Zcc800hwg Operation Manual

ZCC800H CRAWLER CRANE
OPERATING MANUAL
The 1st edition (March, 2013)
Crawler Crane
For you
Our respectable users, thank you very much for choosing ZOOMLION crawler crane.
Before operating the crane, read these operating instructions carefully.
In this manual, we have introduced the important instructions, technical parameters,
safety operation and maintenance of crawler crane to you. Please always keep this
manual ready to your hand in the cab.
Do not operate and maintain the crane before you fully understand the contents in the
manual. If there is anything in this manual or in the individual sections that you do not
understand, please contact with the local service engineer of Zoomlion, and they will
provide you efficient technical support in time. Any risks associated with unspecified
and improper use are the sole responsibility of the cranes owner, operator or user.
The manual is as an integral with the crane. Thus, the manual should be conveyed to
the assignee with the crane as an integral.
The documentation is protected by copyright. It may not be duplicated, reproduced or
for other purpose without permission.
Our products and technical documents are subject to technical improvements and
changes without notice. Therefore, please acquaint yourself with our updated
technology information. If there are differences between illustration and product, refer
to the product. If there is any question, please contact the local service engineer of
Zoomlion.
Crawler Crane
Special information
The following symbols appear in this manual:
Indicate an imminent threat or danger, which could lead to
life-threatening or fatal injury of one or more persons.
Indicate a danger, which could lead to serious injury of one or more
persons.
Indicate a potential danger, which could lead to slight or minor injury of
one or more persons.
Indicate a danger which could lead to severe damage to the machine
or other assets.
Indicate a tip or hint in the machine operating instructions.
Emphasize the importance of the information in operating instructions.
Is located wherever an action that could create a dangerous situation
is prohibited.
ZCC800HWG Crawler Crane
Contents
For you .........................................................................................................................................I

Special information ....................................................................................................................II
Chapter 1 Safety instructions ........................................................................................... 01-1
1.1 Foreword....................................................................................................................... 01-1
1.2 Note .............................................................................................................................. 01-3
1.3 Alarms and warnings .................................................................................................... 01-3
1.4 Component safety features .......................................................................................... 01-3
1.5 Features for operator safety ......................................................................................... 01-4
1.6 Environmental safety .................................................................................................... 01-4
1.7 Personal protective equipment (PPE) .......................................................................... 01-4
1.8 Measured noise level.................................................................................................... 01-5
1.9 Vibration levels ............................................................................................................. 01-5
1.10 Organizational safety measures ................................................................................. 01-5
1.11 Personnel qualification, requirements and responsibilities ......................................... 01-6
1.12 Safety advice regarding specific operational phases ................................................. 01-6
1.13 Special Hazards ......................................................................................................... 01-6
Chapter 2 Description of the crane .................................................................................... 02-1
2.1 Product model .............................................................................................................. 02-1
2.1.1 Product name plate and its position....................................................................... 02-1
2.1.2 Engine type and its manufacturer .......................................................................... 02-2
2.2 Terminology .................................................................................................................. 02-3
2.2.1 Boom configuration ................................................................................................ 02-3
2.2.2 Description of component parts ............................................................................. 02-4
2.3 Product description ....................................................................................................... 02-8
2.3.1 Crane undercarriage .............................................................................................. 02-8
2.3.2 Crane superstructure ............................................................................................. 02-8
2.3.3 Overall dimensions .............................................................................................. 02-10
III

2.4 Technical data ..............................................................................................................02-11
2.4.1 Main technical parameters ....................................................................................02-11
2.4.2 Type of load hook and application of rope reeving .............................................. 02-12
2.4.3 Rope reeving and specification of wire rope ........................................................ 02-12
2.4.4 Lifting height ......................................................................................................... 02-14
2.4.5 Lifting capacity chart ............................................................................................ 02-17
Chapter 3 Safety guidelines .............................................................................................. 03-1
3.1 Operational planning .................................................................................................... 03-1
3.2 Safety technical notes ................................................................................................. 03-2
3.2.1 Safety instructions for crane operator .................................................................... 03-2
3.2.2 Safety instructions for the rigger ............................................................................ 03-3
3.2.3 Safety instructions for the signalman ..................................................................... 03-4
3.2.4 Safety instructions for crane operating crew.......................................................... 03-4
3.2.5 Points for attention during crane operation ............................................................ 03-5
3.2.6 Safety signs ........................................................................................................... 03-5
3.3 Slings .......................................................................................................................... 03-10
3.3.1 Slings introduction................................................................................................ 03-10
3.3.2 Sling identification tags ........................................................................................ 03-10
3.3.3 Angle of choke ......................................................................................................03-11
3.3.4 D/d ratio ............................................................................................................... 03-12
3.3.5 Load angle factor ................................................................................................. 03-13
3.3.6 Load share ........................................................................................................... 03-14
3.3.7 Load angle factor chart ........................................................................................ 03-14
3.3.8 Sling safety .......................................................................................................... 03-14
3.3.9 Sling safety guide................................................................................................. 03-15
3.3.10 Taglines .............................................................................................................. 03-15
3.3.11 Load center of gravity......................................................................................... 03-16
3.4 Requirements for operating site ................................................................................. 03-17
3.4.1 Selecting an operating site .................................................................................. 03-17
3.4.2 Slopes and trenches ............................................................................................ 03-17
3.4.3 Permissible ground pressure ............................................................................... 03-18
3.4.4 Checking safety measures................................................................................... 03-19
3.5 Underground cables ................................................................................................... 03-19
IV

3.6 Checking safety measures ......................................................................................... 03-22
3.7 Crane operation with a load........................................................................................ 03-25
3.8 Hand signals for controlling crane operations ............................................................ 03-43
Chapter 4 Crane operation ................................................................................................ 04-1
4.1 Operation and controlling instrument ........................................................................... 04-1
4.1.1 Operators cab assembly ....................................................................................... 04-1
4.1.2 Left control box ...................................................................................................... 04-3
4.1.3 Right control box .................................................................................................... 04-6
4.1.4 Safety control ......................................................................................................... 04-8
4.2 Instructions for the digital display system ................................................................ 04-12
4.2.1 Load moment limiter ............................................................................................ 04-12
4.2.2 Instrument panel .................................................................................................. 04-12
4.3 Startup of the crane .................................................................................................... 04-15
4.3.1 Adjustment of the operators cab seat ................................................................. 04-15
4.3.2 Pre-startup inspection .......................................................................................... 04-18
4.3.3 Turning on power and relevant preparation ......................................................... 04-20
4.3.4 Starting of the engine ........................................................................................... 04-22
4.4 Safety device .............................................................................................................. 04-23
4.4.1 Emergency stop button ........................................................................................ 04-23
4.4.2 Load moment limiter ............................................................................................ 04-23
4.4.3 Angle indicator ..................................................................................................... 04-24
4.4.4 Lowering limiter .................................................................................................... 04-25
4.4.5 Hoisting limiter ..................................................................................................... 04-25
4.4.6 Working boom limit position alarm and protection system .................................. 04-26
4.4.7 Anemoscope ........................................................................................................ 04-27
4.4.8 Gradient display ................................................................................................... 04-27
4.5 Operation of crane ...................................................................................................... 04-27
4.5.1 Operation of the travel gear ................................................................................. 04-27
4.5.2 Operation of the winch mechanism ..................................................................... 04-34
4.5.3 Operation of the slewing mechanism................................................................... 04-40
4.5.4 Operation of simultaneous movement ................................................................. 04-43
4.5.5 Operation of the crawler carrier extending & retracting mechanism.................... 04-44
4.6 Reeving of the wire rope ........................................................................................... 04-45
V

4.6.1 Reeving of the hoisting rope ................................................................................ 04-45
4.6.2 Reeving of the derricking wire rope ..................................................................... 04-52
Chapter 5 Assembly & dismantling .................................................................................... 05-1
5.1 Technical instructions for safety.................................................................................... 05-1
5.1.1 Notes on assembly ................................................................................................ 05-1
5.1.2 Examination of the safety measures ...................................................................... 05-1
5.1.3 Examination of the wire ropes, hook, pulley and anchoring rod ............................ 05-2
5.1.4 Raising and lowering of the boom ......................................................................... 05-4
5.2 Unloading and installation of the basic crane ............................................................... 05-5
5.2.1 Inspections before operation ................................................................................. 05-5
5.2.2 Unloading of the basic crane ................................................................................. 05-5
5.3 Installation of the counterweight ................................................................................... 05-6
5.4 Available working conditions of the product ................................................................05-11
5.5 Combination of the boom and anchoring rod ............................................................. 05-13
5.5.1 Working condition of the main boom ................................................................... 05-13
5.5.2 Working conditions of the fixed jib ....................................................................... 05-31
5.6 Assembling and dismantling of the main boom .......................................................... 05-43
5.6.1 Preparation for installing the main boom ............................................................. 05-43
5.6.2 Installation of the main boom ............................................................................... 05-43
5.6.3 Electrical connection of the main boom ............................................................... 05-48
5.6.4 Raising of the main boom .................................................................................... 05-50
5.6.5 Lowering and dismantling of the main boom ....................................................... 05-52
5.7 Assembling and disassembling of the fixed jib ........................................................... 05-53
5.7.1 Preparation for installing the fixed jib ................................................................... 05-53
5.7.2 Installation of the fixed jib..................................................................................... 05-54
5.7.3 Electrical connection of the fixed jib..................................................................... 05-59
5.7.4 Raising and lowering of the fixed jib .................................................................... 05-61
5.7.5 Dismantling of the fixed jib ................................................................................... 05-64
5.8 Assembling and dismantling of the tip boom .............................................................. 05-65
5.9 Weights and outline dimensions of the main parts ..................................................... 05-66
5.10 Methods and precautions for transportation ............................................................. 05-69
5.10.1 Methods and precautions for transportation ...................................................... 05-69
5.10.2 Other requirements ............................................................................................ 05-69
VI
Operating Manual for Crawler Crane

Chapter 1 Safety instructions
Thank you for purchasing ZOOMLION crawler crane produced by Zoomlion Heavy
Industry Science and 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.
Certain terminologies are used in the operating manual, and in order to avoid
misunderstandings while operating, these terminologies should be used consistently.
a)
Only qualified and especially trained personnel are permitted to work on the
crane!
b)
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 the 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
cranes owner, operator or user.
Using these instructions in the manual:

l
makes you easier to become familiar with the crane
avoids malfunctions due to improper operation
Observing these instructions in the manual:

l
increases reliability in operations
extends the service life of the crane
reduces repair costs and downtime
Always keep the operating manual handy in crane operators 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.
01 - 1
Chapter 1
1.1 Foreword
Chapter 1
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 distributors before you begin operation.
Any parts of the operating manual may not be copied or distributed, nor used for
competitive purpose. All rights are reserved by Zoomlion.
The operating manual must be read and the regulations in it must be observed by all
persons operating, maintaining, or otherwise working in any capacity on this crane.
The content with respect to the safety is marked with
instructions involved in the book are only the conventional contents.
, the safety
The following terms that are used in the operating manual DANGER, CAUTION, and
NOTE are intended to point out certain important rules of conduct to all persons who
work with the crane.
The term DANGER is used whenever the nonobservance of the warning given may
insure or lead to life-threatening hazards and damaged to the crane.
The term CAUTION is used whenever serious personal injury and damage to the crane
can occur if the operating instructions are not observed and adhered to.
The term NOTE is used whenever the observance of certain instructions or notes is
economically meaningful to the utilization of the crane.
(1) When welding work is conducted on crane, the operator should unplug all
power source plugs of controllers and cut off the master power, otherwise, he
should take all consequences incurred.
(2) 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.
01 - 2
a)
Read this manual and familiarize yourself with any associated documentation before
operating this crane.
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 engineer
who has read this manual and fully understand the information involved in it.
c)
To avoid the risk of electric shock always isolate this equipment from the power supply
prior to carrying out any maintenance adjustment or removing any guards or covers.
d)
Always follow the procedures outlined in the Operating Manual and Maintenance and
Service Manual.
e)
If in doubt ask, do not take personal risk.
f)
Only trained personal can be allowed to install, set, operate, maintain, and
commission this equipment.
1.3 Alarms and warnings

