.44t
intermediate section

9m main boom
G15 00663020101200000 4 0.63t
intermediate section

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 0066305-100-05-20Y

5.5.1.3 Component parts of main boom head

5-23
 0066305-100-05-20Y

Main boom head, sectional view

2 12

5 13

14
8

10

15
11

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 0066305-100-05-20Y
Description of component parts of main boom head
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

1 00663020100401010 Rope guard tube 2 1.86kg

2 00663020100401020 Cover 2 0.3kg

3 00663020100401030 Pulley spindle 1 27.77kg

4 00663020100401040 Shaft sleeve 2 1.84kg

5-25
 0066305-100-05-20Y
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

5 00663020100401050 Single-anchoring rod 2 8.34kg

6 00663020100401060 Shaft sleeve 1 4.44kg

7 00663020100401070 Shaft sleeve 1 1.66kg

8 00663020100401080 Shaft sleeve 1 1.13kg

9 006340000056 PD0406 Retaining plate 120 2 0.42kg

5-26
 0066305-100-05-20Y
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

10 00663020100401100 Shaft 1 48.8kg

11 00663020100401120 Spacing sleeve 5 0.23kg

12 00663020100401090 Threaded rod 1 1.27kg

13 00663024100200000 Rope pulley assy. 2 15.73kg

5-27
 0066305-100-05-20Y
Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
No.

14 00663027800420000 Rope pulley assy. 6 13.3kg

15 00663020100401110 Spacing sleeve 2 2.1kg

5-28
 0066305-100-05-20Y
5.5.1.4 Specification and combination of main boom anchoring rods

Each kind of boom is assigned to an anchoring rod of specific length, and the anchoring rods
should be connected strictly in accordance with the given method. For example, when the basic
boom is 13 m long, the corresponding anchoring rod length is 6.22 m.
When boom length increases by 3m, two 0.3m long double-anchoring rods and two 2.7m long
single-anchoring rods should be added accordingly.
When boom length increases by 6m, two 0.3m long double-anchoring rods and two 5.7m long
single-anchoring rods should be added accordingly.
When boom length increases by 9m, four 0.3m long double-anchoring rods and two 2.7m long
single-anchoring rods as well as two 5.7m long single-anchoring rods should be added
accordingly.
For more information, refer to the following diagram. (Unit: mm)

5-29
 0066305-100-05-20Y

13m

16m

19m

22m

25m

28m

5-30
 0066305-100-05-20Y

31m

34m

37m

40m

43m

46m

5-31
 0066305-100-05-20Y

49m

52m

55m

58m

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 0066305-100-05-20Y

5.5.1.5 Component parts of main boom anchoring rods (unit: mm)

Single-anchoring
rod connected to
main boom head

1, 2

Single-anchoring
rod connected to
derricking 3
traveling block

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 0066305-100-05-20Y

Component parts of main boom anchoring rods

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

1 00663005400201022 Pin spindle 52 1kg

2 00663300100001230 Retaining pin 52 0.1kg

Double-anchoring
3 00663025400210000 26 5.1kg
rod

Single-anchoring
4 00660515400001030 2 47.4kg
rod

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 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

Reducing
5 00663055400210000 1 47.01kg
anchoring rod

Single-anchoring
6 00663025400201020 10 55.5kg
rod

Single-anchoring
7 00663025400201010 10 27.43kg
rod

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 0066305-100-05-20Y

5.5.2 Main boom with fixed jib (SF)

5.5.2.1 Components of fixed jib

The fixed jib length varies from 6m to 18m, and fixed jib intermediate section is 6m
long.

5-36
 0066305-100-05-20Y

G32

G34
6

5
G31

4 3

5-37
 0066305-100-05-20Y

Description of component parts of fixed jib

Part No. ID code Outline dimensions (unit: mm) Name of the part Quantity Weight

1 1040000169 GB/T5783-2000 (ISO4017-1999) Bolt M12×45-8.8 8 0.048kg

2 1040300054 GB/T93-1987 Washer 12 8 0.001kg

3 006340000019 PD0406 Retaining plate 60 4 0.144kg

4 00663000200001011 Pin spindle 4 3.42kg

5 00663000200001022 Pin spindle 12 0.67kg

Retaining spring
6 006340000029 24 0.045kg
(D30,32,35)

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 0066305-100-05-20Y

5.5.2.2 Method and principle of assembling and dismantling fixed jib

The fixed jib can be mounted in the angle of either 10° or 30° to main boom. When
different length of fixed jib is required, the operator only needs to detach the fixed jib
pivot section from fixed jib head, and install fixed jib intermediate sections between
them. In this way, the fixed jib can be assembled to required length.

The detailed assembly method of fixed jib section is the same as that of main boom
section.

Fixed jib assembly table

Fixed jib length Assembly sequence Fixed jib length Assembly sequence
(m) of fixed jib sections (m) of fixed jib sections

6 3+3 18 3+6+6+3

12 3+6+3

Component parts of fixed jib

Part No. Name of the part Length (m) Weight (t)

G31 Fixed jib pivot section 3 0.17

G32 Fixed jib head 3 0.21

Fixed jib intermediate

G34 6 0.17/piece
section

G37 FA-frame 3 0.26

Front tilting-back
G74 1.6 – 2.8 0.046/piece
support of fixed jib

Rear tilting-back
G75 1.5 – 2.33 0.034/piece
support of fixed jib

5-39
 0066305-100-05-20Y

G32

G32 G34

G32 G34 G34

G74

G31 G31 G31

G37 G75

5-40
 0066305-100-05-20Y

Description of component parts of fixed jib

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

Fixed jib pivot

G31 00663020200200000 1 0.17t
section

G32 00663020200400001 Fixed jib head 1 0.21t

6m fixed jib
G34 00663020100400000 intermediate 2 0.17t
section

G37 00663027800000000 FA-frame 1 0.26t

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 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

Front tilting-back
G74 00663003100600001 2 0.046t
support of fixed jib

Rear tilting-back
G75 00663053100200000 2 0.035t
support of fixed jib

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 0066305-100-05-20Y

5.5.2.3 Component parts of fixed jib head

5, 6

7
1, 2
8
9
3

10

11

4 12, 13

14

15, 16

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 0066305-100-05-20Y

Description of component parts of fixed jib head

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

1 00663020200401030 Threaded rod 1 1.5kg

2 1040200102 GB/T6170-2000 Nut M24-8 2 0.089kg

3 00663020200420000 Running wheel assembly 2 9.77kg

4 1080000002 GB1152-1989 Oil cup M10×1 2 0.01kg

5 00663020200401040 Pipe 1 0.67kg

6 1040500057 GB/T91-2000 Pin 4 0.095kg

5-44
 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

7 00663027800420000 Pulley assy. 1 13.3kg

8 00663020200401050 Spacing sleeve 2 2.27kg

9 00663100200401040 Top cover 2 2.27kg

10 00663020200401060 Shaft 1 13kg

5-45
 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

11 00663100200401080 Plate 2 0.31kg

12 1040000090 GB/T5783-2000（ISO4017-1999） Bolt M10×30-8.8 4 0.025kg

13 1040300067 GB/T93-1987 Washer 10 4 0.001kg

14 00663100200401070 Shaft 2 6.36kg

15 1040100038 GB/T70.1-2000 Screw M12×50-8.8 8 0.048kg

16 1040200096 GB/T6170-2000 Nut M12-8 8 0.012kg

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 0066305-100-05-20Y

5.5.2.4 Specification and combination of fixed jib anchoring rods

5.5.2.4.1 Combination of fixed jib rear anchoring rods

When fixed jib is assembled in the angle of 10º to main boom, the length of fixed jib rear anchoring rods is 7.16m;
While fixed jib is assembled in the angle of 30º to main boom, the length of fixed jib rear anchoring rods is 8.06m (i.e., two double-anchoring rods of
0.3m long and two single-anchoring rods of 0.6m long should be added accordingly).
Combination of anchoring rods is shown in following diagram. (Unit: mm)

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 0066305-100-05-20Y

Anchoring rod
connected to
FA-frame

8 9 3 10 11

1, 2 3 4 5, 6 7

5-48
 0066305-100-05-20Y

Description of component parts of fixed jib rear anchoring rods

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

1 00663025400401010 Pin spindle 20 0.81kg

2 1040500005 GB/T91-2000 Pin 5×45 20 0.088kg

Double-anchoring
3 00663025400410000 8 2.48kg
rod

Reducing
4 00663025400420000 1 11.68kg
anchoring rod

5-49
 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

5 00663015410401050 Pin spindle 1 1.44kg

6 1040500173 GB/T91-2000 Pin 6.3×80 1 0.023kg

7 00663025400401050 Reducing piece 1 11.44kg

Double-anchoring
8 00663025400430000 2 8.18kg
rod

9 00663025400440000 Coupling link 1 13.46kg

5-50
 0066305-100-05-20Y

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

Single-anchoring
10 00663025400401030 2 21.6kg
rod

Single-anchoring
11 00663025400401040 2 4.2kg
rod

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 0066305-100-05-20Y

5.5.2.4.2 Combination of fixed jib front anchoring rods

When fixed jib is 6m long, the corresponding anchoring rods is 6.34m long;
If fixed jib increases by 6m long, two double-anchoring rods of 0.3m long and two
single-anchoring rods of 5.46m long should be added accordingly.
Combination of fixed jib front anchoring rods is shown in following diagram. (Unit:
mm)

6m

12m

18m

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 0066305-100-05-20Y

Component parts of fixed jib front anchoring rods (unit: mm)

Connected to fixed jib head

Connected to FA-frame

1, 2 3 4 3 5 3

5-53
 0066305-100-05-20Y

Description of component parts of fixed jib front anchoring rods

Part
ID code Outline dimensions (unit: mm) Name of the part Quantity Weight
no.

1 00663025400401010 Pin spindle 20 0.81kg

2 1040500005 GB/T91-2000 Pin 5×45 20 0.088kg

3 00663025400410000 Double-anchoring rod 10 2.48kg

4 00663025400601010 Single-anchoring rod 4 26.11kg

5 00663025400601030 Single-anchoring rod 4 16.1kg

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 0066305-100-05-20Y

5.5.2.5 Tilting-back supports of fixed jib

5.5.2.5.1 Front tilting-back support of fixed jib

There are two front tilting-back supports of fixed jib in total.

1 2, 3 4 5

5.5.2.5.2 Rear tilting-back support of fixed jib

There are two rear tilting-back supports of fixed jib in total.

9, 10, 7

6, 7 8 11

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 0066305-100-05-20Y

Description of component parts of tilting-back supports of fixed jib

Part no. ID code Name of the part Quantity Weight

1 00663003100610000 Outer tilting-back support 2 18.63kg

2 00663308000001020 Pin spindle 4 1.15kg

3 1040500057 Pin (5×50, GB/T91-2000) 4 0.095kg

4 00663303100401010 Spring 2 1.22kg

5 00663003100620000 Inner tilting-back support assy. 2 23.98kg

6 00663003100401010 Pin spindle 4 1.15kg

7 00663604100001050 Retaining pin 6 0.99kg

8 00663053100210000 Outer tilting-back support 2 18.11kg

9 00663053100201010 Pin spindle 2 0.67kg

10 1040100682 Screw (GB/T825-1988-M8) 2 0.234kg

11 00663053100220000 Inner tilting-back support 2 13.14kg

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 0066305-100-05-20Y

5.6 Assembly and dismantling of main boom

5.6.1 Preparation for assembly

- Choose an appropriate boom configuration and corresponding anchoring rod

combination according to the operational planning and load capacity charts;
- Choose appropriate load hook and rope reeving in accordance with working
requirement (see Section 4.6.1 of Chapter 4);
- Make sure that an auxiliary crane is available and operating personnel get full
prepared for operation.

Note:
(1) 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.
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;
(2) It is prohibited to use any other boom configurations and anchoring rod
combination that have not been stipulated in the operating manual;
(3) Protective mattress should be used between lifting chain, load hook, hoisting
rope and chords, web members; or attach fibre lifting chain to the lifting eye on
boom frame prior to lifting operation;
(4) If the boom head is lifted by an auxiliary crane, at least two pieces of lifting chain
with a breaking force≥15t should be used;
(5) Each dismantled parts should not only satisfy with the requirement of
load-bearing capacity under operating conditions, but also meet the technology
requirement of self-assembly /dismantling operation which should be carried out
strictly in accordance with design requirement since the self-assembly
/dismantling operation is a complicated lifting process;
(6) Do not stand on the lattice boom when it is assembled;
(7) Do not stand beneath the boom when it is being pinned or unpinned;
(8) The use of squared timbers or pad block to support the chord in the middle
position or web members is prohibited; otherwise the boom sections will be
damaged.

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5.6.2 Assembly of main boom

After unloading the basic machine and fitting the counterweight plate, assemble such
components as boom sections and anchoring rods according to working
requirements.

5.6.2.1 Attachment of main boom sections

Preassemble main boom sections according to “Main boom assembly table” in

Section 5.5.1.2. For detailed operation, refer to following methods:
1) Bolt main boom intermediate sections of 3m, 6m or 9m to each other in the
following sequence:
- Position two intermediate sections to be bolted in such a way that the connection
holes in one intermediate section are precisely aligned with those in another
intermediate section (see following figure).
- Join them with double tapered pins (1) and secure on both sides with retaining
springs (2).
Note: the other connecting holes are joined in the same way.

9m main boom
intermediate
section

6m main boom
intermediate
section

3m main boom
intermediate
section

Retaining
spring (2)

Double tapered pin (1)

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 0066305-100-05-20Y

2) Bolt main boom head with assembled intermediate section in the following
sequence:
- Position the assembled intermediate section in such a way that the upper
connecting holes in it are aligned with those in the boom head.
- Join the upper connecting holes with double tapered pins (1) and secure them
with retaining springs (2).
- Join the lower connecting holes in the same way.

Assembled main boom

intermediate section

Main boom head

Slowly drive the basic machine with main boom pivot section attached to the
preassembled main boom.
Operate the derricking winch in such a way (see Section 4.5.2.2 in Chapter 4) that 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).
Operate the derricking winch to adjust the derricking rope until the lower connecting
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).
Detach the anchoring rod of derricking pulley block from the main boom pivot section.

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 0066305-100-05-20Y

Double
tapered pin Retaining spring (2)
(1)

Parts used to connect main boom sections

Part No. Name of the part ID code

1 Double tapered pin 00663000100001031

2 Retaining spring 006340000001

Note:
(1) The connecting pin must always be fitted from outside inwards during assembly.
The pin must be applied with lubricating grease.
(2) It is prohibited to put hand or fingers into the connecting hole during assembly.
(3) While the connecting pin is being removed, no person is allowed to stand
beneath or in the boom.
(4) It is prohibited to climb up the boom, and stand or walk on the boom.
(5) Utilize a ladder or other similar tools to carry out assembly operation.

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5.6.2.2 Assemble main boom anchoring rods and reeve in hoisting rope

- Connect the detached anchoring rods of derricking pulley block to anchoring

rods of main boom intermediate sections with pin spindles and secure them
properly with retaining pins.(the combination of main boom anchoring rods is
detailed in Section 5.5.1.4);

- Operate hoisting winch 1 in the lowering direction and pull the hoisting rope
manually to main boom head, reserve a certain length of rope for load hook
reeving;

Note:
The method for reeving hoisting rope for H1 through the main boom anchoring rods is
detailed in section 4.6 “rope reeving” of chapter 4.
- Move right control lever to the left (see Section 4.1.3) to spool up the derricking
winch until the main boom head is raised by the derricking rope to a proper
position a littler higher than the load hook;

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 0066305-100-05-20Y

- Position the load hook directly under main boom head, and then reeve the
hoisting rope between load hook and boom head in accordance with the rope
reeving plan (for the details, please refer to Section 4.6 in Chapter 4),finally
secure the rope end point with rope lock and rope thimble.

Caution:
Working personnel who guide the wire rope should take great care to prevent against
falling down when walking on the boom frame; otherwise, serious accident may
occur.

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5.6.3 Connect the electrics to main boom

5.6.3.1 Electrical connections

4
1 2, 3

5 6

Description of parts to be connected

Part No. ID code Name of the part Quantity

1 1020701369 Main boom cable drum assy. 1

2 1021400132 Wind speed sensor 1

3 1020400233 Solar lamp 1

4 1020500140 Hoisting limit switch 1

5 1020701370 Fixed jib cable drum assy. 1

Hoisting limit switch weight

6 1029900040 1
assy.

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 0066305-100-05-20Y

5.6.3.2 Electrical connection to main boom

Unplug the cable plug of main boom cable drum (part 1 in above figure), pull the
cable plug along the main boom and then insert it in “lead to junction box” socket of
main boom junction box. Establish the electrical connections from the junction box on
the boom head to associated components respectively.

A view
To main boom
cable drum

Anemometer To fixed jib

H1 junction box
winch

H2 winch

A view

Note:
When establishing connections, the connection sequence mentioned above should
be adhered to.

5.6.3.3 Function check

- Check anemometer

Rotate the vane of anemometer to check whether the wind speed shown on the
screen in the cab is normal.

- Check solar lamp

Switch on the solar lamp switch (placed below the lamp), and then cover the top
of solar lamp with a covering so that the lamp can not be sensitized. At this time,
the lamp must be flashing constantly.

- Check hoisting limit switch for H1

Support and hold the hoisting limit switch weight for H1 to ensure that the switch
is triggered, and then check that the icon “upper limit switch on H1” on the screen
will flash and the buzzer will sound.

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- 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.

5.6.4 Erecting main boom

5.6.4.1 Requirements for erecting main boom

- The crane is properly supported and level;

- The counterweight plates have been attached in accordance with the load
capacity chart;
- 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 have been correctly fitted and are fully operational;
- All pinned connections have been secured;
- 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;
- There are no loose parts on main boom or fixed jib;
- In winter, the main boom, fixed jib and associated components (limit switches,
rope drums, solar lamp, anemometer etc.) must be kept free of ice and snow.

Note:
Incorrectly fitted or faulty limit switches and falling parts (pins, retaining springs, ice
etc.) can cause injury.

5.6.4.2 Erecting main boom

Select the “main boom operating mode” in the Load Moment Limiter in accordance
with actual boom configurations.
- Move right control lever to the left (See section 4.5.2.2 in Chapter 4) to spool up
derricking winch, and the main boom anchoring rods will be tensioned gradually;
- Continue to spool up derricking winch to raise main boom;
- After main boom is erected to required position, move right control lever to the
neutral position to stop erecting main boom.

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Caution:
(1) The main boom angle can be changed between 0° to 80°. When main boom is
raised to 78°, acoustic warning will be given out, but main boom can still be
raised. However, when main boom is raised to 80°, the movement of raising
boom will be switched off automatically along with alarm being sent out. At this
time, only lowering the boom is permitted. Under this condition, even though
bypass key switch is triggered, the main boom can not be raised continuously.
(2) Always monitor the wire rope in process of erecting main boom to make sure that
the wire rope is kept in the rope groove all the time.

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(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 screen,
while other workers should pay attention to environmental changes.
(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.

5.6.5 Lowering and dismantling main boom

5.6.5.1 Lowering main boom

- Move right control lever to the right (see section 4.1.3 in chapter 4) to reel off
derricking winch, and main boom will be lowered gradually;
- Make load hook come into contact with the ground;
- Continue to reel off derricking winch until main boom head is lowered on the
ground;
- Move right control lever to the neutral position to stop operation.

Caution:
(1) In the process of lowering main boom, the winch 1 must be reeled off to avoid the
hook’s collision with the pulley head;
(2) Standing within danger area of crane during operation is prohibited;
(3) The boom-lowering movement should be performed slowly and stably. And
during the operation, the crane operator must observe the data shown on the
screen, while other workers should pay attention to environmental changes.

5.6.5.2 Dismantling boom sections and anchoring rods

- After lowering the anchoring rods down on the anchoring rod supports on the
relevant boom sections, and then secure them with pin spindles for
transportation.
- Separate boom sections using self-assembly system or an auxiliary crane.
- Lower front support of A-frame onto the slewing table.

Note:
(1) Dismantling is carried out in the reverse order to assembly.
(2) Warnings and safety precautions for assembly should be followed during
assembly operation.

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5.7 Assembly and dismantling of main boom with fixed jib

5.7.1 Preparation for assembly

- The crane is properly supported and level;

- The boom is installed;
- An auxiliary crane as well as an assembly working platform is available;
- The safe load indicator system of Load Moment Limiter is set according to the
data given in the load capacity charts;
- Choose appropriate boom configuration and relevant anchoring rods
combinations according to operational planning;
- Attach proper load hook according to working requirements (see Section 4.6.1 in
Chapter 4).

Caution:
(1) 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.
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;
(2) It is prohibited to use any other boom configurations and anchoring rod
combination that have not been stipulated in the operating manual;
(3) Protective mattress should be used between lifting chain, load hook, hoisting
rope and chords, web members; or attach fibre lifting chain to the lifting eye on
boom frame prior to lifting operation;
(4) Each dismantled parts should not only satisfy with the requirement of
load-bearing capacity under operating conditions, but also meet the art
technology requirement of self-assembly /dismantling operation which should be
carried out strictly in accordance with design requirement since the
self-assembly /dismantling operation is a complicated lifting process;
(5) Do not stand on the lattice boom when it is assembled;
(6) Do not stand beneath the boom when it is being pinned or unpinned;
(7) The use of squared timbers or pad block to support the chord in the middle
position or web members is prohibited; otherwise the boom sections will be
damage.

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5.7.2 Assembly of fixed jib

During transportation, the fixed jib pivot section (G31), FA-frame (G37), front
tilting-back support of fixed jib (G74) and rear tilting-back support of fixed jib (G75) are
assembled together. See following figure.

5.7.2.1 Procedure for assembly

- Assemble required main boom sections (for the details, see Section 5.6);
- Lift fixed jib pivot section (together with other components) with an auxiliary
crane until it is aligned with main boom head. Then connect the fixed jib pivot
section to main boom head with pin spindles (1) and secure them with locking
plates (2), washers (3) and bolts (4).

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- According to actual condition, choose and assemble required jib intermediate

sections. All jib intermediate sections are connected with double tapered pins (5),
secured on both sides with retaining springs (6) as follows:

6
5

Parts used for assembly

Part
ID code Name of the part Quantity Weight
no.

1 00663000200001011 Pin spindle 4 3.42kg

2 006340000019 Retaining plate (60, PD0406) 4 0.144kg

3 1040300054 Washer (12, GB/T93-1987) 8 0.001kg

GB/T5783-2000（ISO4017-1999）
4 1040000169 8 0.048kg
Bolt M12×45-8.8

5 00663000200001022 Double tapered pin 12 0.67kg

- Connect anchoring rods of relevant main boom sections according to assembled

main boom length (see the combination of main boom anchoring rods in section
5.5.1.4);
Pre-assemble some anchoring rods to FA-frame according to required angle
(see the combination of fixed jib rear anchoring rods in section 5.5.2.4.1);
Connect fixed jib front anchoring rods according to assembled fixed jib length
(see the combination of fixed jib front anchoring rods in section 5.5.2.4.2).
- Lift FA-frame using an auxiliary crane until the fixed jib front anchoring rods is
tensioned;
Joint the other end of front tilting-back support (G74) to fixed jib pivot section with
pin spindle (2) and secure it with cotter pin (1);
Put rear tilting-back support of fixed jib on the boom frame temporarily;
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Connect the required fixed jib rear anchoring rods (see the combination of fixed
jib rear anchoring rods in section 5.5.2.4.1).

G75
1, 2

G74

Parts used to install front tilting-back support of fixed jib

Part
ID code Name of the part Quantity Weight
no.