To assure personnel safety, please observe 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 crane 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 crane.
Make sure replacement parts include warning or instruction labels where necessary.
For the position of warnings and instruction labels, please see chapter 3 "Safety
Guidelines".
1.4 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.
01 - 3
Chapter 1
1.2 Note
Chapter 1
1.5 Features for operator safety

a)
Safety component crane emergency stop button. Ensure the button is functional.
b)
Steps, handrails, tread plates and fixed guards are provided to assist the personnel to
climb on the crane.
1.6 Environmental safety

1.6.1 A regular service should be taken on the crane strictly in accordance with
maintenance procedures to ensure that engine emission is close to a minimum value.
1.6.2 Consumable materials
l
Diesel spillages must be dealt with immediately to avoid fire hazard and pollution.
Only use the lubricating oil recommended in the service manual.
Local and national regulations must be observed when disposing of waste.
Potentially harmful waste used on this crane includes such items as hydraulic oil, fuel,
coolant, filters and batteries, etc.
Use leak-proof containers for draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them.
Do not pour waste onto the ground, into sewer system or into any water source.
Ensure that all consumable and replaced parts are disposed of safely and with
minimum environmental impact.
1.6.3 Machine disposal. This machine must only be disposed of by a specialist machine
breaker.
1.7 Personal protective equipment (PPE)
a)
Loose or baggy clothing can get caught in running machinery.
b)
Where possible when working close to engines or machinery, only do so when they
are stopped. If this is not practical, remember to keep tools, test equipment and all
other parts of your body well away from the moving parts.
c)
For reasons of safety, long hair must be tied back or otherwise secured, garments
must be close fitting and no jewellery such as rings may be worn.
d)
Correctly wear personal protective equipment.
e)
Recommended personal protective equipment includes:
01 - 4
Hard hat
Safety glasses/Goggles
Hearing protection
Close fitting overalls
Safety boots
Industrial gloves
High visibility vest or jacket
Chapter 1
1.8 Measured noise level

The condition of working site may 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).
1.9 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 are A (1): 1.4m/s2, A (4): 0.7m/s2,
A (8): 0.5m/s2 under normal operating condition.
1.10 Organizational safety measures
a)
The crane must only be operated by a suitably qualified operator 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 crane while it is moving (excluding central
lubrication).
d)
Keep hands, feet and clothing clear of power driven parts and 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. Remove any build-up of grease,
oil and debris.
f)
Disconnect battery ground cable and power supply 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 manufacturers approval.
j)
In the event of safety relevant modifications or changes in the behavior of the machine
during operation, stop the machine and lock it out immediately and report the
malfunction to the competent authority / person.
01 - 5
Chapter 1
1.11 Personnel qualification, requirements and responsibilities

a)
Any work on and / or with the crane 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 crane.
c)
Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
1.12 Safety advice regarding specific operational phases

1.12.1 Standard operation
l
Take necessary precautions to ensure that the crane is used in a safe and reliable
state.
This crane is a conventional assembly & dismantling machine. Do not apply the crane
for other purpose.
Operate the crane only for its 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.
Ensure that any local barriers erected to stop unauthorized entry to this equipment are
in place.
Before starting the engine ensures it is safe to do so.
1.12.2 Malfunction
In the event of any malfunction or operational difficulty, stop the crane immediately.
1.12.3 Unguarded areas
l
In-running nip points on moving machinery can cause serious injury or even death.
Do not reach into unguarded machinery. Your arm could be pulled in and amputated.
Stop the crane before removing any safety devices.
Limit access to the machine and its surrounding where barrier guards are
appropriately erected to reduce the risk of residual mechanical hazards, falling lifted
loads.
1.13 Special Hazards

1.13.1 Electrical energy
a)
External considerations and hazards

When working with the crane, maintain a safe distance from the overhead electric
lines. If overhead lines are in the immediate vicinity, a risk assessment must be
completed prior to operating this crane.
01 - 6
b)
c)
Vacate the area
Warn others against approaching and touching the crane.
Report the incident and have the live wire de-energized.
Chapter 1
If your machine comes into contact with a live wire:
Machine Electrical
-
The electrical equipment of the crane must be inspected 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 crane is wired on a negative earth. Always observe correct polarity.
Battery
-
Always disconnect battery leads before carrying out any maintenance to the
electrical system.
Recharge the battery in a well ventilated area.
The battery contains sulphuric acid, an electrolyte which can cause severe burns
and produce explosive gases. Avoid contact with the skin, eyes or clothing.
No smoking when maintaining battery.
Wear appropriate PPE.
1.13.2 Gas, dust, steam, smoke and noise

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

a)
Welding, flame cutting and grinding work on the crane 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 crane as it will affect its structural integrity.
c)
Avoid all naked flames in the vicinity of this crane.
01 - 7
Chapter 1
1.13.4 Hydraulic equipment

a)
Work on hydraulic system must be carried out by persons having special knowledge
and experience of hydraulic system.
b)
Check all lines, hoses and screwed connections regularly for leaks and obvious
damage. Repair damage immediately. Sprayed oil may cause personal injury.
c)
Always relieve pressure from the hydraulic system before carrying out any kind of
maintenance or adjustment work.
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 lines 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.
01 - 8

Chapter 2 Description of the Crane
2.1 Product model
Chapter 2
2.1.1 Product name plate and its position
Fig. 02-1 Product name plate
02 - 1
Chapter 2
Fig. 02-2 Position of name plate

2.1.2 Engine type and its manufacturer
-
Engine type: WP10.270N
Engine manufacturer: WeiChai Power Co., Ltd.
02 - 2
2.2 Terminology
Chapter 2
2.2.1 Boom configuration
SF
Fig. 02-3 Boom configurations

Table 02-1 Instructions for boom configuration
Configuration no.
Description
Parameters
Main boom
S = 13 58m
SF
Main boom with fixed jib
S = 37 49 m
F = 6 18 m
02 - 3
2.2.2 Description of component parts
Chapter 2
1.1
1.2
1.4
1.3
1.5
Fig. 02-4 Crane undercarriage
02 - 4
2.1
2.2
Chapter 2
2.3
2.4
2.5
2.6
2.7
2.8
Fig. 02-5 Crane superstructure
02 - 5
Chapter 2
2.7
3.1
3.7
3.2
3.3
3.6
2.6
3.4
2.5
3.5
Fig. 02-6 Overview of crane superstructure from above
02 - 6
Components
No.
1.2
Names of the
components
Additional
support
Crawler
carrier
1.3
Undercarriage
central section
1.1
1.4
1.5
Horizontal
anchoring rod
Crawler
carrier
extending &
retracting
cylinder
Components
No.
2.1
Names of the
components
A-frame assy.
Components
No.
3.1
Names of the
components
Slewing
mechanism
3.2
Fuel tank
3.3
Air-conditioning
condenser
3.4
Engine
2.4
Main boom pivot

section
Main boom
tilting-back
support
Rear
counterweight
2.5
Main boom
derricking winch
3.5
Hydraulic oil
tank
2.6
Hoisting winch 2
3.6
Main valve
2.7
Hoisting winch 1
3.7
Electrical control
box
2.8
Operators cab
2.2
2.3
The illustrations above are simplified to make them easier to understand. They are
for reference only. For actual components of superstructure and undercarriage,
please take the product as the standard.
02 - 7
Chapter 2
Table 02-2 Description of components
2.3 Product description

2.3.1 Crane undercarriage
a)
Undercarriage central section
Chapter 2
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 360continuous rotation
b)
Crane engine
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.
02 - 8
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.
e)
Main boom derricking winch
Chapter 2
Composed of built-in axial piston hydraulic motor, balance valve, reducer and normally
closed brake, derricking pulley block as well as wire rope;
Fitted with a ratchet wheel mechanism
f)
Slewing mechanism
Composed of built-in axial 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 gears 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
Fitted on the rear section of slewing table
h)
Crane operators 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 operators cab (L W H): 1850mm900mm1650 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 (optional), main boom
angle indicator, derricking limiter, hoisting limiter, safety catch, balance valves and
overflow valves as well as ratchet wheel mechanism for derricking winch.
j)
Electrical system
24V DC, negative ground, 2 batteries of 165 AH each
The classification group of ZCC800H crawler crane is A1, and the classification
groups of mechanisms are: traveling mechanism (M1), slewing mechanism (M2),
hoisting winch (M3) and derricking mechanism (M2).
02 - 9
2.3.3 Overall dimensions
Chapter 2
Unit: mm
Fig. 02-7 Overall dimensions of crane
02 - 10
2.4 Technical data

2.4.1 Main technical parameters
Table 02-3
Unit
Value
Max. lifting capacity radius
tm
804
Deadweight with basic boom
72.8
Main boom length
13 - 58
Fixed jib length
6 - 18
Max. lifting capacity on fixed jib
Fixed jib angle
10, 30
Max. length of main boom with fixed jib
4918
Remarks
Chapter 2
Item
131
Hoisting winch 1
m/min
(110 during
free-fall operation)
On the 4th rope layer
Hoisting winch 2
m/min
131
Main boom derricking

winch
m/min
93
Slewing speed
rpm
0-2
Traveling speed
km/h
0 - 1.67
30
MPa
0.083
13.53.43.2
kW/r/min
199/2000
Max. single
rope speed
of winches
Gradeability
Ground pressure
Overall dimensions (LWH)
Rated power /
rotational speed
Engine
Max. output torque /

rotational speed
Distance between track center

crawler contact length crawler width
Noise
Noise level outside

operators cab during
operation
Noise level in
operators cab during
operation
Nm/
r/min
mm
1270/1200 - 1500
42005440800
26005440800
(dB)
107
(dB)
79
With A-frame and

main boom pivot
section
Weichai Power
Crawler carrier
extended
Crawler carrier
retracted
02 - 11
2.4.2 Type of load hook and application of rope reeving

Table 02-4
Maximum rope reeving
Weight of load hook (kg)
80 t
12
1250
50 t
920
30 t
600
8t
264
Chapter 2
Type of load hook
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
(1) Rope reeving for different boom lengths
Table 02-5
Boom (or jib)
Rated lifting capacity (t)
length (m)
Crane operation with

main boom
Crane operation with

main boom and fixed
jib
02 - 12
Rope reeving
13
80
12
16
66.8
11
19
51.8
10
22
51.7
25
41.5
28
40.7
31
33.8
34
33.5
37
28.4
40
23.8
43
23.2
46
22.6
49
17.8
52
17.8
55
14.3
58
14
6 - 18
(1) If the crane is working with hoisting rope reeving less than the value listed in
the above table, single hoisting rope load must be checked to make sure that
the max. permissible load capacity of single hoisting rope is not exceeded.
(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) Specification of wire rope
Table 02-6
Description and
intended use
Rotation-resistance
or not
Type of rope
Nominal rope
diameter
Rope length
Minimum breaking
load
Direction and type
of lay
Tensile strength of
rope
Hoisting rope for

winch1
Hoisting rope for

winch 2
Derricking rope
Yes
Yes
No
357IWS-1960
357IWS-1960
6T29+77-20-1910
24mm
24mm
20mm
240m
160m
150m
406KN
406KN
290KN
Left-hand ordinary
lay
Left-hand ordinary
lay
Right-hand lang lay
1960N/mm2
1960N/mm2
1910N/mm2
(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.
02 - 13
Chapter 2
(2) The maximum permissible lifting capacity of single hoisting rope is 7000kg.
2.4.4 Lifting height
The boom lifting height curve is drawn without considering boom deflection.
Lifting height (m)
Chapter 2
(1) Lifting height on S boom
Fig. 02-8
(1) The X-axis indicates the working radius in meters, and the Y-axis indicates the
lifting height in meters.
(2) For S boom configuration, S= 13m 58m.
02 - 14
Lifting height (m)
Chapter 2
(2) Lifting height on SF boom
Fig. 02-9
(2) For SF boom configuration, S= 37m 49m, F= 6m 18 m, and F-jib angle = 10.
02 - 15
Lifting height (m)
Chapter 2
Fig. 02-10
(2) For SF boom configuration, S= 37m 49m, F= 6m 18 m, and F-jib angle = 30.
02 - 16
2.4.5 Lifting capacity chart
The rated lifting capacity is given in t, and */*indicates lifting capacity/radius.