1 00663308000001020 Pin spindle 4 1.15kg

2 1040500057 Pin (GB/T91-2000, 5×50) 4 0.095kg

- Operate control lever to reel off hoisting winch 2, and then pull the hoisting rope
to fixed jib head and reserve a certain length of rope for reeving load hook;
- Operate control lever to spool up derricking winch until main boom is raised to a
proper position. And then connect and secure the rear tilting-back support of
fixed jib on main boom head with pin spindle(3)and cotter pin(1);

1, 2

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Parts used to install rear tilting-back support of fixed jib

Part
Name of the part ID code Weight Quantity
no.

1 Pin spindle 00663003100401010 1.15kg 4

2 Retaining pin 00663604100001050 0.35kg 6

Note:
(1) Make sure that the hoisting rope near the boom head is not exposed to crushing
force;
(2) Ensure that the running wheel on jib head is always rolling on the ground;
(3) Great care should be taken to connect the rear titling-back support of fixed jib to
main boom head after main boom is raised in a proper position.
- Operate control lever to spool up derricking winch until main boom together with
fixed jib is raised to a position a little higher than the load hook. Position the
auxiliary load hook directly under the fixed jib head, and then connect it to the
hoisting rope for winch 2 with a rope lock.

Note:

(1) The method for reeving hoisting rope for H2 through the main boom anchoring
rods is detailed in section 4.6 “rope reeving” of chapter 4.

(2) Rope reeving plan: the hoisting rope for winch 2 is first led via the rope pulley on
FA-frame and then via the rope pulley on jib head, finally connected to auxiliary
load hook.

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5.7.3 Connect the electrics to fixed jib

5.7.3.1 Electrical connections

1 2 3

Description of parts to be connected

Part Part Part

Name of the part Name of the part Name of the part
no. no. no.

Fixed jib junction

1 Anemometer 2 Jib head lamp 3
box

5.7.3.2 Electrical connections to main boom with fixed jib

After the installation of main boom and fixed jib, first pull out the 16-core plug of main
boom junction box and insert it in fixed jib cable drum on fixed jib pivot section (code 5
in Fig. 5.6.3.1), fix the cable on boom frame by chain, then plug the other end of fixed
jib cable drum into fixed jib junction box. After that, demount the warning lamp,
anemometer and hoisting limiter switch for H2, and fit them in corresponding
positions on fixed jib head. The fixed jib junction box is shown as follows:

To main boom A view

cable drum

H2 winch

Anemometer

A view
Note:
When establishing connections, the connection sequence mentioned above should
be adhered to.

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5.7.3.4 Function check

- Check solar lamp

Switch on the solar lamp switch (placed below the lamp) , and then cover the top
of solar lamp with a covering so that the lamp can not be sensitized. At this time,
the lamp must be flashing constantly.
- Check anemometer
Rotate the vane of anemometer to check whether the wind velocity shown on the
screen in the operator’s cab is normal.
- Check hoisting limit switch for H2
Support and hold the hoisting limit switch weight for W2 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.

5.7.4 Erecting and lowering main boom with fixed jib

5.7.4.1 Prerequisites

- All electrical connections have been established.

- Check control lever for main boom angle limit switch for smooth movement.
- Check solar lamp.
- Check anemometer for smooth rotation and functional work.
- Check hoisting limit switch.
Operate the hoisting winch, and adjust the hoisting limit switch on the jib head
manually. Requirement for this operation: the hoisting movement of hoisting
winch should be stopped when the upper limit has been reached, and “hoisting
limit” indicator light on the screen will flash.

Caution:

Incorrectly fitted or faulty limit switches and falling parts (pins, retaining pins, ice etc.)
can cause injury.

5.7.4.2 Requirements for erecting main boom with fixed jib

- The crane is properly supported and level;

- The counterweight plates have been attached in accordance with the load
capacity table;
- Required boom sections have been attached in accordance with load capacity
table;
- All limit switches has been correctly fitted and are fully operational;
- All pinned connections have been secured;
- The hoisting rope has been correctly placed in the rope pulleys and prevented
from jumping out (from rope groove) using rope retaining pins;

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- No person are present in the danger zone;

- There are no loose parts on main boom or fixed jib;
- In winter, the main boom, fixed jib and associated components (limit switches,
rope drums, warning lamp, wind speed gauge etc.) must be kept free of ice and
snow.

Caution:

Incorrectly fitted or faulty limit switches and falling parts (pins, spring-loaded safety
pins, ice etc.) can cause injury.

5.7.4.3 Erecting main boom with fixed jib

- Select the “fixed jib operating mode” in the Load Moment Limiter in accordance
with boom configurations.

Caution:
Performing slewing motion while the fixed jib is erected off the ground is
prohibited.
- Move right control lever to the left (section Section 4.1.3) to erect the boom frame
until it reach required working position.

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Note:

Notice on erecting and setting down 58m main boom or 49m main boom with fixed jib

(1) The boom should be positioned straight ahead of the crawler crane (i.e. the drive
sprocket is at the back of crane);

(2) Before erecting the boom, a certain length of hoisting rope should be unwound to
guarantee that the hook is still in contact with the ground before the boom angle
has reached 30°. Before lowering the boom, a certain length of hoisting rope
should be unwound to ensure that the hook has lowered down on the ground
once the boom angle is less than 30°;

(3) The boom should be erected or set down stably at even speed.

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Pad wooden chock under the front of crawler

5.7.5 Dismantling main boom with fixed jib

- Move right control lever to the right (see Section4.1.3) to reel off the derricking
winch so as to make the fixed jib head come into contact with the ground, then
disconnect the rear tilting-back support of fixed jib from the main boom head.
(See following figure.)

Unpin the pin at this point

- Continue to reel off the derricking winch so as to make fixed jib head roll forwards
on the running wheel until the entire boom gets into contact with the ground.
Move right control lever to neutral position to stop the movement.

Caution:
(1) The boom-lowering movement should be performed slowly and stably. And
during the operation, the crane operator must observe the data shown on
the display, while other workers should pay attention to environmental
changes;
(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.
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- Push right control lever backwards to wind the hoisting rope onto the drum and
secure it.

Caution:
The winding of wire rope should be supervised by a person appointed, and no
person is standing within danger zone during operation.
- Tilt FA-frame forwards to an appropriate position with the help of an auxiliary
crane, and then disassemble the front and rear anchoring rods of fixed jib.
- Spilt the jib sections one by one, leaving the fixed jib pivot section assembled.
- Detach the fixed jib pivot section (together with other components) from the main
boom head.

Caution:

All crane movement should be carried out smoothly, and all safety precautions
should be followed, otherwise accident may occur.

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5.8 Assembly and dismantling of tip boom

1
4

Parts used for assembly

Part no. ID code Name of the part Qty. Weight

1 00663300100001230 Retaining pin 4 0.1kg

2 00663000100001162 Pin spindle 2 2.32kg

3 00663020100001010 Pin spindle 2 1.1kg

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5.9 Weight and dimensions of main component parts (weight and dimension listed in the following table are design values)

Name of the part Outline dimensions (mm) Weight (t) Quantity Remarks (mm)

Basic machine 41.8 1 Width: 3400

Counterweight base
5.21 1 Height: 605
plate

Counterweight plate 3.35 2 Height: 560

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Name of the part Outline dimensions (mm) Weight (t) Quantity Remarks (mm)

Counterweight plate 3.35 2 Height: 560

Counterweight plate 4.1 2 Height: 560

Load hook (80T) 1.25 1 Width: 650

Load hook (50T) 0.92 1 Width: 484

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Name of the part Outline dimensions (mm) Weight (t) Quantity Remarks (mm)

Load hook (30T) 0.605 1 Width: 405

Load hook (6T) 0.264 1 Width: 350

Main boom head

1.195 1 Width: 1700
(with tip boom)

3m main boom
0.30 1 Width: 1700
intermediate section

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Name of the part Outline dimensions (mm) Weight (t) Quantity Remarks (mm)

6m main boom
0.58 1 Width: 1700
intermediate section

One piece:
0.68;
9m main boom
Total 4 Width: 1700
intermediate section
weight:
2.72

Fixed jib pivot

section (with
0.70 1 Width: 740
titling-back supports
and FA-frame)

6m fixed jib
0.17 1 Width: 560
intermediate section

Fixed jib head 0.31 1 Width: 560

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5.10 Transport means and safety precautions for transport

5.10.1 Transport means and safety precautions for transport

- After being dismembered, crawler crane can be transported by a low-loader, train

or by other transport equipment for a long distance. During transportation, the
crane is fixed by rope, with its doors and windows locked up. If necessary, take
preventive measures against rain.
The crawler crane should be dismembered and transported in accordance with
the permissible load carrying capacity of transport vehicle and the weight,
dimensions of dismantled parts which are shown in 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.
- The folding brackets must be fixed near the driven sprocket.
- The counterweight anchoring rod on A-frame and the rear anchoring rod of
A-frame should be secured on the rear end of slewing table.
- To understand the detailed transport means, please consult our company.

5.10.2 Other requirements

If the crane is not put into use for a long time (over 6 months), take the following
protective measures.
- Wipe off the dust and oil dirt to keep the crane clean;
- Retract all the piston rods of the cylinders completely;
- Put the battery in a dry and ventilating place and charge it periodically;
- Surfaces of all exposed components should be greased to prevent them from
corroding;
- Clean the wire ropes and grease them again with ZG-3 graphite calcium base
grease;
- 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;
- Starting the machine once a month and running all mechanisms with no load to
check whether they are in good condition;
- Assign a person responsible for completeness of the crane so that it can be put
into operation at any time.

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Chapter 6 Maintenance
 0066305-100-06-20Y

6.1 General

In order to ensure a good and safe condition of crane all the time, the maintenance worker
must service and maintain crane periodically.

6.1.1 Crane maintenance

Before inspecting and maintaining crane, following prerequisites must be fulfilled:

a) The boom is laid down on the ground;
b) The engine is switched off;
c) All the safety devices are locked;
d) The key is taken out from ignition switch to prevent engine from being switched on by
unauthorized person.

Caution:
Failing to observe this regulation may result in death or serious injury.

6.1.1.1 Basic requirements for crane maintenance

a) The maintenance worker should wear specified clothes during maintenance;

b) The crane should be set up on level and firm ground, where a warning board marked
“Inspection” is placed around;
c) Use ladder and safety belt when working in high position 2m above the ground;
d) When there is a need to move crane for maintenance, the operator must operate crane
according to the signals.
e) When inspecting or maintaining hydraulic system, the dust and impurities are not allowed
to enter into system;
f) If some parts need to be repaired and adjusted at once are found, please repair and
adjust them immediately;
g) If crane needs to be repaired, the customer can contact local service station of Mobile
Crane Branch Company of Zoomlion;
h) In order to ensure the performance of crane, please use the accessories and lubricating
grease specified by Zoomlion;
i) The consumables such as filter cartridge should be changed in time to avoid malfunction
occurring owing to delay in changing these parts;
j) If uncertain failure is found during inspection or maintenance, please contact local service
station of Mobile Crane Branch Company of Zoomlion.

6.1.1.2 Notes on crane maintenance and service

a) Set up warning board during maintenance

Before carrying out inspection and maintenance, put a warning board marked “Never
start engine during inspection and maintenance.” on ignition switch.
b) Use clean lubricating grease
The room for storing lubricating grease must be kept clean. Never make dust and water
enter into container. Ensure that the used lubricating grease is not mixed with water.

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c) Keep machine clean

Clean machine to make operator easy to find such abnormal phenomena as oil leakage,
crack and loosing of connector. Especially keep grease nipple, air vent and oil dipstick
clean.

Note:
(1) After cleaning machine, lubricate the propeller shafts and connecting parts of
slewing table.
(2) The steering wheel, operating desk, control panel and floor as well as dirty
decoration inside operator’s cab should only be washed by warm water with cleaning
agent.
(3) Never use corrosive cleaning agent.
d) Deal with oil stain
When adding or changing fuel, hydraulic oil and lubricating grease, or replacing filter
cartridge, the oil will be spouted out. At this moment, wipe off oil to prevent a fire.
e) Never spray water on electric elements and fittings when washing the machine.