(1) Lifting capacity on S boom
Unit: t
Main boom length (m)
Working
radius
(m)
Working
radius
(m)
13
80
68
66.8
52.3
52
51.8
51.7
42.3
42
41.9
41.7
40
39.5
35.5
35.2
35
34.8
34.6
33.97
33.8
33.5
29.5
29.3
29.2
29.1
29
28.9
28.8
28.6
28.4
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
17.2
17
16.9
16.6
16.2
16
15.8
15.5
14
14.37
14.2
13.9
13.6
13.4
13.1
12.9
16
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
7.7
7.65
7.6
7.5
24
6.8
6.75
6.7
26
28
5.9
28
30
5.5
5.4
30
4.2
32
14
16
18
24
26
32
16
19
22
25
28
31
34
37
4
5
6
7
8
02 - 17
Chapter 2
Table 02-7

Working
radius
(m)
40
43
46
49
52
55
58
Chapter 2
Working
radius
(m)
9
10
23.8
23.2
22.6
12
18.6
18.6
18.2
17.8
17.8
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
8.9
8.8
8.6
20
22
8.2
8.2
8.1
7.9
7.7
7.5
22
24
7.45
7.2
7.1
6.9
6.8
6.6
24
26
6.6
6.5
6.4
6.2
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
4.8
4.6
4.5
30
32
4.2
4.2
4.1
3.8
32
34
4.1
4.1
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
2.9
2.6
38
2.8
2.7
2.6
2.5
2.3
40
2.3
2.3
2.2
42
1.8
1.6
44
46
1.6
1.3
46
48
1.5
48
0.8
50
40
42
44
50
10
12
The lifting capacities highlighted in grey are determined by the strength.
02 - 18
(2) Lifting capacity on SF boom

Table 02-8
Unit: t
Main boom
length (m)
Fixed jib
length (m)
37
12
18
Fixed jib angle ()

Working
radius (m)
10
30
10
12
14
16
5.5
18
5.5
20
5.5
22
5.5
24
5.5
26
6.7
6.7
5.5
28
6.1
5.5
6.1
5.5
5.5
3.5
30
5.4
4.8
5.4
4.8
3.5
32
4.9
4.4
4.9
4.4
3.3
34
4.3
4.3
3.2
36
3.9
3.7
3.7
3.2
38
3.5
3.4
3.5
3.1
3.2
3.2
40
10
30
10
30
5.5
42
02 - 19
Chapter 2
Main boom
length (m)
Fixed jib
length (m)
40
6
12
18
Chapter 2
Fixed jib angle ()

Working
radius (m)
10
10
12
30
10
14
16
5.5
18
5.5
20
5.5
22
5.5
24
5.5
26
6.4
6.1
5.4
5.5
28
5.5
5.5
5.5
4.8
3.7
30
5.2
4.2
3.7
32
4.4
4.3
4.3
3.5
34
3.9
3.9
3.5
36
3.6
3.5
3.6
3.5
3.8
3.3
3.1
3.2
3.2
3.1
2.7
2.7
2.6
2.5
2.4
2.5
2.3
38
40
42
02 - 20
30
10
30
5.5
Main boom
length (m)
Fixed jib
length (m)
43
6
12
18
Fixed jib angle ()

Working
radius (m)
10
12
14
10
30
10
16
18
20
5.5
5.5
5.5
22
5.5
24
5.5
26
6.3
5.5
6.3
5.5
28
5.5
4.7
5.5
5.4
5.4
30
4.8
4.3
4.8
4.7
32
4.2
4.2
4.2
4.1
4.5
34
3.5
36
3.6
3.6
3.7
3.6
3.6
3.5
38
3.3
3.3
3.4
3.4
3.3
40
3.1
3.1
3.1
42
2.7
2.7
2.7
2.7
2.5
2.5
2.5
44
30
Chapter 2
30
02 - 21
Main boom
length (m)
Fixed jib
length (m)
46
6
12
18
Chapter 2
Fixed jib angle ()

Working
radius (m)
10
12
14
30
10
16
18
5.5
20
5.5
22
5.5
24
6.5
5.5
26
5.8
5.9
5.7
5.5
28
4.9
4.9
30
4.7
4.6
4.6
4.5
4.8
32
4.3
4.4
3.8
34
3.7
3.7
3.8
3.5
36
3.5
3.5
3.5
3.5
3.5
3.3
38
3.2
3.2
3.2
3.2
3.2
3.2
40
2.9
2.9
2.9
2.6
2.5
2.6
2.5
2.5
2.5
2.4
2.4
42
44
02 - 22
30
10
30
5.5
Main boom
length (m)
Fixed jib
length (m)
Main boom
length (m)
Fixed jib
length (m)
49
6
12
18
Fixed jib angle ()

10
12
14
16
18
20
22
24
30
10
30
10
30
Working
radius (m)
12
14
5.5
16
5.5
18
5.5
20
5.5
22
6.5
6.5
5.5
24
26
5.7
5.5
5.7
5.5
5.5
26
28
5.1
4.9
28
30
4.5
4.4
4.6
4.4
4.5
30
32
3.7
32
34
3.6
3.6
3.5
3.5
34
36
3.4
3.3
3.3
3.4
3.2
3.3
36
38
3.2
3.2
38
40
2.8
2.8
2.8
2.8
2.8
40
42
2.5
2.5
2.5
2.5
2.5
2.7
42
2.2
2.2
2.3
2.3
2.3
44
1.9
1.9
1.9
1.8
46
44
46
02 - 23
Chapter 2
Working
radius (m)
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.
Chapter 2
1.
Rated total lifting capacity =
Rated lifting
capacity
(Actual load)
(Weight of load hook and

other load handling
devices)
Fig.02-11
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 hooks weight auxiliary load hooks weight slings
weight wire ropes 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:
L cos(a - b )
L2
G2 = G - G1 1 + 2
- G3 - G4 cos(a - b ) + 1
2 L1
L
4 1
Where, G= rated lifting capacity
G1= weight of fixed jib head and fixed jib pivot sectionweight of 6m fixed jib
intermediate section (number of 6m fixed jib intermediate sections) + fixed jib
02 - 24
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 cos)
Chapter 2
L2= fixed jib length

= main boom angle
= fixed jib angle (10o or 30o)
Fig.02-12
6.
The rated total lifting capacity indicates the cranes 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
02 - 25
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.
Chapter 2
11. Crane operation with main boom and fixed jib:

The maximum lifting capacity on fixed jib (7 t) includes the weight of 8t auxiliary
load hook and wire rope, which weigh 0.6t in total. Therefore, the maximum
actual lifting capacity should not exceed 6.4 t.
12. When crane is traveling with load,
02 - 26
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.
(3) Lifting capacity on main boom under SF boom configuration (fixed jib attached
with a load hook)
Table 02-9
37m main boom

37
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
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
02 - 27
Chapter 2
Fixed jib length (m)
Working radius
Table 02-10
40m main boom

40
Chapter 2
Working radius
(m)
12
18
Fixed 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
02 - 28
Table 02-11
43m main boom

43
(m)
12
18
Fixed 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
02 - 29
Chapter 2
Working radius
Table 02-12
46m main boom

46
Working radius
(m)
12
18
Chapter 2
Fixed 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
02 - 30
Table 02-13
49m main boom

49
Working radius
(m)
12
18
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
02 - 31
Chapter 2
Fixed jib angle ()
(4) Lifting capacity on fixed jib under SF boom configuration (main boom attached
with a load hook)
Table 02-14
37m main boom
Chapter 2

37
Working radius
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
10
12
5.1
6.2
14
5.9
5.1
6.1
16
5.9
5.1
6.1
5.3
4.8
18
5.9
6.1
5.3
4.8
20
5.9
6.1
5.3
4.7
3.5
22
5.9
6.1
5.2
4.7
3.4
24
5.9
6.1
5.2
4.7
3.4
26
5.6
5.8
5.2
4.7
3.4
28
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
02 - 32
4.8
2.9
2.8
2.9
2.5
38
2.5
2.5
2.7
2.3
2.3
2.3
2.2
40
Chapter 2
36
02 - 33
Table 02-15
40m main boom

40
Chapter 2
Working radius
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
10
12
5.1
6.2
14
5.9
5.1
6.1
16
5.9
6.1
5.3
4.8
18
5.9
6.1
5.3
4.7
20
5.9
6.1
5.2
4.7
3.5
22
5.9
6.1
5.2
4.7
3.4
24
5.9
6.1
5.2
4.7
3.4
26
5.3
5.2
4.6
4.7
3.3
28
4.4
4.4
4.9
3.9
4.2
30
4.1
3.9
3.3
4.2
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
02 - 34
40
42
2.2
2.1
2.3
2.3
1.7
1.8
1.7
1.7
1.4
1.6
1.5
Chapter 2
38
02 - 35
Table 02-16
43m main boom

43
Chapter 2
Working radius
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
12
5.9
14
5.9
5.1
6.1
16
5.9
6.1
5.3
4.7
18
5.9
6.1
5.3
4.7
20
5.9
6.1
5.2
4.7
3.5
22
5.9
6.1
5.2
4.7
3.4
24
5.9
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
3.1
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
02 - 36
2.1
2.1
2.2
2.3
42
1.7
1.7
1.8
1.9
1.5
1.6
1.7
44
Chapter 2
40
02 - 37
Table 02-17
46m main boom

46
Chapter 2
Working radius
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
12
5.9
14
5.9
5.1
6.1
16
5.9
6.1
18
5.9
6.1
5.3
20
5.9
6.1
5.2
4.7
22
5.9
5.2
4.7
3.4
24
5.4
5.2
4.7
3.4
26
4.9
4.7
4.9
4.8
4.6
3.3
28
3.9
3.8
4.1
3.3
30
3.6
3.5
3.6
3.9
3.3
32
2.9
3.2
3.1
3.5
3.1
34
2.9
2.6
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
02 - 38
42
44
1.8
1.8
1.9
2.1
2.2
1.5
1.5
1.6
1.6
1.7
1.5
1.5
1.6
Chapter 2
40
02 - 39
Table 02-18
49m main boom

49
Chapter 2
Working radius
(m)
12
18
Fixed jib angle ()

10
30
10
30
10
30
12
5.9
14
5.9
5.1
16
5.9
6.1
18
5.9
6.1
5.3
20
5.9
5.2
4.7
22
5.9
5.2
4.6
3.4
24
5.4
5.5
5.2
4.6
3.4
26
4.6
4.4
4.7
4.6
4.6
3.3
28
3.9
4.1
3.3
30
3.4
3.3
3.6
3.5
3.6
3.3
32
2.9
2.9
3.1
3.1
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
2.3
2.1
2.4
02 - 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
1.1
1.2
1.3
1.4
1.5
0.9
0.9
44
46
Chapter 2
40
02 - 41

Chapter 3 Safety guidelines
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.
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
(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!
03 - 1
Chapter 3
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:
3.2 Safety technical notes

3.2.1 Safety instructions for crane operator
Chapter 3
The crane operators 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.
03 - 2
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.
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 lifting devices 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
03 - 3
Chapter 3
The following improper operating errors should be avoided.
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.
Chapter 3
Qualifications for signalman:

a)
Familiar with the lifting task so as to cooperate with crane operator and other workers;
b)
Make sure that only authorized personnel are allowed to carry out work;
c)
Be qualified with the work in hearing, eyesight and reaction;
d)
Be able to estimate the distance, height and clearance correctly;
e)
Be trained in hand signals for operating and familiar to use them;
f)
Use standard hand signals for crane operation. If necessary, use a radio device to
send out correct and clear order;
g)
Be capable of conducting the operating of crane to move the load safely;
h)
Position himself in a safe location from where he can see the whole process of
operation and be seen clearly by the crane operator.
In order to assure yourself and other persons interest, please operate crane in
accordance with specified regulations, and take precautions against possible
dangers caused by improper operation.
3.2.4 Safety instructions 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.
03 - 4
3.2.5 Points for attention during crane operation
Observe the rated lifting capacity of crane and working radius specified in load
capacity charts.
(1) The crane is not allowed to work at working radius which is not specified in load
capacity charts. This case is also applicable to the condition that the load is not
attached to the load hook. If not, there is a risk of accident.
(3) Slowly activating and stopping 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.
3.2.6 Safety signs
There are safety signs affixed on the important components before the crane delivery.
The safety signs affixed around the operators cab are shown as follows:
Emergency exit
Note: First aid kit
03 - 5
Chapter 3
(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.
Chapter 3
Note: lifting height curve
Note: points for attention for

operation
Warning: operation of crawler carrier
Note: operation of slewing fixing pin
03 - 6
Note: instruction for

high-voltage line
Prohibited: Dont push
Note: free-fall operation
The safety signs affixed around the slewing table are shown as follows:
Prohibited: Access
prohibited
Danger: Crush hazard
Danger symbol
Danger: Risk of burn
Note: Fire extinguisher
Prohibited: Naked flames
Danger: snagging /dragging
Note: oil level indication
Chapter 3
Safety sign
03 - 7
Chapter 3
Safety sign
Safety sign
Note: battery master switch
The safety signs affixed around the undercarriage are shown as follows:
Warning: Dragging /
entanglement
03 - 8
Note: Lift point
Warning: Risk of falling
Warning: Crushing /
collisions
Note: traveling direction
Chapter 3
The safety signs affixed around the boom system are shown as follows:
Note: lift point
Prohibited: No standing under the boom
(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 operators 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.
03 - 9
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 are essentially the same as
the strengths and the weaknesses of the wire rope from which it is made.
Chapter 3
Slings are generally one of six types:

-
Chain
Wire rope
Metal mesh
Natural fiber rope
Synthetic fiber rope
Synthetic web
Usage and inspection procedures tend to place these slings into three groups with each
type having its own particular advantages and disadvantages:
-
Chain
Wire and mesh rope
Fiber rope and fiber web rope
Factors that must be taken into consideration when choosing the best sling for the job
include:
-
Size
Weight
Shape
Temperature
Sensitivity of the material to be moved
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:
-
Manufacturers name or trademark
Diameter or size of sling
Material of sling
Rated load for the types of hitches used
Lift angle the load rating is based
03 - 10
3.3.3 Angle of choke

The angle used on the choker hitch reduces the sling capacity.
Table 03-1
Sling rated capacity (%)
90 - 120
87%
60 - 90
74%
30 - 60
62%
0 - 30
49%
Chapter 3
Angle of choke
Fig. 03-1
03 - 11
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 into the diameter of the load
(see the following figure). 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.
Chapter 3
Table 03-2
D/d ratio
Efficiency (%)
40
95
30
93
20
92
15
89
10
86
83
75
65
50
Fig. 03-2
03 - 12
a)
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.
b)
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 horizontal line decreases, the rated capacity of the sling also
decreases (see following figures 2, 3, 4).
c)
The smaller the angle between the sling leg and the horizontal is, the greater the
stress on the sling leg and the smaller or lighter the load will be, the sling can safely
support. The smaller the angle is, the greater bending forces are imposed on the load
will be.
The capacity can be readily determined by multiplying the slings vertical capacity by
the appropriate load angle factor.
Fig. 03-3
03 - 13
Chapter 3
3.3.5 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.
Chapter 3
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.
Table 03-3
Sling angle
Load angle factor
90
1.000
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
11.49
Following angles are not recommended when

rigging.
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.
03 - 14
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 or
hoist operators should watch the load at all times when it is in motion.
Never allow anyone to ride on the hook or load.

3.3.9 Sling safety guide
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.
j)
Do not impact the load.
k)
A sling cannot be pulled from under a load when the load is resting on the sling.
Chapter 3
a)
3.3.10 Taglines
The safest method for a rigger to control a load suspended from a hook is with a tagline.
(see following figure)
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)
Never stand directly underneath a load.
03 - 15
Chapter 3
Fig. 03-4
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.
03 - 16
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.
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.
Safety distance is measured from the foot of the trench and it is:
Soft or backfilled soil = 2 depth of trench (A2 = 2T)
Hard or grown soil = 1depth of trench (Al = 1T)
Fig. 03-5
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.
03 - 17
Chapter 3
The most essential requirement for safe crane operation is working on firm ground
with the capacity to support your loads.
3.4.3 Permissible ground pressure
Table 03-4
Soil type
10-1MPa
A) Back-filled, not naturally compacted ground
0 1
B) Natural soil, apparently undisturbed

1. Mud, peat, marshy soil
2. Non-cohesive, sufficiently compactly layered soil:

Fine to medium grained sand;
From coarse-grained sand to gravel
1.5
2.0
Chapter 3
3. Cohesive soil:
Loamy
Soft
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:
In cohesive layer order
15
In massive or column-style shape
30
C) Artificially compacted ground

1. Asphalt;
2. Concrete
5 15
Concrete group B I;
50 250
Concrete group B II
350 550
If there is any doubt about the load-bearing capacity of the ground at the operating
site, soil test should be carried out.
03 - 18
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 crane.
e)
Check whether there are obstacles which will hinder required 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.
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:
c)
1)
Utility companies (electricity, gas or water)
2)
Cable users (telephone companies, factories, transport companies)
3)
Building authorities.
Only use the latest, up-to-date plans.

03 - 19
Chapter 3
The crane operation belongs to dangerous operation; so much attention should be

given to the working condition of crane before and during crane operation.
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.
f)
The relevant utility companies, cable users and public authorities:
g)
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.
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
Chapter 3
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.
03 - 20
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.
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 crane operator do if a gas pipe is damaged and gas escapes, or a
leak is suspected?
a)
Stop work immediately.
b)
Leave the crane 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 near the construction
equipments.
e)
Clear the danger area and secure a wide area with barriers. Do not allow access by
unauthorized personnel.
f)
Inform the relevant gas company of the following:

-
The extent of the damage
The exact location of the site
The exact circumstances of the accident
How long ago the accident occurred
A name and telephone number for a return call.
03 - 21
Chapter 3
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.
g)
If there is the slightest suspicion that the gas is 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.
Chapter 3
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:
j)
Must assist all specialist personnel from the gas company during the repair work.
Can only leave the building site with the consent of the specialist personnel.
Work on the building site can only begin again if authorization has been given by the
relevant gas company.
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, and boom angle indicator etc., are in good working order.
a)
The load moment limiter must be set according to the current crane configuration.
b)
The lifting height of crane as given in the load capacity charts must be adhered to. The load
given in the load capacity charts must not be exceeded.
c)
The crane operator must know the weight and dimensions of the load before operating
the crane.
d)
Load handling devices, lifting equipment and tackle must be in accordance with
specified requirements.
03 - 22
e)
Make sure that the weight of hook block and the weight of tackle are subtracted from
the load given in the load capacity charts.
Example:
Table 03-5
Maximum permissible load according to chart
27t
Weight of the hook block
0.38t
Weight of the slinging rope
0.04t
Actual useful load of the crane
26.58t
3.6.1 Counterweight
The required counterweight must be installed prior to lifting operation and after the crawler
carriers are extended to specific positions.
If the counterweight is not installed properly 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.)
If the maximum tensile force is exceeded, the wire rope may snap or the winch
motor may be damaged.
03 - 23
Chapter 3
In this case, the load to be lifted may not exceed 26.58t.
3.6.3 Electromagnetic influences

Strong electromagnetic fields are likely to be present if the construction site is close to a
transmitter.
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.
Chapter 3
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.
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)
03 - 24
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
All components of crane are in running-in state at the initial operating period. So, for the
first 100 operating hours, the working load should not be too great and the working speed
should not be too high. The maximum lifting load can not exceed 80% of its rated load.
And the maximum working speed is forbidden.
b)
The ground on jobsite should be firm and flat and the gradient should not be greater than
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.
Chapter 3
a)
03 - 25
The permitted temperature range for cranes 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 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 fixed jib is assembled.
Chapter 3
c)
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.
03 - 26
Wind force
Beaufort Description
0
Calm
1
2
3
4
5
6
7
8
Light air
Light
breeze
Gentle
breeze
Moderate
breeze
Fresh
breeze
Strong
breeze
Stiff wind
Gale force
wind
Effects of the wind in the inland

Wind speed (m/s)
0 - 0.2
No wind, smoke rises straight up
Wind direction is shown only by observing the
0.4 - 1.4
trail of smoke, not by the wind sock
Wind can be felt on the face, the leaves rustle,
1.6 - 3
wind sock moves slightly
Leaves and thin twigs move. Wind extends a
3.4 - 5.3
small breeze flag.
Swirls up dust and loose paper, moves twigs and
5.5 - 7.8
thin branches
Small deciduous trees begin to sway, foam forms
8 - 10.6
at sea.
Thicker branches move; telephone lines begin to
10.8 - 13.7
whistle, umbrellas are difficult to use
13.9 - 17
Entire trees swaying; difficult to walk into wind
17.2 - 20.6
Gale
20.8 - 24.5
10
Severe
gale
24.7 - 28.3
e)
Breaks twigs off trees, walking becomes difficult

Minor damage to property(chimney tops and
roofing tile are blown off)
Trees are uprooted, significant damage to
property
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:
Table 03-7 The safe clearance from high-voltage power lines