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f) Prevent a fire
The rubbish attached with oil stain or other flammable substances must be placed in a
safe place. Know about the position of fire extinguisher and master its use methods.

g) Pay attention to the rotary parts

When checking fan belt or water pump, the operator is liable to be hurt. Therefore, he
should first switch off engine, and then check belt or water pump.

h) Pay attention to water temperature and oil temperature

It is very dangerous to drain water, oil or replace filter cartridge immediately after engine
stops. This operation can be done only when the temperature of engine has fallen down.
When oil temperature is too low, heat oil to make its temperature reach 20 – 50℃, and
then drain oil.

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i) Check waste oil and used filter cartridge

Check if there are metallic bits or impurities when changing 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.

k) Clean joint face

After dismantling O-ring or other shims, clean sealing surface and replace sealing
elements with new ones. During assembly, apply thin oil on the sealing elements.
l) Pay attention to the pressure inside
As there is pressure produced in hydraulic system, air compressing system and fuel
system, the operator must release pressure first before dismantling their pipelines,
fittings and other components.

m) Notes when carrying out welding operation

Cut off power supply; disconnect power lead of battery; never constantly apply voltage
more than 200v; set up grounding device 1m away from welding point. Never install
sealing device or bearing between welding point and 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 container, and then deal with it according to the requirements for
industry discharge substances.
o) The unauthorized personnel are prohibited to maintain crane and replace parts.

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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 following requirements. Inspect them before crane is
working for the first time, after crane has not been used for a long time, or before crane is
working for the first time after maintenance. The inspection result list refers to attached table.
a) Check the crane log to ensure that all regular inspections, maintenance and repair work
is performed.
b) Check lowering limiter, boom angle indicator, tilting-back supports and other safety
devices for functional work.
c) Check the load-bearing parts carefully, such as wire rope (hoisting rope, derricking rope
and sling etc.), boom frame, outriggers and load hook.
d) Check if there are some bolts, nuts and pins lost, and the components are cracked or
damaged.
e) Ensure that no modification has been made to the crane without permission, e.g.,
increase or decrease in counterweight plates, and improper repair of boom frame.
f) Check fuel lines and hydraulic oil lines for leakage.
g) Check if the values shown on instruments are correct after starting up the engine.
h) Check if control mechanisms work normally.
i) Check brake and clutch. Test the braking performance by lifting a load away from the
ground and holding it in the air for a moment.
j) Under working condition, the brakes for hoisting and derricking system will bear a limit
torque which is 33% larger than the torque transmitted from winding drum to brakes.
k) Mechanisms with dynamic brake systems (e.g. hydraulic brake valve, electrical braking)
shall have a secondary holding brake system which is independent of the dynamic
brakes restraining the same load moment as for the primary holding brake.
l) In order to avoid free fall of load, the holding brake shall perform the function of an
emergency brake in the event of failure of dynamic brake system. The holding brake will
work automatically when energy supply is switched off.
m) The deceleration in an emergency case should not lead to damage to the structure, wire
rope and winding drum as well as mechanisms.

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6.1.3 Attached tools for maintenance

Table of attached tools for maintenance

Ser. No. Code Description Specification QTY.

1 1991100032 Crow bar 1
2 1991100032 Crow bar 1
3 1991100032 Engine oil funnel 1
4 1991100032 Grease gun 400 1
5 1991100032 Adjustable wrench 300 1
6 1991100032 Adjustable wrench 375 1
7 1991100032 Needle-nose pliers 160 1
8 1991100032 Wire cutter 200 1
9 1991100032 Allen wrench (9 pieces) 3-17 1
10 1991100032 Cross type screw driver 2P-100 1
11 1991100032 Plain type screw driver 2P-125 1
12 1991100032 Bend circlip plier for hole 200 1
13 1991100032 Bend circlip plier for shaft 200 1
14 1991100032 Round hammer 355*116*34 1
Double-ended spanner
15 1991100032 5.5-32 1
(10 pieces)
16 1991100032 Double-ended spanner 32-36 1
17 1991100032 Double-ended spanner 41-46 1
18 1991100032 Single-ended spanner 50-55 1
19 1991100032 Single-ended spanner 65 1
20 1991100032 Single-ended spanner 75 1
21 1991100032 Socket sleeve 46*20L 1
Tenon with bended
22 1991100032 WB20 1
handle
23 1991100032 Spring lock 38 2
24 1991100032 Toolbox 1

Note:
The tools are located in the front right-hand side of slewing table.

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6.2 Superstructure maintenance and inspection plan

Maintenance Section Inspection

Component Item
interval No. method
Visual
6.2.1.1 Fuel pipe or hydraulic pipe Damage
inspection
Start-up, leakage
6.2.1.2 Engine
or noise
6.2.1.3 Pipeline and joint Leakage
6.2.1.4 Slewing lock Functional work Operation
Operation
6.2.1.5 Horn, lamp and wiper Functional work and visual
inspection
6.2.1 Visual
Every day or 6.2.1.6 Air filter Blockage
inspection
every 5 hours Connecting pin, anchoring Damage and Visual
6.2.1.7
rod and cotter pin tight fit inspection
Visual
6.2.1.8 Bolt and nut Tight fit
inspection
6.2.1.9 Hoisting limiter Functional work Operation
6.2.1.10 Boom limit switch Functional work Operation
6.2.1.11 Derricking ratchet switch Functional work Operation
Glass, ladder, handrail Damage, crack Visual
6.2.1.12
and guardrail and tight fit inspection
Operation
Damage and
6.2.2.1 Fan belt and visual
tight fit
inspection
Leakage and Visual
6.2.2.2 Radiator and oil cooler
damage inspection
Foundation bolt and Operation
Damage and
6.2.2.3 damping rubber cushion and visual
tight fit
of engine inspection
6.2.2 Hydraulic motor and Leakage and Audiovisual
6.2.2.4
Every month or reducer abnormal sound inspection
every 100 Visual
6.2.2.5 Hydraulic valves Leakage
hours inspection
Visual and
Leakage and
6.2.2.6 Hydraulic pump audiovisual
abnormal sound
inspection
Wear and Visual
6.2.2.7 Ratchet mechanism
damage inspection
Operation
Functional work
6.2.2.8 Refueling pump and hose and visual
and damage
inspection
6.2.3
Every 6 months Leakage and Visual
6.2.3.1 Energy accumulator
or every 600 damage inspection
hours

Note:
The section number in above table should be consistent with that in following context.

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6.2.1 Maintain and inspect superstructure every day or every 5 hours

6.2.1.1 Fuel pipe or hydraulic pipe

Check fuel pipe or hydraulic pipe for leaks and damage.

Note:
If pipeline leaks oil, wipe it clean at once and repair leaking point completely.

6.2.1.2 Engine

Start engine and check it for starting condition and abnormal noise.

6.2.1.3 Pipeline and joint

Check pipelines and joints for damage and leaks.

6.2.1.4 Slewing lock

Check that slewing lock pins can be inserted smoothly, and check the lock pins and
connecting rods for deformation.

6.2.1.5 Horn, lamp and wiper

Switch on the switches to check that the horn, lamp and wiper can work properly.

6.2.1.6 Air filter

When air filter is clogged, the indicator will display red color.

6.2.1.7 Connecting pin, anchoring rod and cotter pin

Check connecting pins, anchoring rods and cotter pins for damage or tight fit.

6.2.1.8 Bolt and nut

Check bolts and nuts for tight fit.

6.2.1.9 Hoisting limiter

Check hoisting limiter for functional work.

6.2.1.10 Boom limit switch

Check boom limit switch for functional work.

6.2.1.11 Derricking ratchet switch

Check derricking ratchet switch for functional work.

6.2.1.12 Glass, ladder, handrail and guardrail

Often wipe the glass, ladder, handrail and guardrail with a clean cloth, especially when they
are polluted by grease.

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6.2.2 Maintain and inspect superstructure every month or every 100 hours

6.2.2.1 Fan belt

Check the tension of fan belt. Press its middle position; if deflection is between 10mm and
15mm, it is normal.

Caution:
Switch off engine before checking the fan belt; otherwise serious injury may occur.

6.2.2.2 Radiator and oil cooler

Clean radiator core and check radiator and oil cooler for deformation and abnormal condition.

6.2.2.3 Foundation bolt and damping rubber cushion of engine

Check foundation bolt for tight fit and damping rubber cushion for damage.

6.2.2.4 Hydraulic motor and reducer

Check following mechanisms for leakage and abnormal sound:

Hydraulic motor and reducer of slewing gear
Hydraulic motors and reducers of winch 1 and 2
Hydraulic motor and reducer of derricking winch

6.2.2.5 Hydraulic valves

Check hydraulic valves for leaks.

6.2.2.6 Hydraulic pump

Check hydraulic pump for leaks and abnormal sound.

6.2.2.7 Ratchet mechanism

Check ratchet mechanism for wear and damage.

6.2.2.8 Refueling pump and hose

Check refueling pump for functional work.

Check hose for damage.
Component parts possible to be changed during maintenance are the filter cartridges of oil
suction pipe and oil return pipe, filter cartridge of hydraulic oil pipe, oil filter of oil drain pipe,
fuel filter and so on.

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6.2.3 Maintain and inspect superstructure every 6 months or every 600 hours

6.2.3.1 Energy accumulator

Check energy accumulator for leaks;

Check that energy accumulator is filled with nitrogen.

Caution:
(1) Assemble/dismantle energy accumulator carefully.
(2) Do not make energy accumulator close to heat source.
(3) Do not have energy accumulator welded or processed with machine.
(4) The valve cap can not be removed unless the energy accumulator is in charge.
(5) It is forbidden to stand or put heavy load on the energy accumulator.
(6) Inspect air pressure of energy accumulator every two years.
(7) It is forbidden to dismantle energy accumulator without permission.

6.3 Undercarriage maintenance and inspection plan

Maintenance Section Inspection

Component Item
interval No. method
Visual
6.3.1.1 Pipeline and pipe fitting Leakage
inspection
6.3.1
Pin, anchoring rod and Damage and tight Visual
Every day or 6.3.1.2
cotter pin fit inspection
every 5 hours
Visual
6.3.1.3 Bolt and nut Tight fit
inspection
Hydraulic motor and Leakage and Audiovisual
6.3.2.1
reducer abnormal sound Inspection
Visual
6.3.2.2 Hydraulic valves Leakage
inspection
Crawler carrier
6.3.2 Leakage and Visual
6.3.2.3 extending/retracting
Every month or damage inspection
mechanism
every 100
Visual
hours 6.3.2.4 Centre revolving joint Leakage
inspection
Audiovisual
6.3.2.5 Slewing ring Abnormal sound
Inspection
Tension, wear and Visual
6.3.2.6 Track pad
damage inspection
Drive sprocket, driven
6.3.3 Leakage and Visual
6.3.3.1 sprocket, track roller and
Every 3 months damage inspection
track-carrier roller
or every 250
Mounting bolt for slewing Visual
hours 6.3.3.2 Tight fit
bearing inspection
6.3.4
Every 6 months Undercarriage centre Damage and
6.3.4.1 Operation
or every 600 section crack
hours

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6.3.1 Maintain and inspect undercarriage every day or every 5 hours

6.3.1.1 Pipeline and pipe fitting

Check pipelines and pipe fittings for damage and leaks.

6.3.1.2 Pin, anchoring rod and cotter pin

Check connecting pins, anchoring rods and cotter pins for damage and tight fit.

6.3.1.3 Bolt and nut

Check bolts and nuts for tight fit.

6.3.2 Maintain and inspect undercarriage every month or every 100 hours

6.3.2.1 Hydraulic motor and reducer

Check hydraulic motor and reducer for leaks and abnormal sound.

6.3.2.2 Hydraulic valves

Check hydraulic valves for leaks.

6.3.2.3 Crawler carrier extending/retracting mechanism

Check it for leaks and damage.