Output voltage of
high-voltage power line
(V, kV)
Safe clearance (m)
V1
1< V 15
15 <V 40
40<V100
1.5
100<V200
6
03 - 27
Chapter 3
Table 03-6 Wind force beaufort
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 people around the crane not to move and not touch the crane.
(4) Move the crane away from the danger area.
Not observing above points can lead to (fatal) accidents and damage!
Only the crane without fault is allowed to work.
Chapter 3
f)
3.7.2 Instructions for safe 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.
03 - 28
It is forbidden to lift load over the people.
d)
It is forbidden to lift the load when someone stands on it.
Chapter 3
c)
03 - 29
Chapter 3
e)
Overloading operation and lifting staggered load is prohibited. Never pull load obliquely.
f)
It is forbidden to lift the load hidden in the ground or frozen on the ground. Otherwise, the
crane may topple over, and the boom may be broken off.
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.
03 - 30
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.
Chapter 3
h)
03 - 31
Under any condition, there must be three windings of wire rope left on the hoisting drum.
k)
When a load is suspended in the air, the operator is not allowed to leave the cab.
Chapter 3
j)
03 - 32
Operation should be carried out stably and gently. Never operate control lever jerkily and
carry out switchover operation abruptly.
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.
03 - 33
Chapter 3
l)
Getting on and off the crane should be careful to avoid casualty.
o)
It is prohibited to make any modifications to the crane without permission; otherwise you
should take the consequences. It is prohibited for unauthorized person to repair and
change the components.
p)
Stop the crane operation if one of the following conditions occurs:
Chapter 3
n)
1)
03 - 34
The crane is overloaded or the weight of load is uncertain;
2)
The load falls down due to bad binding or hanging;
3)
No protective mat is added between the edges of load and wire rope;
Chapter 3
03 - 35
Chapter 3
03 - 36
4)
In case of poor visibility and /or darkness, it is difficult to identify load or 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.
Anyone is not permitted to ride 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.
Chapter 3
q)
03 - 37
Keep the windows of crane operators 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.
Chapter 3
s)
v)
03 - 38
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.
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.
Chapter 3
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.
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.
03 - 39
Chapter 3
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.
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:
03 - 40
i)
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.
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.
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:

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 operators cab
until the danger is obviated. If operator must leave the crane, hed better jump rather
than climb down the cab.
k)
The operators 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.
03 - 41
Chapter 3
h)
1)
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.
Chapter 3
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
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 operators cab or safety devices.
j)
Take precaution measures against storm or lightning strikes.
k)
Take precaution measures against frostbite in winter.
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.
03 - 42
3.8 Hand signals for controlling crane operations

1
Preparation
2
Use main hoist
3
Use auxiliary hoist
Description
Arm stretched out over

the head, palm of the
hand facing forwards.
Tap fist on the safety

helmet; then use regular
signals.
Bend one hand and hold it

upward, tap the elbow
with the other hand; then
use regular signals.
Ser. No.
Signal
4
Hoist
5
Lower
6
Raise load slowly
Description
With forearm vertical,

palm of the hand facing
forwards, move hand in
small horizontal circle.
With
arm
extended
downwards with a 30
angle to the bodypalm of
the hand facing inwards,
move hand in small
horizontal circle.
With forearm vertical,

palm of the hand facing
upwards, wave hand up
repeatedly.
Chapter 3
Ser. No.
Signal
Illustration
Illustration
03 - 43
Ser. No.
Signal
Chapter 3
Description
7
Rotate
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.
Turn left: With right

of the hand facing
outwards, lower the
forearm sideways
horizontally, fingers
rotation.
8
Lower load slowly
With arm extended
downwards with a 30
angle to the bodypalm of
the hand facing
downwards, wave hand
down repeatedly.
Illustration
Ser. No.
Signal
Rotate slowly
Description
Illustration
03 - 44
Turn left: With right

of the hand facing
outwards, move forearm
horizontally and
repeatedly, fingers
rotation.
Turn right: With left

of the hand facing
outwards, move forearm
horizontally and
repeatedly, fingers
rotation.
10
Indicate load lowering
position
Extend the fingers to point

at the position the load
should fall on.
Ser. No.
Signal
11
Raise boom
12
Lower boom
Description
With arm stretched

sideways horizontally,
thumb pointing upwards,
the remaining fingers
closed, wave forearm up.
With arm stretched

sideways horizontally,
thumb pointing
downwards, the
remaining fingers closed,
wave forearm down.
14
Lower boom slowly
15
Stop
13
Raise boom slowly
Bend one hand with
thumb pointing upwards;
place other hand
motionless above hand
moving up and down.
Ser. No.
Signal
Description
Chapter 3
Illustration
Bend one hand with

thumb pointing
downwards; place other
hand motionless below
hand moving up and
down.
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.
Illustration
03 - 45
Ser. No.
Signal
Description
17
End of a movement
With fingers extended,
cross both hands before
the forehead.
Chapter 3
Illustration
(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. Misunderstanding of hand signals may lead to serious accidents.
(3) In any case, national traffic regulations must always be observed when abroad.
03 - 46

Chapter 4 Crane operation
4.1 Operation and controlling instrument
Chapter 4
4.1.1 Operators cab assembly
Figure 04 - 1 Operators cab assembly
04 - 1
Table 04 - 1 Arrangement of the operators cab

Code
Designation
Digital display system
Screen
of
winch
monitoring system
Monitor the winch and crane tail in real time.
Freefall pedal
Control the freefall brake. The brake releases upon

step-down.
Travel gear pedal (with

handle lever)
Accelerator pedal
Air conditioning unit
Seat
Left control box
Right control box
Chapter 4
04 - 2
Description
The upper part is the display of the load moment limiter
and the lower part is the instrument panel of the control
system (see section 4.2 for details).
Control travelling to leftward or rightward.

Control the rotational speed of the engine.
Lie on the rear side of the operators cab (see section
8.1 for details).
Its status is adjustable (see section 4.3.1 for details).
Control the actions as slewing (see 4.1.2 for details).
Control the actions as hoisting winch 1 and 2, and
derricking winch (see section 4.1.3 for details).
4.1.2 Left control box
1
3
Chapter 4
Winch limit
bypass
Slewing
alignment
Figure 04-2 Left control box
04 - 3
Table 04 - 2 Description of the left handle
Chapter 4
Code
Designation
Slewing
lever
control
Safety lever
Cigar lighter
Emergency
switch
Slewing alignment
switch
Spare
Spare
stop
Free swing button
Winch
limit
bypass switch
04 - 4
Description
Push forward to control the rightward rotation and push
backward to control the leftward rotation (see section 4.1.2.1
for details).
Fully push it forward to power on the control system.
Otherwise, the power is cut off.
Begin heating after being pressed down and pull it up if
required.
CAUTION: Do not press it for more than 10 seconds to
avoid overheat.
Press down the switch upon an emergency or need to stop the
crane.
CAUTION: The whole working power supply is cut off
and the engine is shut down by pressing down the red
emergency stop rotary knob.
When the ground is flat, it is recommended that the switch be
opened to make the slewing operation more stable; it is not
suggested to open it when the ground is not smooth.
Reducing lateral force of the boom can prevent the boom from
being damaged by excessive lateral force.
CAUTION: Prevent vigorous swaying of the weight
brought by sudden stop of slewing action.
In case of over-winding or over-lowering safety alarm limitation
action, limitation to action can be temporarily released by
rotating the switch clockwise, and speed of all actions can be
reduced as 25% of the primary one.
1. Slewing control lever
Chapter 4
Figure 04 - 3 Slewing control lever

Table 04 - 3 Description of the slewing control lever
Code
Designation
Swing
brake
cylinder switch
Horn switch
Description
Turn the switch to ON to open the swing brake cylinder and
conduct slewing operation; turn it to OFF to close the swing
brake cylinder and stop slewing operation.
Control the warning horn.
DANGER: Horn can only be used in danger to ensure
that it can warn all personnel around the crane.
04 - 5
Chapter 4
4.1.3 Right control box
Figure 04 - 4 Right control box

Table 04 - 4 Description of the right control box
Code
1
Designation
Derricking control
lever
Hoisting winch 2
control lever
Hoisting winch 1
control lever
04 - 6
Description
Control derricking. The forward and backward moves respectively
refer to the decoiling and coiling of the cable of the derricking.
Control the hoisting winch 2. The forward and backward moves
respectively refer to the decoiling and coiling of the cable of the
hoisting winch 2.
Control the hoisting winch 1. The forward and backward moves
respectively refer to the decoiling and coiling of the cable of the
hoisting winch 1.
Designation
Key switch.
Manual
throttle
select switch
Hoisting winch 2
high-speed knob
7
8
9
Power switch
Micro-positioning
switch
Free-fall switch
11
Derricking ratchet
pawl switch
Spare
12
Spare
10
Description
Power can be turned on by using the key switch to start the engine.
Insert the key into the key switch and clockwise rotate it to the gear
2 to turn on the power, and then continue to rotate it to start the
engine.
CAUTION: 1. In each restart of the engine, the key switch
must firstly be reset and then it can be started; 2. The engine
will be started after automatically preheating when it is cold.
Moreover, delay start of the engine is normal.
Throttle control mode turns into manual control when the switch is
clockwise rotated. Since throttle is controlled by the knob (No. 17 in
the figure), throttle pedal control is invalid.
Control hoisting winch 2 high-speed. When the knob is
counterclockwise rotated to its greatest extend, the high-speed is
zero, and when the knob is clockwise rotated to its greatest extend,
the high-speed reaches the maximum one.
Control the power of the overall crane controller.
When the switch is pressed down, speed of all actions are reduced
to the 25% of the original one.
Hoisting winch 1 clutch is disconnected when the switch is pressed
down, then free-fall hook operation can be done. If free-fall pedal
(No. 2 in Figure 4.1.1) is stepped down at the moment, free-fall
hook action is started.
Control derricking pawl, see section 4.5.2.2.(d) for detailed
description
The engine flames out when the switch is pressed down.

13
Engine
switch
shutdown
14
Oil cooling switch
15
SetUp switch
16
Hoisting winch 1
high-speed knob
17
Engine
throttle
control knob
CAUTION: 1. When the engine flames out, it is better to

reset it again after keeping over 30 seconds of on-off state, or
working hours of the engine this time cannot be saved; 2.
Before the engine is ignited, the switch must be reset.
When oil temperature is too high, hydraulic oil is cooled by using
the switch.
In case of overload (below 110%) or safety warning limitation
action for main boom angle less than 30, limitation to action is
released by pressing down the switch, and speed of all actions are
reduced to the 25% of the original one (see section 4.1.4 for
detailed usage of Setup switch).
Control the hoisting winch 1 high-speed. When the knob is
counterclockwise rotated to its greatest extend, the high-speed is
zero, and when the knob is clockwise rotated to its greatest extend,
the high-speed reaches the maximum one.
The engine rotational speed is adjusted through the knob under the
manual throttle mode, and the clockwise direction is the rotational
speed acceleration one.
04 - 7
Chapter 4
Code
4.1.4 Safety control

Table 04 - 5 Action limitation and release method for safety warning
Warning name
Limitation
action
Release method
Remarks
1. Release the Setup

switch when it is pressed
down. When there is
Chapter 4
Overload
(100%-110%) or
minimum main
boom angle
Overload (above
110%)
Over-winding
Over-lowering
Max.
boom
angle (80)
04 - 8
Coiling
cables of
hoisting
winches 1
2
decoiling
cable of
derricking
winch
Coiling
cables of
hoisting
winches 1
2
decoiling
cable of
derricking
winch
Coiling
cables of
hoisting
winches 1
2
decoiling
cable of
derricking
winch
Decoiling
cables of
hoisting
winches 1
2
decoiling
cable of
derricking
winch
Coiling
cable of
derricking
winch
the
the
and
and
the
the
the
the
and
and
the
the
the
the
icon or
icon
shown on the load
moment limiter, action
limitation
can
be
released.
2. Release the bypass
key switch when it is
clockwise rotated. When
there is
icon
shown on the load
limitation
can
be
released.
Release the bypass key
switch
when
it
is
there is
icon
shown on the load
limitation
can
be
released.
the
the
1. Action limitation can

be released by clockwise
rotating
winch
limit
bypass switch (No. 9 in
Figure
4.1.2)
and
keeping it.
2. Release the bypass
key switch when it is
and
and
the
the
there is
icon
shown on the load
limitation
can
be
released.
and
and
the
the
the
the
Release is not allowed.
1 Setup switch is active

when pressed down once,
and it becomes invalid by
being pressed down again.
2 If overload is released
and it has acted once,
Setup switch requires to be
pressed down again for
releasing it again.
3
icon is displayed
by pressing down Setup
switch
when
it
is
overloaded,
icon and
icon are displayed

simultaneously by pressing
down Setup switch when
the main boom is in the
minimum angle.
4 Bypass (repair) key
switch is active by being
rotated once, and it stops
working when it is rotated
again or engine stops.
Action time of once lasts for
30 minutes.
(1) The bypass key switch can release limitations of all other safety warning to
action expect for the maximum boom angle, and the action speed is reduced
to 25% of the original one after being released.
(2) The action speed remains unchanged (except for bypass key switch release)
when warning limitation is released under no load angle. The action speed is
reduced to 25% of the original one when warning limitation is released under
load angle.
(3) Release in table refers to the temporary obtaining of the operation
authority towards dangerous direction through the switch after safety
warning is arisen and action is limited, not referring to safety warning
removed.
(4) In case of any of or multiple safety warnings in the above table, the slewing
action is not allowed if Slew limit switch in electrical control box for slewing
table is in open state.
Table 04 - 6 Tricolor light alarm logic

Green
light
Before
release
Overload or
minimum
main
boom
angle
Over-winding
After
release
Before
release
After
Moment
percentage
is greater
than
0%
and
less
than 90%.
Moment
percentage
When
is 90% at
load
least and
angle
100%
at
most.
Moment
percentage
is greater
than 100%
and 110%
at most.
No load angle
Yellow
light
Red light
Buzzer
Interrupted
Interrupted
Interrupted
Interrupted
04 - 9
Chapter 4
(5) All other switches are self-resetting switches except for the slew limit switch,
and the bypass key switch and slew limit switch are installed in the electrical
control box for slewing table (see section 4.1.4.1 for details).
Green
light
Yellow
light
Red light
Buzzer
release
Over-lowering
Max.
angle
boom
Chapter 4
When bypass
key switch is
active under
any
circumstance
When
moment
percentage is
90% at least
and 100% at
most
Before
release
After
release
Release
is
not
allowed
Interrupted
Interrupted
Interrupted
(1) Release in table refers to the temporary obtaining the operation authority
towards dangerous direction through the switch after safety warning is
arisen and action is limited, not referring to safety warning removed.
(2) in table refers that the light is not on or the buzzer makes no sound,
refers that the light is on or the buzzer make continuous sound, and
interrupted refers that the light flickers or the buzzer make interrupted
sound.
All operation releasing safety warning limitation must be used under the
circumstances of commissioning, repair conducted by the professionals or
avoiding other accidents from happening.
04 - 10
4.1.4.1 Electrical control box for the slewing table
Chapter 4
Figure 04 - 5 Electrical control box for the slewing table

Table 04 - 7 Description for the electrical control box for slewing table
Code
Designation
Slew limit switch
Bypass
switch
key
Description
The left refers to the off-state and the right refers to on-state. In
case of any safety warning when the switch is on, the slewing
action is automatically forbidden.
The switch is started when it is clockwise rotated and limitations
of all other safety warnings except for the maximum boom
angle limitation can be released when it is started.
DANGER: Operation of bypass key switch must be
used under the circumstances of commissioning, repair
conducted by the professionals or avoiding other
accidents from happening.
04 - 11
4.2 Instructions for the digital display system
Figure 04 - 6
Digital display system
Table 04 - 8 Digital display system

Code
Description
Display of load moment limiter
Instrument panel
Chapter 4
4.2.1 Load moment limiter

See instructions for the load moment limiter for detailed operation of load moment
limiter.
In load moment limiter commissioning, safe operation rules of the crane must be
followed and operation is conducted according to rated lifting moment table.
4.2.2 Instrument panel
The instrument panel is used for real-time monitoring of the working condition of the
crawler crane, which can show the rotational speed of the engine, service time of the
engine, water temperature, oil temperature, oil level and pump pressure etc., and the
display interface flickers to give an alarm or warning in case of abnormities, as shown in
the following figure:
04 - 12
Chapter 4
Figure 04 - 7
Instrument panel
Table 04 - 9 Description of the instrument panel

Code
1
2
3
4
5
Designation
Bus meter
Main
pump
(1)
pressure gauge
Main
pump
(2)
pressure gauge
Slewing
pump
pressure gauge
Control pressure
Description
Display related parameters and various kinds of warning
indication of the engine (see bus meter description for details).
Display the working circuit pressure of main pump I.
Display the working circuit pressure of main pump II.
Display the working circuit pressure of the slewing pump.
Display the working circuit pressure of the control pump.
When hoisting winch 1 or leftward travelling is active, main pump I starts to work;
when hoisting winch 2 or derricking winch or rightward travelling is active, main
pump II starts to work, and when slewing is active, the slewing pump starts to
work.
04 - 13
Figure 04 - 8 Bus meter

Table 04 - 10 Description of the bus meter
Code
Designation
Hydraulic
oil
blocking
warning
Water
temperature
warning
Power
indication
Rotational
speed
hour
meter
Spare
Spare
Spare
Oil manometer
Spare
10
Spare
11
Spare
12
Oil
pressure
warning
The indicator light in on when the engine oil

pressure is less than 0.06 MPa.
13
Fuel
warning
The indicator light is on when fuel level is less than

10%.
14
Water
thermometer
15
Fuel gauge
Chapter 4
1
2
3
4
04 - 14
level
Icon
Description
The indicator light is on when the hydraulic oil circuit
is blocked.
The indicator light is on when the cooling liquid
temperature of the engine is higher than 96.
The indicator light is on when the overall crane
power is on.
Indicate the current rotational speed of the engine
and show the total working hours of the engine.
Indicate the current engine oil pressure.
Indicate the current cooling liquid temperature of the

engine.
Indicate the oil level height percentage of the fuel
tank.
4.3 Startup of the crane

4.3.1 Adjustment of the operators cab seat
Chapter 4
4.3.1.1 Adjustment of the seat head cushion height
Height of the head cushion can be manually adjusted, and force shall be appropriate
during adjustment to prevent it from being pulled up.
04 - 15
Chapter 4
4.3.1.2 Adjustment of the seat armrest
Armrest height can be adjusted by rotating the armrest adjustment roller.

4.3.1.3 Adjustment of the front and rear of seat
Turn the seat upwards to adjust the switch forward and backward, push the seat
cushion and release the switch when it is in the appropriate location.
04 - 16
4.3.1.4 Adjustment of the seat height
Chapter 4
There are two seat height adjustment switches, the front and back switches
respectively control the height adjustment of the front and back height of the cushion.
The cushion can be raised by pulling up the switch during operation.
04 - 17
Chapter 4
4.3.1.5 Adjustment of the seat angle
Turn the seat upwards to adjust the switch forward and backward, release the switch
when the seat back is pushed to the appropriate location.
4.3.2 Pre-startup inspection
The following inspection must be conducted before the engine is started.
4.3.2.1 Filter and oil level inspection
a)
Diesel engine oil level.
b)
Oil level of hydraulic oil tank of the crane hydraulic system.
c)
Oil filter on the hydraulic oil tank.
4.3.2.2 Fuel level inspection

Inspect the fuel level on the fuel gauge in drivers cab.
4.3.2.3 Cooling liquid level inspection
Cooling liquid must be filled in the edge of the oil filling nozzle.
Cooling liquid level must not be inspected if the engine is uncooled. In inspection,
the engine must be cooled, or it is in danger of burning.
04 - 18
4.3.2.4 Inspection of overall status of the crane
a)
Inspect the work log to ensure that all regular inspection, maintenance and repair
work is done.
b)
Inspect whether the boom over-wind protection device, angle indicator of the boom,
tilting-back support and other safety devices are normal.
c)
Carefully inspect whether the heavy-bearing components, such as wire rope

(hoisting rope, derricking rope and bracing cable etc.), boom, folding bracket, hook
and lifting device, are in normal status.
d)
Inspect whether it lacks bolts, nuts and pins and whether components have cracks
and damages.
e)
Make sure that there is no unauthorized rebuilding, as counterweight increasing

and decreasing, and incorrect boom repair.
f)
Inspect whether various instrument has normal indicated value when the engine is
started.
g)
Inspect the leakage conditions of fuel and hydraulic oil.
h)
Test whether the various control mechanisms operate normally.
i)
Inspect the brake and the clutch, and lift the loads away from the ground slightly to
test the performance of the brake.
j)
Maintain exchanges between operators and hoisting workers.
k)
Estimate the loading conditions before lifting it.
l)
The crane operation can be conducted within the minimum radius; there is no
barrier within the necessary operation range, and the site ground shall bear the
weight of various predictable heavies.
m) Make sure that the working area and the suspended loading of the crane have a
clear view and are barrier-free, inspect whether the communication system
between the crane operator and signalman is unobstructed to ensure the safe
operation.
n)
Verify the ring capacity of the ground or working face of other cranes, ensure that
the crane has appropriate ring to avoid operation on the floppy and instable ground,
as well as the ground with high water content and part of frozen earth. When the
crane operates next to the groove, the groove shall be reinforced or sloped to avoid
collapse or landslide. If the ground cannot bear enough weight, the crane might be
tipped over or collapsed, so there is need to fill up such things as sleepers, steel
plate and concrete foundation under the crawler to disperse the loads without
over-ranging ring capacity of the ground; the crane must be kept level.
04 - 19
Chapter 4
Before starting the crane, the driver must ensure that all the following conditions are
met:
Before operating the boom in any direction, ensure that there is no any other
loose object on it, or there will be in danger of accidents by hitting people on the
ground or striking other objects due to object falling.
4.3.3 Turning on power and relevant preparation
4.3.3.1 Insert the key into the key switch hole and clockwise turn it into the gear 2 to
turn on the power.
Turning on the
power
Figure 04-9 Turning on the power
Chapter 4
4.3.3.2 Air conditioning operation in operators cab

a)
The crane operators cab can be heated or cooled according to the expected
temperature, and the operation panel is located above the wallboard of the right
side in operators cab.
Operation panel of
air-conditioning
Figure 04-10 Operation panel of the air conditioner

b)
Heating: Press down the heating select switch and unscrew the toggle switch
behind the electrical control box for slewing table to adjust the temperature inside
the operators cab by rotating the blowing rate knob.
c)
Refrigeration: Wind speed and temperature inside the operators cab can be
adjusted by rotating the blowing rate and temperature knob.
04 - 20
4.3.3.3 Starting of the front/top windshield wiper