6.3.2.4 Centre revolving joint

Check centre revolving joint for leaks.

6.3.2.5 Slewing ring

Check slewing ring for abnormal sound.

6.3.2.6 Track pad

Check track pad for tension and wear.

Note:
(1) If track pads are connected with each other tightly, they will be worn out quickly so as to
make connecting elements broken. On the other hand, if they are connected loosely, the
crawler will fall off from drive sprocket and driven sprocket.
(2) It is normal that the crawler tension length varies from 10mm to 20mm. As long as
crawler travels the same distance forward as its length, the upper crawler will appear a
certain degree of relaxation.

6.3.2.7 Component parts possible to be changed during maintenance

They are the filter cartridges of oil suction pipe and oil return pipe, filter cartridge of hydraulic
oil pipe, oil filter of oil drain pipe, fuel filter and so on.

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6.3.3 Maintain and inspect undercarriage every 3 months or every 250 hours

6.3.3.1 Drive sprocket, driven sprocket, track roller, track-carrier roller

Check them for leaks and damage.

6.3.3.2 Mounting bolt for slewing bearing

Check mounting bolt for tight fit.

Note:
(1) If the bolt looses, demount it for check. If it is damaged, replace it.
(2) If the demounted bolt is not damaged, wipe it clean, grease NO. 271 LOCTITE glue (or
similar glue) on it and then screw it down with 1.8KN.m tightening torque.

6.3.4 Maintain and inspect undercarriage every 6 months or every 600 hours

6.3.4.1 Undercarriage centre section

Check undercarriage centre section and crawler carrier for crack and damage.

Caution:
If uncertain failures needing to be repaired are found during inspection or maintenance,
please contact local service station of Mobile Crane Branch Company of Zoomlion.

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6.4 Boom frame maintenance and inspection plan

Maintenance Section Inspection

Component Item
interval No. method
Upper﹠lower pulley Deformation and Visual
6.4.1
block crack inspection
Load hook and Visual
6.4.2 Damage and tight fit
safety catch inspection
Deformation, damage Visual
6.4.3 Rope support
and wear inspection
Deformation, damage Visual
6.4.4 Rope pulley
and wear inspection
Deformation and Visual
6.4.5 Main boom and jib
damage inspection
Connecting pin, Visual
Every day or
6.4.6 anchoring rod and Damage and tight fit inspection
every 5 hours
lock pin
Visual
6.4.7 Bolt and nut Tight fit
inspection
Deformation and Visual
6.4.8 Tilting-back supports
damage inspection
Deformation and Visual
6.4.9 A-frames
damage inspection
Deformation , damage Visual
6.4.10 Wire rope
and wear inspection
The deficiencies that Visual
6.4.11 Load hook 1 and 2
may impair safety inspection

Note:
The section number in above table should be consistent with that in the following context.

6.4.1 Upper﹠lower pulley block

Check upper & lower pulley block for deformation and crack.

Caution:
(1) It is prohibited to touch wire rope with bare hands. Otherwise, the operator will be injured
by rope’s convex section.
(2) Keep yourself away from rotary drum and running wire rope.
(3) Failure to observe such regulation may result in death or serious injury.
(4) Keep ladder, platform and guardrail clean and dry. When climb the crane, tighten safety
belt. Otherwise, the operator may fall down from crane.

6.4.2 Load hook and safety catch

Check pulley, bearing of load hook and safety catch for damage.
Check bolts and nuts for tight fit.

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 0066305-100-06-20Y

6.4.3 Rope support

Check rope support in boom intermediate sections and boom head for deformation, damage
and wear.

6.4.4 Rope pulley

– Rope pulley on 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.

6.4.5 Main boom and jib

Check main boom and jib for deformation and damage. Do not use deformed and (or)
damaged main boom and jib.
Replace or repair deformed or damaged main boom and jib.

Note:
Since main boom and jib are made of high-tensile steel, if they need special art technology for
maintenance, please contact local service station of Mobile Crane Branch Company of
Zoomlion.

6.4.6 Connecting pin, anchoring rod and lock pin

Check them for damage and tight fit.

6.4.7 Bolt and nut

Check bolts and nuts for tight fit.

6.4.8 Tilting-back supports

Check tilting-back support of main boom and tilting-back support of jib for damage and
deformation. If necessary, apply lubricating grease.

Note:
If tilting-back supports need special art technology for maintenance, please contact local
service station of Mobile Crane Branch Company of Zoomlion.

6.4.9 A-frame

Check A-frame for damage and deformation.

Note:
If the A-frame needs special art technology for maintenance, please contact local service
station of Mobile Crane Branch Company of Zoomlion.

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 0066305-100-06-20Y

6.4.10 Wire rope

Check wire rope for damage and deformation. Never use wire rope with wire breaks and knot.
If wire rope is broken during operational period, serious accident will occur. Therefore, wire
rope must be inspected periodically. It is forbidden to use the corroded, abraded wire rope or
wire rope with wire breaks. As to the determinant of safety degree and discard standard for
wire rope, please refer to the Practical Criterion for Inspection and Scrap Wire Rope of Crane
GBT5972-2006 or local relevant regulations for machine use. The methods for common
situations are listed in following table.
Serial
Conditions of wire rope Measures
No.
There is 10% wire breaks in a strand (not including filling
thread). It is very difficult to check the inner wire breaks. Bend
1 wire rope forcibly to expose wire breaks in groove. If there is
wire breaks in groove, which means there is wire breaks
inside the rope. Therefore, wire rope reaches its fatigue limit. Change wire
The diameter of wire rope is narrowed by 7% than nominal rope at once
2
size due to corrosion.
3 The evidence of knot
4 Excessive deformation and wear
Excessive extension because of overloading or jumping out of
5
the rope pulley Change wire
6 Having been used as lead of short circuit rope as soon as
Burned wire rope due to short-circuiting, gas-cutting or wire possible
7
rope exposed to high temperature

6.4.11 Maintenance of load hook 1 and 2

Since load hook 1 and 2 are used in different operating conditions, they should be inspected
every day (begin with alternate operation). Carefully observe any deficiencies that may impair
safety in operational period. Do not use load hook 1 and 2 until the deficiencies are overcome.
Daily check and maintenance include following contents:
a) Wipe load hook 1 and 2 clean;
b) Lubricate rope pulley (when equipped with grease nipple), rotary part and other parts
which are mentioned in “Lubrication Guide”, and equipped with grease nipple;
c) Check all bolts and screws, and ensure all cotter pins are complete and opened;
d) Check whether the groove and flange of rope pulley are abraded evenly, and check
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;

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 0066305-100-06-20Y

Note:
The safety catch must keep loose sling and other load handling devices on the hook,
however, it can not be loaded.
j) Check load hooks and snap rings;
Check load hook and snap ring at least once a year by using coloring inspection method,
magnetic powder inspection method, ultrasound detection method or X-ray detection
method.

Note:
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.

6.5 Maintenance and inspection for engine and high-mortality parts

6.5.1 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 arrives first.
a) Daily check or adding oil
Check following parts: air intake pipe, cooling fan, pipe of crankcase breather, engine oil
pipe and fuel pipe, hydraulic elements, cooler fan drive system and its hydraulic pipeline,
injection pump, engine coolant and engine oil level.
Maintain the following part: drain condensation water out from water separator
b) Every 250 hours or every 3 months
Check following parts: air resistance indicator for air filter, air-to-air intercooler pipe,
air-to-air intercooler, mounting element of fuel injection pump, mounting element of air
compressor and so on.
c) Every 500 hours or every 5 months
Check following parts: cooling system, coolant filter and battery cable and terminal
Maintain following parts: fuel filter, engine oil filter
Change engine oil and battery.
d) Every 1000 hours or every a year
Check following parts: drive belt, belt driven fan hub, cooling fan belt tensioner.
e) Every 2000 hours or every 2 year
Check following parts: rubber shock absorber, gummy shock absorber, engine
suspension
Maintain following parts as follows: discharge air from cooling system / wash cooling
system / add coolant; wash engine with steam; clean exhaust pipe of air compressor
f) Every 5000 hours or every 4 year
Maintain following part: adjust valve clearance

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 0066305-100-06-20Y

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:
Electrical parts, conducting wire, fuel injector, belt and hose, bearing (ball-type or conical
roller-type), ECM and ECM connector
(5) When ambient temperature is less than -18℃ or more than 38℃, or when crane works in
dusty 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) To reduce noise emission, noise reducing mats are installed in the engine. They are very
flame-resistant and some, depending on application, are fireproof. If engine compartment
is not cleaned regularly, oil and fuel may splash on the mats when maintenance and
repair work is performed. At this time, oil and fuel must be removed, as they are
flammable. The same is true for insulating mats in exhaust system area. Clean the
engine compartment only with non-flammable cleaning fluids. In addition, the fluid may
not be corrosive or chemically damage to hoses and cables.
(8) Check exhaust system, particularly the exhaust flanges and exhaust flap retention straps,
and make sure that they seal and move properly. The return springs that open the
exhaust flaps must function properly, because seized exhaust flaps during engine
operation will result in considerable overheating.
(9) All electrical lines and wires must be arranged and fastened properly. They should be
kept away from exhaust pipes. Examine all wiring insulation or casings for signs of
chafing or brittleness as a result of operational activities. Any wiring that is not in perfect
condition shall be immediately and professionally replaced.
(10) 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.
(11) It is especially important to note that under no circumstances may pipelines and hoses
installed in the engine room be stepped upon during repairs and service work. This is
particularly important for fuel injection pipelines. Protect the engine with a board or similar
support plate if stepping on the hoses is unavoidable during assembly.
(12) To prevent pollution, engine oil, gear oil, hydraulic oil, lubricating grease and fuel as well
as coolant should not be spilled onto the ground and they also should not flow into
ground water, sewage or wastewater system. Comply with the regulations specified by
local authorities before disposing of any of these items or substances.
(13) The engine V-room must be inspected regularly, and any oil or diesel oil must be cleaned

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 0066305-100-06-20Y

up, particularly after maintenance and repairs work. Any diesel oil that has collected in
V-room can spread throughout the engine room while the crane is traveling on the road
and can ignite if it comes into contact with hot surfaces.
(14) As to detailed engine maintenance and service, please observe Engine Maintenance
Manual.

6.5.2 Maintenance guidelines for high-mortality parts

When replacing drive components such as diesel engine, gear, axles and so on, you must
observe the following:
a) 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.
b) Conduct initial maintenance according to Chapter “Periodic maintenance”; thereafter,
maintain in accordance with the specified periodic maintenance intervals.

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 low
condensed hydraulic oil L-HV32 complied with GB11118.1-94. The volume is of 800 liter.

Note:
The product is full hydraulically 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
should be changed in time without considering operating hour. The inspected item and oil
change interval are shown in following table.
Oil checks and oil change
Serial Inspected
interval (operating hours) Remarks
No. Item
5 500 2000
1 Check oil level ○
2 Clean oil tank Main ○
Change oil tank
3 ○ 800liter
hydraulic oil

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 0066305-100-06-20Y

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 should comply with the limitation value and the requirements in following table.
For hydraulic oil which is out of limitation range, change it at once.
Hydraulic Oil Physical & Chemical Character Variation
Inspected item Limitation Value
L-HS NUTO H46，L-HV L-HM
Kinematic viscosity (40℃)
±10% ±10% ±10% - 15%
(mm2/s)
Acid value addition
0.3 0.3 0.3
(mgKOH/g)
Moisture (%) 0.1 0.1 0.1
Flash point (℃) -76 -76 -76
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
temperature
Ambient temperature working temperature Hydraulic oil
of cold start
temperature of cold start temperature of hydraulic brand
(without
(with load) with load oil
load)
-40℃ -35℃ -15℃ 50℃ SH 0358-95
below -30°C 10# aviation
-35℃ -22℃ -5℃ 60℃ hydraulic oil
GB11118.1-94
low
above -30°C -28℃ -15℃ 0℃ 70℃ condensed
hydraulic oil
L-HS22
☆ESSO
NUTO H46
between GB11118.1-94
-20°C and -20℃ -10℃ 5℃ 80-85℃(*) low
40°C condensed
hydraulic oil
L-HV32
ESSO
NUTO H68
GB11118.1-94
above 40°C -5℃ -3℃ 20℃ 100℃ ( **) low
condensed
hydraulic oil
L-HM68

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 0066305-100-06-20Y

Note:
(1) If crane starts in cold area, it should first run without load for a while. After the lowest
working temperature is reached, the load can be added gradually and the system can
work.
(2) The oil property should be identical with that of the original brand when changing oil. The
original oil should be washed away thoroughly.
(3) The domestic brand of hydraulic oil mainly includes Kunlun, the Great Wall, Tongyi,
Nanhai, Haibrand, Daqing, Hengyun, Guta, Jiali, Jiarun, Haili, etc. and foreign brand such
as ESSO, Mobil, etc. are also available in China.
(4) If you find any special working conditions which are not listed in the above table, please
consult the related departments of our company.

Caution:
(1) Check and measure oil temperature of system at any time!
(2) The suitable temperature range for hydraulic system in working condition is 20℃ to 70℃.
The 85℃ may occur for a short time or in some position.
(3) When oil temperature is too high (nearly 100°), pay attention to the cooling of system.
The working load should not be too heavy and the working frequency should not be too
high.
(4) The hydraulic oil of different types and different brands can not be mixed together!

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. Use
new hydraulic oil to drain used oil out of every circuit in the system until the new oil flows out
of the master oil return pipe. The used oil is not allowed to return to the hydraulic oil tank. At
this time, the oil pump stops running. While the used oil in each return line is changed, the
new oil should be added into hydraulic oil tank continuously to prevent the oil pump from
inhaling air.
Connect master oil return pipe with oil tank, make each component to initial state and add
hydraulic oil to oil tank until the oil level reaches prescribed position.

Note:
(1) Filter or change hydraulic oil in time whenever it is polluted seriously.
(2) Select proper hydraulic oil according to ambient temperature.
(3) Hydraulic oil of different brands can not be mixed.
(4) Service life of hydraulic oil can not exceed 24 months. The hydraulic oil can not be used
even though it is filtered, if it has been used for 24 months.

6.6.1.5 Temperature of hydraulic oil

Observe the temperature of hydraulic oil from the scale on the liquid temperature meter, and
the highest temperature of hydraulic oil (L-HV32) is 80°C.

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 0066305-100-06-20Y

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.

6.6.2 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 transfer case have
already been filled with 90# industrial gear oil. The traveling reducer has been filled with
L-CKD220 industrial closed gear oil.

6.6.2.1 Table of gear oil change interval

Delivery Three months Replace

Add oil Every 12 months
date oil

Caution:
(1) If gear oil is polluted seriously, replace it at once even though it has not reached the oil
change interval.
(2) Often check oil level. If necessary, add oil.
(3) The gear oil of different brands can not be mixed!
(4) Use proper gear oil according to ambient temperature, since unqualified gear oil or gear
oil with improper viscosity will damage reducer mechanism.

6.6.2.2 Replaced gear oil volume for each mechanism

Description Brand of gear oil Volume (liter)

Hoisting winch reducer 90# industrial gear oil 3

Derricking winch reducer 90# industrial gear oil 2

Slewing reducer 90# industrial gear oil 5.5

Traveling reducer L-CKD220 7

Transfer case 90# industrial gear oil 1

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 oil is
visible in the middle of inspection hole;
4) Screw down oil filler plug.

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 0066305-100-06-20Y

Add oil after removing

this plug.

When add oil, remove the

plug of inspection hole to Drain off oil after removing
check if the inspection hole oil drain plug.
is completely full of oil.

b) Change gear oil of slewing reducer

1) Unscrew and remove the 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
inspection hole is completely full of oil;
4) Screw down oil filler plug.

Check oil level

Drain oil after removing

oil drain plug.

Note:
The gear oil volume is about 5.5 L.

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 0066305-100-06-20Y

c) Change gear oil of transfer case

Add oil after removing

this plug.

Drain off oil after removing

oil drain plug.

6.6.3 Lubricating grease

Use the lubricating grease recommended in this manual and this crane uses ZL-2 and ZG-3
lubricating grease.

6.6.3.1 Injecting method

Grease or inject with gun

Parameter
Work
Drop Moisture (%)
wimble
Type Appearance point no more
degree
(℃) than
(1/10mm)
Smooth inunctum with the
ZL-2lubricatin
color from pale yellow to 175 265 - 295 ——
g grease
brown
ZG-3
Equal inunctum with the color
lubricating 90 220 - 250 2.5
from pale yellow to brown
grease

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 0066305-100-06-20Y

6.6.3.2 Parts needing to be lubricated

In order to keep crane in good working condition, all machinery parts that need lubrication
should be supplied with specified grease periodically. All of them, except for those purchased
components, are marked in following diagram.
a) Add lubricating grease to superstructure and undercarriage
1) Table of superstructure and undercarriage lubricating points
Serial Lubricating Lubricating lubricating
Lubricating points
No. interval Method Grease Type
ZL-2 lithium base
1 Ratchet mechanism Every day Grease
grease
Grease and ZL-2 lithium base
2 Slewing ring Every week
inject with gun grease
Connecting rod and Grease and
3 Every week Engine oil
pin spindle inject with gun
Every 6 Grease and
5 Track roller GL-5 85W/90
months inject with gun
Every 6 Grease and
4 Track-carrier roller GL-5 85W/90
months inject with gun
Every 6 Grease and
6 Driven sprocket GL-5 85W/90
months inject with gun

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 0066305-100-06-20Y

2) Diagram of superstructure and undercarriage lubricating points

Every week or
every 25 hours

Every week or
every 25 hours

Every day or
every 5 hours

Every 6 months or
every 500 hours

Every 6 months or
every 500 hours

Every 6 months or
every 500 hours

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 0066305-100-06-20Y

b) Add lubricating grease to boom frame system

1) Table of boom frame system lubricating points
Serial Lubricating Lubricating Lubricating
Lubricating point
No. interval method grease type
Pivot section bolting Grease and ZL-2 lithium
1 Every day
cylinder inject with gun base grease
Grease and ZL-2 lithium
2 Pin spindle of A-frame 1 Every day
inject with gun base grease
Tilting-back support of ZL-2 lithium
3 Every week Grease
main boom base grease
ZL-2 lithium
4 Main shaft of fixed jib Every week Grease
base grease
ZL-2 lithium
5 A-frame2 shaft of fixed jib Every week Grease
base grease
Upper＆lower pulley ZL-2 lithium
6 Every month Inject with gun
block spindle base grease
ZL-2 lithium
7 Shafts of load hook 1 Every month Inject with gun
base grease
ZL-2 lithium
8 Shafts of load hook 2 Every month Inject with gun
base grease
According to
ZL-2 lithium
9 Derricking rope working Grease
base grease
conditions
According to
ZL-2 lithium
10 Hoisting rope for winch 1 working Grease
base grease
conditions
According to
ZL-2 lithium
11 Hoisting rope for winch 2 working Grease
base grease
conditions

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 0066305-100-06-20Y

2) Diagram of boom frame system lubricating points

Note:
(1) The oil cup and the surface to be oiled should be wiped clean before adding oil.
(2) The sliding surfaces which are not listed in above table must be greased periodically.
(3) The lubricating grease of different brands can not be mixed.
(4) Add grease to bush, shaft and bearing until the used grease is squashed out.

Caution:
(1) Switch off engine before lubrication.
(2) Keep ladder, platform and guardrail clean and dry. When climb the crane, tighten safety
belt. Otherwise, the operator may fall down from crane.
(3) Failure to observe such regulation may result in death or serious injury.

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 14 liter.
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.

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 0066305-100-06-20Y

Note:
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 used 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 cap of oil filler.

Note:
When replace engine oil, the filter cartridge should be replaced together.

Caution:
(1) Don not remove oil drain plug when engine oil is still hot. Otherwise, you may get
scalded.
(2) Failure to observe this regulation may result in death or serious injury.

6.6.5 Fuel

Check and change fuel.

Fuel checks and fuel change
Serial No. Inspected item interval (operating hours) Volume
5 1000
1 Clean fuel tank ○
2 Change engine fuel ※ 300 liter

Note:
(1) The sign “※” means the fuel needs to be changed.
(2) The method for cleaning fuel tank: Remove the oil drain plug to drain water and
sediments.
(3) In order to minimize the sediment, top up the fuel tank after operation every day.

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.

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 0066305-100-06-20Y

6.6.6 Coolant

6.6.6.1 Check and change coolant

Coolant checks and coolant change

Serial interval (operating hours)
Inspected item Volume
No.
5 100 250 500 1000
1 Check coolant level ○
2 Change coolant ○ 43 liter

Note:
The above change interval is applicable to normal conditions. For special conditions, change
it every 6 months.

6.6.6.2 Check coolant level

a) Remove radiator cover to check coolant level, and check fluid level of auxiliary water
tank;
b) When coolant is insufficient, add softened water to water injection hole, and top up
auxiliary water tank.

Caution:
(1) Do not open the radiator cover when crane is warm up. Remove cover with thick cloth or
gloves after coolant does not bolt. When engine is in working temperature, the coolant
has high temperature and pressure.
(2) Failing to observe this regulation may result in death or serious injury.

6.6.6.3 Change coolant

a) Remove the plug at the bottom of radiator to drain coolant;

b) Mix softened water with durable coolant, and then add the mixed fluid to radiator until it is
visible at the bottom of water injection hole. In order to avoid air entering into the radiator,
the water should be added slowly. When the fluid level no longer falls down, screw down
the lid;
c) Start engine and run it for one minute, then stop to check the fluid level. If the fluid level is
not enough, add water again.

Caution:
(1) Do not drain coolant when crane is warm up, since hot coolant may burn the skin. Only
when coolant has been cooled down, can it be drained out.
(2) Failing to observe this regulation may result in death or serious injury.

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 0066305-100-06-20Y

6.6.7 Lubrication and maintenance of crane in irregular conditions

6.6.7.1 Lubrication and maintenance in dusty circumstance

Item Measures
Air filter Clean or replace in time
Radiator, oil cooler Clean in time to prevent them from being blocked.
Filter, filter cartridge Replace them in time
Engine oil Replace oil in time
Slewing gear ring Lubricate it in time
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
Lubrication
with grease nipple completely and carefully.
Basic
Clean crane body, radiator and oil cooler in time to get rid of salt.
machine

6.6.7.3 Lubrication and maintenance in cold area

Points for
Item Measures
attention
Use engine oil suitable for this temperature(see Operating When add the
Manual for Engine) oil, the oil of
CH-4,CG-4 of API classification different brands
The ambient -25℃ - -10℃ - -15℃ - or different
Engine temperature -20℃ 20℃ 40℃ quality grades
oil when engine can not be
starts mixed. The
Viscosity of SAE10W/30 SAE20W/30 SAE15W/40 volume of all
engine oil replaced oil is 23
liter.
Use fuel suitable for following temperature
Ambient temperature Type
Above -5℃ JIS#2 light diesel oil
Fuel
Between -5℃ and -15℃ JIS#3 light diesel oil
Below -15℃ JIS special #3 light diesel oil
Drain water before working and top up oil tank after working.
Make proper proportion of antifreeze fluid to water in Sometimes,
accordance with ambient temperature. proportion is
(volume of coolant: 43 liter) different
according to
Ambient Antifreeze fluid
Water difference
temperature (condensing)
brands of
Coolant -40C 39 liter 4 liter antifreeze fluid.
-70C 37 liter 6 liter It is
-130C 32 liter 11 liter recommended to
-170C 30 liter 13 liter use final
-210C 28 liter 15 liter antifreeze fluid
-250C 26 liter 17 liter that has already

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 0066305-100-06-20Y

Points for
Item Measures
attention
-310C 24 liter 19 liter been matched
-40℃ 22 liter 21 liter according to
difference
temperature.
After adding
Fully charge (The proportion of electrolyte is more than 1.22) distilled water,
Batter
The electrolyte of fully-charged battery is more anti-freezing run engine to mix
y
than that of that of under-charged battery in low temperature. it with
electrolyte.

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0066305-100-06-20Y

6 - 32
Chapter 7 Crane inspections
7—1
 0066305-100-07-20Y

7.1 General

The crane has been tested by manufacturer’s facilities prior to shipment in accordance with
GB/T3811-1983 and FEM standards.
The safety level achieved during initial commissioning may not be attainable during operation.
Examples of the root cause of such deviation include; e.g., wear and tear, corrosion, effects of
forced operations, changes in the environment and changes to the mode of operation. The
operator is responsible for taking the necessary steps to ensure that the maximum level of
safety is maintained. For that reason, the crane must be inspected by a competent inspector,
depending on application situations and the operating condition, at least once a year, counting
from the day of initial service.
Periodic inspections are principally a visual inspection, wherein the inspector appraises the
condition of the crane and its components. The purpose of the inspections is 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 also apply.
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).
A competent engineer is someone who engages in the designing, manufacturing and
servicing crane and is knowledgeable about all the relevant regulations and standards, and is
a position to judge whether the crane functions normally through inspection so as to ensure
long-term safe operation.
A number of important examples of items that are particularly important during the periodic
crane inspections are listed in the following: we wish to advise that the competent inspectors
and competent engineers take sole responsibility for the inspections that they carry out. This
chapter does not necessarily cover the entire scope of the inspections.
Attached is a checklist for periodic inspections of ZOOMLION crawler cranes. If the inspector
has any questions they should be directed to our Service Department.

Danger:
Non-observance of the following inspection guidelines and non-adherence of the inspection
intervals can lead to a serious accident!

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 0066305-100-07-20Y

7.2 Inspection of steel bearing structures

Steel bearing components such as lattice boom, slewing table, chassis, and support systems
(sliding arms or folding supports) 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 powder inspection, ultrasound or X-ray detection. The specialists should
then advise whether or not the damaged area can be repaired by welding or other means.
The welds or steel structural zones that require inspection may be present more than once
and in various forms. The joints or zones must be inspected all around at the locations
identified by arrows.

Note:
The scope and extent of all inspections remain the sole responsibility of the inspectors.
The following diagrams are given as an aid for the inspector. The diagrams are only examples
and are not necessarily 100% complete.
Crawler carrier

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0066305-100-07-20Y

Slewing table

FA-frame

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 0066305-100-07-20Y

Welding joints on main boom

Welding joints on fixed jib

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 0066305-100-07-20Y

7.3 Inspection of hosting and derricking winches

The hoisting, derricking winches and slewing reducer are designed using integrated planetary
gears. The gears are designed for long service life and the drive shaft and drive gear are
rated for endurance. Even though these gears are designed for long service life, an external
visual inspection is not adequate, since their life can be significantly affected by bad
maintenance (insufficient oil), defective seals, improper operation or overuse. The inspection
must therefore be carried out by a competent inspector in accordance with the following
guidelines.

7.3.1 Inspections

a) Inspection intervals
Every 1000 operating hours, at least once a year (annually)
b) Inspection
Check oil level. For hoisting and derricking winches, we recommend that the oil be
drained and the amount compared to the specified oil quantity.
c) Checking oil color
Assume that the oil has been overheated if it is black and/or a burnt oil smell is detected.
In this case, the oil must go bad.
d) Checking for foreign substances
This inspection should be carried out in a qualified laboratory. The used oil shall be
dribbled onto the specified filter medium. The oil sample is visually checked under a
microscope for foreign particles. If any particles are detected, the oil must then be sent to
a qualified laboratory and analyzed to determine the makeup of the particles.
e) Evaluation of foreign substances found in the oil
1) The maximum permissible quantity of foreign material measured by weight is
0.15% of total oil weight.
2) Maximum permissible foreign particle size from fine abrasion is 0.25my.
3) If above values are exceeded, the gearbox must be dismantled to determine the root
cause of increased contamination and then the gearbox should be refilled with fresh
oil.

Caution:
These repairs may only be carried out by specialists with appropriate equipment
knowledge.
f) Visual inspection
The drive devices shall be checked for leakage, since any loss of oil, in addition to
polluting the environment, can lead to gearbox failure.
g) Inspection the drive device brakes
Check the brakes at the same check the drive devices.
If the brakes cannot hold the specified test load of 33% rope tension increase on a single
rope strand and fully spooled drum, they shall be dismantled to determine the cause.
Whenever a planetary gearbox is dismantled because of increased contamination, the
brakes shall also be inspected.

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 0066305-100-07-20Y

Caution:
Only qualified personnel with specialized knowledge can inspect the gearboxes and
brakes.
h) Documenting the completed inspection
The results of the annual inspections and maintenance work, including all competed
tasks, shall be documented by the competent inspector, if necessary, and signed off by
inspection station or specialty shop.

7.3.2 Requirements for monitoring the winches

7.3.2.1 Theoretical service life

Crane winches are classified according to FEM98 as follows:

Drive group: M5

Load collective: L2

Load collective factor: 0.25

Theoretical service lifeT5: 6000 hours

Caution:
The “theoretical service life” is not equal to the real (true) life of a winch.
The actual life of a winch is affected by many additional outside factors, for example:
a) Overloads: the crane was not used as intended.
b) Inadequate maintenance: oil is not changed at the proper intervals;
c) Improper operation: excessive acceleration or deceleration of load; load falling onto
the cables;
d) Improper maintenance:
1) Using the wrong type of hydraulic oil;
2) Too much or too little lubricating oil;
3) Contamination during oil change
e) Assembly errors during repair and maintenance:
1) Undetected oil leakage
2) Improperly set safety devices
3) Hidden damage from accidents;
f) Extreme environmental conditions:
1) Extremely low or high temperatures
2) Corrosive atmosphere
3) Dust and dirt

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 0066305-100-07-20Y

7.3.2.2 Used portion of theoretical service life

The crane operator is obligated to have the crane inspected at least once a year.
The used portion of theoretical service life must also be determined. If necessary, the crane
operator can subcontract this work to an authorized inspector.
The actual operating conditions (load collective) and the winch operating hours at each
inspection interval are required to determine the proportion of the theoretical service life that
has actually been used. The operator is responsible to have it documented in the crane
inspection log.

7.3.2.3 Determining the operating condition (load collective)

The load collective of the crane is classified into groups, please refer to FEM9.5.11.

7.3.2.4 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
operating time for the superstructure can be estimated at 60% of the total operating hours of
the crane. If the hoist winch proportions is estimated at 20% of the superstructure operating
hours, the resulting hours as a percent of the total crane operating hours is: 12%.

Note:
The percentage staged above normally applies to main hoist winches.

7.3.2.5 Determining the actual used portion of the theoretical service life

The actually used proportion Si of the theoretical service life is given by the following formula:
kmi
Si ＝ ———— × Ti
km
Where,
km ＝ Load collective factor that was used to select the winch ratings. This factor is given in
the operating manual.
kmi ＝ load collective factor for inspection interval i
Ti ＝ effective operating hours for inspection interval i
The actually used hour proportion is subtracted from the remaining theoretical service life Di
after each inspection interval (see example).
If the remaining theoretical service life is not long enough to cover the next operating period, a
general overhaul of the winch is required.
If the theoretical service life D has been reached, the winch may only be operated after
conducting a general overhaul.

Note:
(1) A general overhaul of the winch is required not later than 10 years after putting the crane
into service.
(2) The general overhaul shall be arranged by operator and carried out by the manufacturer

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 0066305-100-07-20Y

or the manufacturer’s authorized representatives and must be documented in the

inspection log.
For example:
Drive gear group: M5
Load collective: light L1, km ＝ 0.125
theoretical service life: D ＝ 6000 h
Actual used proportion S of the theoretical service life is calculated using the individual
inspection intervals as follows:
First inspection (year 1)
The crane was used for assembly work during the past year:
Load collective L1, which means km1 ＝ 0.125.
The hour meter for crane engine indicates 1800 hours. The winch operated about 12% of the
time, i.e. T1=216.
The actual used proportion S of the theoretical service life at the time of the first inspection is
therefore:
0.125
S1 ＝ ————× 216 h ＝216 h.
0.125
Remaining theoretical service life:
D1 ＝ 6000 h – 216 h ＝ 5784 h
Second inspection (year 2)
Load collective L2, which means km2 ＝ 0.25.
The hour meter for crane engine indicates 3400 hours, i.e. during this period: 3400-1800 h＝
1600 h (1800 h were used during the first year of operation)
The winch operated about 12% of the time, i.e., T2 ＝192 h.
The actual usage proportion S2 of the theoretical service life at the time of the second
inspection is therefore:
0.25
S2 ＝ ———— ×192 h ＝ 384 h
0.125
Remaining theoretical service life:D2 ＝5784-384＝5400 h
Do the same for the rest calculation.

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 0066305-100-07-20Y

7.4 Inspection of load hook

The load hook must be inspected annually by a competent inspector.

These inspections are made to prevent accidents through early detection of deficiencies.
Any deficiencies determined by the inspector must be documented, corrected, and
subsequently re-inspected.
a) Check the hook for distortions; e.g., at the hook jaw;
The hook should be inspected for distortion as required, but at least once a year; e.g., at
the hook jaw.
b) Inspect all bolts and screws, and ensure all cotter pins are complete;
c) Check that the rotary connection of hook can move easily, and the clearance is not too
large;
d) Check the easy rotation of the hook: rotate the hook by hand. If it is stiff, it indicates that
the bearing has been damaged;
e) Check the safety catch for integrality and functional work;
f) Check the hook for corrosion and wear and tear.
Unscrew the nut from the hook shank so that the wire rope can be inspected for corrosion
and wear and tear.

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

The rope pulleys should be checked once a year, including:

a) Check rope pulley for damage and cracks;
b) If rope pulleys have been hit during crane operation (for example on buildings) or if they
were subjected to other stress factors, they must be then extensively checked for
damage or cracks;
c) Check for wear on the rope groove. Replace the pulley if the bottom of the rope groove
has been worn down more than 1/4 of the rope diameter;
d) If any damage or cracks are found, then the rope pulley must be replaced immediately. If
this is not observed, there is great danger of causing a serious accident!
e) Check rope pulley for tight fit. Loose and shaken rope pulley means that the bearing and
bearing bush is damaged.

Caution:
If any damage or cracks are found, then the rope pulley must be replaced immediately. If
this is not observed, there is great danger of causing a serious accident!

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 0066305-100-07-20Y

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.
Increased 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
inspection to make sure that there are no cracks or notches. If any cracks or notches are
detected, the rods must be replaced immediately; rod repairing is prohibited.
b) Elongation
The elongation of the rods must be inspected by measurement. Maximum permissible
elongation is 0.2%; for example, over a length of 7000mm=14mm
c) Wear and abrasion
The inside holes and pins must be inspected for signs of wear and abrasion, including the
spring keepers and cotter pins used for securing the pins.
d) Enamel coating
The anchoring rod coating must be inspected regularly for signs of corrosion. Eroded
spots must be repainted. The anchoring rod must not be stored in aggressive agents,
such as sea water.
e) Deformation
The anchoring rod, once being distorted, should be replaced immediately.

Caution:
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!

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 0066305-100-07-20Y

7.7 Inspection and maintenance of wire rope

Being a crucial component for crane lifting, the wire rope will directly affect the assembling
work and safety on the construction site. Therefore, much emphasis should be put on the use,
maintenance and regular inspection of wire rope.

7.7.1 Handling and transport of wire rope

The wire rope should be handled and transported with utmost care. When loading a wire rope
down, never push it down directly from a higher position in order to avoid causing any damage
to the rope or to the reel.
A proper means of transport is to make use of a steel bar through the middle hole or axle of
the reel. The reel can then be lifted with a forklift or directly with a sling attached to a crane.
When the reel or coil is rolling on the ground, the illustrated bar can only be placed
underneath both flanges of the reel, without getting in contact with the rope. The ground
should be even, and the rope is not allowed to contact the sharp objects or the fork of the
forklift, even if the outer lay of the rope is protected.
Improper methods:

Proper methods:

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 0066305-100-07-20Y

7.7.2 Inspection of wire rope

Any torsional stresses and sudden acceleration of load caused by impact loaded on wire rope
and load hook will cause serious damage to wire rope, a comprehensive check should be
therefore performed on the wire rope. While checking, pay attention to the following points:
a) Whether the rope end connections are in proper order;
b) Notches on pulley groove;
c) Corrosion, wear and tear and rope deformation;
d) Type and number of wire breaks, and location and consequence of wire break;
e) Narrowing of the rope diameter during the operational period.

7.7.3 Change 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;
b) Corkscrew-like deformation more than 1/3 of the rope diameter (Figure 1);
c) Basket formation (Figure 2);
d) Sharp protruding strands(loop formation) or strand clusters (figure 3);
e) Decrease of rope diameter by more than 15% of the nominal diameter;
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);
j) Kinking section of snapped strands (figure 7).

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 0066305-100-07-20Y

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.
Wire ropes are sensitive and they should be kept clean and dray, and be prevented from
coming in contact with the ground; Wire rope transporting and replacing must be carried out
according to actual requirements; When replacing ropes, the new ropes must be of the same
strength rating and diameter as the replaced ones. Should another type of wire rope be used,
permission must first be obtained from the crane manufacturer.

7.7.3.1 Preparation

a) 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 performance is at least
as good as those of the rope that was taken down;
b) 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;
c) 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;
d) Before starting to use the rope on 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.

7.7.3.2 Unwinding of the wire rope

The wire rope can be unwound from a reel or uncoiled on the floor. If the later method is
applied, the floor should be clean and even; otherwise, foreign substances such as sand
grains stuck to lubricating grease will damage the wire rope when it passes through the rope
pulley.
In no circumstances shall the rope be pulled from a reel or a coil which is laying on its side,
otherwise a twisting force will be inevitably generated on each rope layer. Every twisting force
will change the twist pitch of rope strand; alter the proportion of each component part in every

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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.

7.7.3.3 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.
It is recommended that the old rope should be removed prior to fitting a new rope. If the old
rope is used as a lead rope to pull the new one through the reeving system, do not connect
them together by directly welding or binding their rope ends; instead, they should be
connected with a Chinese finger. There is still another way to change a rope: use a thinner
rope as a lead rope to pull the new one through the reeving system. This way is usually
applied to the installation of a rope on new equipment.
a) Unwinding the rope from the reel onto the drum

In the manufacturing process, when a rope is wound onto a reel, the rope suffers bending
with a special direction. After the rope is delivered to customer, it is also bended towards
the same direction. Therefore, when the rope is unwound from a reel onto drum, it is
advantageous to maintain the direction of bending as it leaves the reel (see the above
figure).
If the above mentioned method is not observed, the wire rope will be kinked between the
reel and the drum or resume its original bending direction when used, which will result in
changes in the structure of rope.
b) 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

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into the lower rope layer under loading, which would result in serious damage to wire
rope. And the unwound rope can even get stuck, which will result in the reverse rotation
of the rope drum during the unwinding of rope, and thus causing the sudden increase in
tension 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 shafts (see the figure above).
Note:
We should on no account produce the tensioning force by means of compressing
the wire rope, such as putting the wooden board directly underneath the wire rope,
because the changes incurred in rope structure will make the rope deformation
irremediable.

c) 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.
d) Testing of wire rope

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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
undergoing “trial-running”, all components of the rope can be adjusted to real operating
condition.
The crane should be used for lifting at approximately 10% of the normal load in order to
stabilize the rope.
During the trial-running, crossing, kinking, twisting, and excessive bending as well as
scratch of wire rope should be avoided.

7.7.4 Maintenance and care of wire rope

The wire rope should be protected against exposure to such dangerous medium as heat
source, acid and alkali. And it should be free of sands and dirty adhered, and be greased.
Regular maintenance and care of the ropes enhances the safety of crane operation and
substantially increases the rope’s service life.
a) Wire ropes must be greased or oiled at regular intervals, especially around the drums
and pulleys, areas where they are turned and flexed the most. The grease or oil must be
compatible with that already on the ropes. Well lubricated wire ropes demonstrate 4 times
as much flex-play as unduplicated ones.
b) Dirty wire ropes must be cleaned regularly; the best results may be achieved by brushing.
c) If the lower layers on the drum are hardly used or not used at all, they are loose and must
be unwound and then rewound under a preliminary tension.
d) A rope works most economically when its entire length is used. Therefore, an
appropriately adapted rope length should be used for crane operation of long durations. If
partial sections of a rope are subject to different and varying loads, the rope, after a
certain time, can be turned around. In doing so, the previously free end of the rope is
attached onto the drum so that the part of the rope which has been subjected to the most
wear and hard use is now in the “quiet” zone, and vice-versa. The service life of a rope
can be noticeably increased.
e) If wear results mainly from the multi-layer winding of the drum, the service life of the rope
can be increased by shortening it by a length equivalent to 1/3 of the drum perimeter.
f) Extension torsion in torsion free hoisting rope and its elimination
1) A torsion compensation is not only required after a new rope has been placed, but
also if extension torsion has been established after a long working period, resulting
from stretching and settling of the rope structure.
2) Torsion compensation can be noticed when the hook block turns in multi reeve
operation and when the load is set down and / or the outer strand seem to loosen up.
In extreme cases, the rope shows an arch formation.
3) If a crane is operated for a long period of time with the same reeving, without
unreeving or changing the hoisting rope reeving, then we recommend installation of
a rope twist catcher on the fixed point of the hoisting rope.

Caution:
If this is not observed, the rope can be damaged!
g) Measures to eliminate torsion compensation
1) Set down the load hook
Lower the load hook as much as possible, so that the greatest rope length between
pulley block and load hook is exposed to compensation (twist, point 4).
2) Determine the direction of rope lay

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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 or such a number will be reeved.
In this case, the fixed point of the rope is easily accessible on the load hook and it
can easily be released.
4) Turn the end of the rope by 180° to 360° carefully to compensate for the turn of the
load hook.
To compensate for the turn, turn the separately shown end of the rope as marked by
the solid line arrow.
Note:
It is important that the correct reference point is taken and that the crane
operator should hold the cable in front of him.
The rope (Z) with right-hand lay direction as shown in figure 1 and the rope(S) with
left-hand lay direction as shown in figure 4 are turned in for compensation, while the
rope (Z) with right-hand lay direction as shown in figure 2 and the rope(S) with
left-hand lay direction as shown in figure 3 should be turned out for compensation.

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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
Since a non-stretch rope construction is relatively safe from torsion and it can only
be stretched a little (actually, the torsion will not make the rope deviate from the
groove of rope pulley), the hoisting movements without a load must be repeated
several times.
After getting the compensating turn to the end of the rope, reattach the rope end
again to the fixed point and repeat the hoisting movements without a load one or
several times so that the torsion compensation can be distributed over the complete
length of the rope past the rope pulley.
If necessary, in case the stretch was especially severe (multiple twisting of the lower
pulley block and /or slackening of the outer strands over a long stretch, or at several
points) then repeat this procedure several times, depending on hoist rope length.

7.8 Inspection of oil and fuel tanks

a) 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.
b) Repairs shall only be carried out by trained and knowledgeable specialists.
c) Improper repairs such as welding, brazing or soldering are not permitted without
consulting our company.

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7.9 Inspection of load bearing components

a) Checking the mounting bolts of slewing ring and winch.

b) Overloading or load impact may cause impact on bolting joints, resulting in damage to
bolts.

Note:
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 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 QUY80

Diameter of
Bolts Specification mounting
(GB/T1228-1991) hole
(mm)
Strength grade（GB3098.1-82） 10.9
2
M30 33 Limit of strength σsmin (N/mm ) 900
Pre-tightening moment (Nm) 1800
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.

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7.10 Inspection of engine

a) The engine must be inspected prior to every operation; i.e., daily check that all oil and
fuel lines are leak-free and dry. The fuel filter, oil filter and injection pumps shall also be
inspected for leakage.
b) Every day, check that the hydraulic components, fan drive hydraulic motors and their
supply lines are properly sealed and do no leak.
c) Check the exhaust system, especially the exhaust flanges and the exhaust flap brakes,
and make sure that they seal and move properly. The return springs that open the
exhaust flaps must function properly, because seized (therefore closed) exhaust flaps
during operation will cause increases in temperature and considerable overheating.
d) Check if electrical lines are functioning and mounted properly, and ensure that there is
sufficient clearance to hot exhaust pipes. Ensure that they are not damaged and still
properly insulated.
e) To reduce noise emission, noise reducing mats are installed in the engine area (engine
covering) for certain types of cranes. The fiberglass mats, after being cleaned, are
flame-resistant and fireproof.
f) If engine compartments are not cleaned regularly, oil and fuel may splash on the mats
while conducting maintenance and repair work. Oil and fuel soaked on noise reducing
mats must be removed, as they are flammable. The same is true for insulating mats in
the exhaust system area.
g) Clean the engine compartment only with nonflammable cleaning fluid. In addition, the
fluid may not be corrosive or chemically damaging to hoses and cables.

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Chapter 8 Additional equipment
 0066305-100-08-20Y

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 system is combined with the heating and ventilation systems of the cabin.
Its control panel is on the air conditioning cover behind the seats.

1 2 3 4

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
Turn it upwards, the heating mode is activated;
Turn it downwards, the cooling mode is activated.

Note:
Open the shutoff valve at the back of electrical control box near slewing table before
heating mode is activated.
4 Indicator light Turn switch (3) downwards, the indicator light will light up.
Note: When this indicator light lights up, it means that cooling mode is
activated.

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

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indicator light goes out and the compressor stops working. At this moment, set this
temperature to the rated value.
When the temperature in the cab is higher than this value, the indicator light lights up, the
compressor starts automatically and the cooling system begins to work.
When the temperature in the cab is lower than this value, the indicator lamp 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.

Caution:
(1) During “three guarantee” period, it is forbidden to dismantle air conditioning system
without manufacturer’s permission.
(2) Check the tension of compressor straps periodically and adjusts it in time.
(3) Wash off the dirt on the surface of condenser radiating rib. In this way, the cooling
performance can be protected.
(4) When changing the components of air conditioning system, add freezing oil according to
the requirements. As there’s difference between compressors in system, the brand and
type of new freezing oil should be the same as that of freezing oil used in the compressor.
Different freezing oil, which is not given explanation of being capable of mixing with the
freezing oil in the system, is never permitted to fill into the system.
(5) When add or change refrigerant, its brand and type should be the same as that of
refrigerant used by original system.
(6) Lower the temperature in the cab with the evaporator at high gear position, and keep the
temperature in cab at middle gear position or low gear position.
(7) When the components in the system break down, they should be replaced with the spare
parts supplied or designated by manufacturer. Otherwise, the system may be damaged.
(8) Under the condition of low temperature & high humidity, the evaporator should not work
at low speed. Otherwise, it may be frozen.
(9) If air conditioning is not used in winter, switch the 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
Check and repair Once a quarter
and motor

Evaporating fan
Check and repair Once a quarter
and motor
Once a month or increase
Check condenser for blockage. maintenance times
Condenser
If necessary, clean it. according to its working
condition

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Once a month or increase

Check evaporator for functional work and
maintenance times
Evaporator abnormal sound.
according to its working
Clean the air inlet.
condition
Electromagnetic Check that it works properly.
Once a quarter
clutch If necessary, clean it

Socket Check that the wire connector is fitted

Once a month
connector tightly.

8.2 Media Player

ZCC800H crawler crane can be equipped with radio or CD, DVD player according to
customer’s demands. For details, please refer to relative accessories.

Note:
Radio or CD, DVD player are not the basic configurations of crane. Customers can select to
assemble according to their different demands.

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