In case of controlling the crane in rainy days, front windshield wiper can be started by
pressing down the front windshield wiper switch on the upper right side of the operation
panel inside the operators cab; top windshield wiper switch is at the seat top inside the
operators cab, and the top windshield wiper can be started by pressing down the
switch.
Top windshield
wiper switch
4.3.3.4 Horn
Horn switch must be pressed down before the work is started (see No. 2 in Figure
4.1.2.1) to test whether the horn is to sound.
4.3.3.5 Lighting
When the crane works at night requiring lighting, the instrument indicator lights will be
all on by turning the master switch on the operation panel of the upper right side
wallboard inside the operators cab into gear 1; the work lights are all on by turning it
into gear 2; and lookum light is on by turning on the lookum light switch.
Master switch
of lighting
Figure 04-12 Master switch of lighting
04 - 21
Chapter 4
Figure 04-11 Top windshield wiper switch
4.3.4 Starting of the engine

Insert the key into the key switch, and continue to clockwise rotate it when the power is
on to start the engine.
Operation chart of starting of the engine
Starting the engine
Figure 04-13 Starting of the engine
Chapter 4
(1) The engine will be started after automatically preheating when it is cold.
Moreover, delay start of the engine is normal!
(2) The crane engine can only become full load when it achieves the running
temperature.
(3) The engine starting will not use accelerator. If the engine fails to start after
about 5 seconds, slowly step on the accelerator to the full range. If the
engine fails to start within 5 to 10 seconds, restart it 1 minute later. If it can
not be started in three successive times, stop starting immediately and
restart it when the reason is found out and the fault is cleared. If the engine is
heated, the accelerator can not be stepped during starting to prevent black
smoke emission. When the engine is started, the button shall be released
immediately to reset the key switch, and attention shall be paid to various
parameters of the engine.
04 - 22
4.4 Safety device

Before each crane operation, the driver must check whether all safety devices work
normally.
The crane with safety device out of order is not allowed to be operated!
4.4.1 Emergency stop button
The electronic control system and diesel engine of the crane are turned off by pressing
down the button, so all actions will be stopped immediately.
Emergency stop button can only be used in real emergency rather than as
operating shutdown device! If the crane movement is stopped immediately, there
are risks of accidents caused by oscillatory loadings.
4.4.2 Load moment limiter (see annex Instructions for Usage of Load Moment Limiter
Load moment limiter is an electronic computer-centered measuring and control device,

which can reflect basic real-time parameters of the crawler crane under various working
conditions. It gives an early warning signal when the actual load reaches 90% of the
rated one, and it gives a warning when the actual load reaches or exceeds the rated
one and stops operation in all dangerous directions (namely, stretching out and drawing
back the boom, rising and lowing the boom) to make the boom operate towards the safe
directions, so as to prevent the crawler crane from causing accidents as tipping-over,
breaking off the boom and personal injuries due to overload in construction and ensure
that the crawler crane operates normally and safely.
When the load moment limiter judges the crane as overload, it can give an auto-stop
control signal which can cut off the actions of the crane toward dangerous directions
through the electrical circuit of the crane itself and hydraulic control mechanism.
When actual moment reaches 90100% of the rated moment, yellow light on the
moment limiter is on and the buzzer makes interrupted sounds.
When the actual moment exceeds 100%, the red light and yellow light on the moment
limiter are on simultaneously and the buzzer makes continuous sound to stop coiling
and decoiling the cable of the derricking and actions of dangerous direction of the hook
hoisting through PLC. See section 4.1.4 for releasing methods of overload.
Overload releasing operation must be used under the circumstances of

commissioning, repair conducted by the professionals or avoiding other
accidents from happening.
04 - 23
Chapter 4
for specific operation)
4.4.3 Angle indicator
Chapter 4
Boom angle indicator is installed at lower back of the base section (right side of the
operators cab), the operator can clearly observe and accurately indicate the boom
elevation seating in the operators cab.
Figure 04 - 14
04 - 24
Angle indicator
4.4.4 Lowering limiter
Figure 04 - 15
Chapter 4
In order to prevent rewind due to complete release of wire rope on the drum, when
there are only three circles of wire rope left on the drum, button on the drum is released,
the buzzer and indicator light give warnings inside the operators cab, tricolor light, red
light and yellow light outside of operators cab are on simultaneously and the buzzer
continues to give sound alarm, and the winch decoiling action is stopped, so the rope
coiling action can only be conducted. See section 4.1.4 for over-lowering limitation
release method.
Lowering limiter
The derricking releasing switch or bypass key switch can only be allowed to use
under the circumstance of commissioning, repair or avoiding other incidents
from happening.
4.4.5 Hoisting limiter
Lift limit switch installation is to prevent hook pulley block from running into boom head.
Before each use of the crane, the switch must be checked by operating the hook pulley
to the upper height. Hook hoisting and lowering derricking action must be stopped.
When the hook hoisting height exceeds the specified one, the limit weight is collided
and the travelling switch is opened, the buzzer on the control box gives an alarm and
stops operation of actions as hook hoisting to ensure safety. At the moment, only hook
lowering and boom rising can be controlled. See section 4.1.4 for hoisting limit release
method.
04 - 25
Figure 04-16 Hoisting limiter
Chapter 4
The derricking release switch or bypass key switch can only be opened during
the crane in operation when one observer carefully observes the distance
between hook pulley and boom head. The observer must directly contact with the
crane driver, and hoisting action at the moment must be extremely careful and be
conducted at the lowest possible speed.
The derricking release switch or bypass key switch can only be used under the
circumstance of commissioning, repair or avoiding other incidents from
happening.
4.4.6 Working boom limit position alarm and protection system
Real-time detection of the system is conducted according to data acquired by angle
sensor, it will give an alarm and stop dangerous operation in time when the detected
boom working angle exceeds the safe range to ensure that the crane boom operates
within the safe range.
4.4.6.1 Working condition of the main boom
The maximum main boom working angle is 80; when the main boom derricking angle
reaches 78, the overall crane will give a sound alarm, while derricking upwards
remains allowed. However, when the main boom derricking angle reaches 80, it will
automatically stop the main boom coiling derricking and give an alarm, and only
decoiling derricking is allowed, so any release method is invalid at the moment.
4.4.6.2 Working condition of the fixed jib
Requirements for the main boom working angle are the same as that of the main boom
working condition, and fixed jib has two installation angles, e.g. 10 and 30.
04 - 26
4.4.7 Anemoscope
Anemoscope is installed at the main boom top, which can conduct real-time diction of
wind speed of boom top and display it on the load moment limiter.
The crane shall stop operating when the wind speed is greater than 9.8m/s.When
the main boom working condition is in no-load state and wind speed is greater
than 21 m/s, the boom shall be dropped down; when the fixed jib is in no-load
state and wind speed is greater than 15 m/s, the boom shall be dropped down.
4.4.8 Gradient display
The mechanical gradienter is installed on the crawler crane which can measure the
gradient of the crane.
4.5 Operation of crane
4.5.1 Operation of the travel gear
The travel gear consists of four wheels and one crawler (drive sprocket, driven sprocket,
track carrier roller, track roller and track pad), crawler carrier, travelling motor and
travelling reducer etc. Travelling reducers are separately installed in the rear of the left
and right crawler carriers. Hydraulic oil source is supplied to lower structure travelling
motor by superstructure main pump via main group valve I, main group valve II and
central swivel joint.
Figure 04 - 17
Four wheels and one crawler mechanism
Table 04 - 11 Four wheels and one crawler mechanism

Code
Description
Drive sprocket
Track carrier roller
Track roller
04 - 27
Chapter 4
4.5.1.1 Composition of the travel gear
Code
Description
Track pad
Track carrier roller
Crawler carrier
Bearing chain plate
Driven sprocket
4.5.1.2 Operation of the travel gear

Travelling is controlled by travel gear pedal (with hand lever). The left pedal (or the left
hand lever) controls left crawler to go forward or backward, while the right pedal (or the
right hand lever) controls right crawler to go forward or backward. Its possible to drive
the overall crane in a straight line and conduct turning on the move or spot turning etc.
During travelling, the travelling warning device installed at the bottom of the Operators
cab will send a sound alarm.
Go forward
to the right
Go forward
to the left
Chapter 4
Go backward to
the right
Go backward to
the left
Left pedal
Figure 04 - 18
Right pedal
Operation of travel gear
During crane operation, make sure that there is no obstruction or person within
the danger zone. Send an audible signal before every crane operation.
At any time, slowly and carefully operate the control lever. This will not only
prolong the service life of crane, but also will help avoid accidents.
04 - 28
4.5.1.3 Operation when driving on level road

a)
Drive forward in a straight line:

Push the two control levers forward at the same time with just about the same
feeding stroke, low speed preferred, so as to let both crawlers move forward
simultaneously.
b)
Drive backward in a straight line:

Push the two control levers backward at the same time with just about the same
feeding stroke, low speed preferred, so as to let both crawlers move backward
simultaneously.
c)
Turn left:
Push the right hand lever forward without moving the left hand lever.
d)
Turn right:
Chapter 4
Push the left hand lever forward without moving the right hand lever.
Turn left
Turn right
Figure 04 - 19
e)
Turn left and right
Large leftward steering (leftward differential steering)

Push the right hand lever to a large extent (the speed of right crawler is higher) and
push the left one to a small extent (the speed of left crawler is lower), i.e. the speed
of right crawler is bigger than that of left crawler.
f)
Large rightward steering (rightward differential steering)

At such time, the extent of pushing right hand lever shall be smaller than the left
hand lever.
04 - 29
Leftward differential steering
Chapter 4
Figure 04 - 20
Rightward differential steering

Differential steering
The operator is allowed to operate the hand lever in a stepless manner so

that the crawlers on both sides will move forward at different speeds, so as
to change the turning radius in a stepless manner.
g)
Rightward pivot steering with small radius (rightward center steering):

Operate the two crawlers at the same time, pull back the right hand lever to a great
extend to turn the right crawler backward; push the left hand lever to a great extent
to turn the left crawler forward.
h)
Leftward pivot steering with small radius (leftward center steering):

At such time, pull back the left hand lever to a great extend to turn the right crawler
backward; push the right hand lever to a great extent to turn the right crawler
forward.
04 - 30
Rightward steering with small radius
(1) If its to stop travelling or turning, just return the hand lever to the neutral
position (null) and the travelling brake will brake automatically. No other
operations are needed.
(2) When crawler crane is travelling under load, the boom is right in the front
of crane and the crane is only allowed to move forward. The maximum
allowed elevating capacity during travelling shall not exceed 70% of the
rated elevating capacity.
(3) When driving crawler crane along a long distance, make sure that the
travelling motor is behind the crawler, i.e. at the rear of the rotary table.
4.5.1.4 Operations when driving on a ramp
Operate the crawler crane as to face the front and place the slewing control lever on the
neutral position (null). When the crawler crane is climbing a ramp, keep the speed of the
engine at intermediate speed. Shorten the boom as much as possible. When driving the
crawler crane on a ramp of the maximum allowed gradient, only basic boom is to be
carried.
04 - 31
Chapter 4
Figure 04 - 21
Figure 04 - 22
a)
Driving on a ramp
Driving the crane on a ramp with accessories
Chapter 4
The gradeability of crane is subject to the following:

1)
The position of the center of gravity of the complete crane.
2)
Friction coefficient between the road surface and the track pad.
3)
Shift between the horizontal direction and the inclined direction.
4)
A maximum gradient of 30.
When driving the crane on a ramp, the following must be satisfied:

(1) The road surface must be able to bear the possible pressure.
(2) The friction coefficient between the road surface and the track pad must
be so big as to generate possible sufficient driving force; slipped road
surface may lead the crane to slide to one side that is not allowed.
Because of this, there is a hazard which may lead to accidents.
(3) The direction of slewing platform must be consistent with that of the
crawler, and be fixed to prevent from rotation.
(4) The maximum allowed wind speed is 9 m/s.
(5) Tilting to one side is not allowed.
(6) Drive slowly. Great care must be taken to every acceleration and
deceleration action.
(7) Transition from ramp to flat ground must be very gentle, vice versa.
Variation of gradient must be constant.
04 - 32
b)
Steering on a ramp
If its necessary to steer to a direction when the crawler crane is going down on a
ramp, the top and bottom of the ramp shall be graded or provided with a bearing
plate so as to form a flat grade line as shown in the following figure to prevent the
crawler crane from shifting from its center of gravity. The load is primarily on some
section of the crawler.
Spike removed
Gentle slope
Schematic diagram of slope finishing
Figure 04 - 23
Schematic diagram of slope finishing
(2) If the ramp is short and there is no obstruction ahead, or when the road
is very narrow because of a bearing plate for the purpose of driving a
crawler crane, the crane might be slipped. In such case, dont stop. Just
drive the crane forward.
When driving the crawler crane at a rated gradient, its not possible to get a
special parameter based on the ground condition. For the purpose of safety,
during climbing, counterweight and boom shall be removed so as to reduce
the total weight of the crawler crane.
4.5.1.5 Operation during travelling with suspended load
The crane is allowed to travel with suspended load provided that the following
precautions are taken:
a)
The foundation surface must be flat and level (with no gradient).
b)
The foundation must be able to bear the maximum working weight of the crane
plus suspended load.
c)
Only travelling at a low speed is allowed.
d)
Movement caused by the vibration of the crane must be avoided.
e)
Suspended load must be fixed with a guy rope to prevent it from swinging.
f)
Its forbidden to steer with the crawler.

04 - 33
Chapter 4
(1) When driving the crawler crane from flat ground to a ramp, if there is
center-of-gravity shift, stop the crawler crane, and then move on after the
center of gravity has been adjusted.
4.5.2 Operation of the winch mechanism

4.5.2.1 Hoisting winch
Composition and features of the hoisting winch
The hoisting winch consists of hydraulic motor, winch reducer, brake, rope guider,
lowering limiter, hoisting limiter, wire rope and main hook and auxiliary hook etc. The
speed of hoisting winch is adjusted through the dip angle of control lever which ranges
from -26.5 to 26.5. The larger the dip angle is, the higher the hoisting speed is. After
the control lever is pulled forward or backward to its greatest extent, the handle will stop
automatically.
a)
Operation of hoisting winch

The hoisting winch consists of hoisting winch 1 and hoisting winch 2. They are of
the same structure, but their positions on the crane and their purposes are different.
Hoisting winch 1 is used for the working condition of the main boom and hoisting
winch 2 is used for the working condition of the fixed jib and tip boom.
Chapter 4
Lifting and lowering operations of the hoisting winch 1:

Control
lever
of
derricking winch
Control lever of
winch 2
Control lever of
winch 1
Front
Figure 04 - 24
Control lever
Pull the control lever of the hoisting winch 1 backward to lift the weight; push the
handle forward and the weight will be lowered by the driving force.
b)
Lifting and lowering operations of the hoisting winch 2:

Pull the control lever of the hoisting winch 2 backward to lift the weight; push the
handle forward and the weight will be lowered by the driving force.
04 - 34
c)
Fast lifting and lowering

Both hoisting winch 1 and hoisting winch 2 are capable of fast lifting and lowering.
Its possible to lift or lower the main hook or auxiliary hook very fast by adjusting the
high-speed knob of the hoisting winch 1 or hoisting winch 2 (See No.6 and No.16 in
the figure of section 4.1.3).
Jogging function
Hoisting winch 1/2 and derricking winch provide jogging function. After pressing the
micro-positioning switch (see No.8 in the figure of section 4.1.3), all winch
mechanisms will move at a speed 25% of the normal speed.
(1) Select proper rope reeving rope based on the length of the crane boom.
If the hook swirls due to twisting of the wire rope, put down the weight.
Its only allowed to hoist after the wire rope is totally untied.
(2) The number of coils of wire rope on the winch drum shall be no less than
3 under any lifting condition.
(3) In case of lifting operation, lift the load away from the ground and hold
for a second, then continue to lift after confirming that there is no
potential safety hazard; before the load is lifted away from the ground,
it's not allowed to lift it away from the ground with the boom where only
hoisting operation is allowed.
(4) Its not allowed to shift the control lever from hoisting to lowering all
of a sudden, vice versa. In case of shifting, the handle shall be returned
to the neutral position. After confirming that the drum has stopped
rotating, then continue to operate. Otherwise, the machine part will be
damaged.
(5) Hoisting winch has a very good performance of speed regulation under
jogging condition. Under jogging condition at a slow speed, keep the
engine at a constant speed. Dont randomly change the engine
accelerator because if you do so, the speed of coiling winch will be
unstable and the hoisted weight will oscillate!
(6) When operating at dead slow gear, please keep the speed of the
engine at 1,500 r/min.
(7) Winch high-speed knob is only allowed for operation under idle load or
light load condition. It must be placed on null under any other working
conditions.
(8) When the main boom is under working condition, after the boom is
extended and the hoisting height is increased, the length of wire rope
might be not long enough. In such case, it can be adjusted by changing
the reeving ratio of wire rope. Before changing the reeving ratio, height
04 - 35
Chapter 4
d)
limit weight must be properly installed.

(9) In case of overload, hoisting winch 1/2 wire rope over-hoist or over
roll-out, the safety device will automatically cut off the system and send
an alarm.
After the system has sent an alarm, its only allowed to operate toward safe
directions. If its necessary to continue to operate toward dangerous
direction, refer to 4.1.4 Safety control. Any operation concerning safety limit
release can only be used under such conditions as when professionals are
debugging or repairing or avoiding other accidents.
4.5.2.2 Operation of the derricking mechanism
a)
Composition and features of the derricking mechanism
Chapter 4
The derricking mechanism adjusts the boom angle by changing the length of wire
rope between derricking pulley blocks (including derricking movable pulley block
and derricking fixed pulley block) through derricking winch, so as to change the
working range. In case of operation employing A-frame in conjunction with boom,
place the derricking fixed pulley block at the top of the A-frame and place the
movable pulley block at the other end of the anchoring rod. Change the boom
angle by adjusting the length of wire rope between derricking pulley blocks.
04 - 36
2
3
Chapter 4
5
4
Figure 04 - 25
Composition of the derricking mechanism
Table 04 - 12 Derricking mechanism

Code
Description
Derricking movable pulley block
Derricking fixed pulley block
A-frame assembly
Derricking wire rope
Rear tilting-back support of the main boom
Boom
Anchoring rod
04 - 37
Operation of the derricking mechanism

Operating the derricking winch control lever forward is to decoil the derricking
winch; operating backward is to coil the derricking winch; put the control lever on
neutral position is to stop.
Control lever of the

derricking winch
Chapter 4
Front
Figure 04 - 26
Control lever of the derricking mechanism
4.5.2.3 Derricking working condition setting and definition

a)
Working condition of the main boom operation

The main boom angle ranges from 0 to 80.
Hoisting winch 1main hook lifting and lowering, derricking winchmain boom
derricking.
04 - 38
Working condition of the main boom operation in conjunction with the fixed jib
There are two central included angles between the main boom and the fixed jib,
10 and 30. Once its preset, it cant be changed during working.
Hoisting winch 1main hook lifting and lowering, derricking winchmain boom
derricking, hoisting winch 2auxiliary hook lifting and lowering.
Ratchet mechanism
Derricking winch is provided with brake and ratchet mechanism. The winch can be
locked with the ratchet if its not to work for a long time. The boom may be placed at
anywhere.
04 - 39
Chapter 4
b)
When there is pressure oil flowing through the brake valve, press the ratchet
opening switch once and release it after the pawl and ratchet are fully separated
from each other. Once they are separate, release the opening switch and the
ratchet will still be separate. When the derricking mechanism is not to work for a
long time and needs to be shut down, to lock the brake and cut it off from power,
just press the ratchet opening/closing switch until the pawl on the ratchet cylinder
engages with the root of ratchet.
Chapter 4
(1) Operation shall be stable. Sudden operation will result in serious impact
on crane during weight hoisting.
(2) In case of weight hoisting, its not allowed to derrick toward dangerous
direction to prevent from turning over due to overload!
(3) When using the derricking mechanism, slightly jog the derricking
mechanism reversely; then operate by correct method to make sure that
the pawl and ratchet will separate from each other smoothly. Meanwhile,
be careful that when the ratchet is not fully opened, dont rush to operate
the derricking mechanism.
(4) When derricking mechanism is out of use, its allowed to release the
opening/closing button only after the pushing tooth engages with the
root of ratchet.
(5) If the ratchet is not fully opened, the wire rope of the derricking
mechanism can only be coiled and not be decoiled.
4.5.3 Operation of the slewing mechanism
4.5.3.1 Composition and features of the slewing mechanism
Slewing mechanism consists of piston hydraulic motor, planetary gear reducer, slewing
brake valve, brake, drive gear and slewing ring. It's capable of 360 full-circle slewing
by driving the slewing ring with the drive gear. Slewing speed is adjusted by adjusting
the dip angle of the handle.
The hydraulic system of this mechanism adopts independent closed piston pump as oil
04 - 40
supply source. The slewing valve adopts load-sensitive proportional valve which can
subtly adjust the slewing speed.
4.5.3.2 Operation of the slewing mechanism
The two slewing warning devices on the counterweight will send an audio-visual
warning.
4.5.3.2.1 Rightward slewing: place the slewing brake switch on the slewing control lever to
on, and push the lever forward at the same time.
4.5.3.2.2 Leftward slewing: place the slewing brake switch on the slewing control lever to
on, and pull the lever backward at the same time.
4.5.3.2.3 Stop: return the slewing control lever to neutral position and stop slewing.
Right slewing
Left slewing
Front
Chapter 4
Slewing control lever
Figure 04-27
Slewing control lever
(1) The range of speed of slewing movement must be set based on the
working condition.
(2) Operation at a high slewing speed will increase the possibility of hazard
which may lead to accidents! Before starting any slewing movement, the
crane driver must be certain that there is no obstruction or person within
the slewing radius. Otherwise, the possibility of hazard leading to
accidents will increase.
(3) Before crane slewing, an audible signal shall be sent.
04 - 41
4.5.3.3 Slewing fixing device

Slewing fixationafter slewing the superstructure right ahead, pull up the securing pin
spindle and rotate for 180, and then insert it back.
Figure 04-28
Installation of the slewing securing pin
Chapter 4
(1) Release slewing fixation in an order reverse to the above.

(2) Before slewing and hoisting operation, be sure to extract the pin of slewing
fixing device. Be sure to insert the pin after operation, during transportation,
when its not to work for a long time and before driving.
4.5.3.4 Operation of the slewing free swing switch
During weight lifting, if the hook is not on the vertical line of gravity of the weight, its
possible to reduce the lateral force of the boom by opening the free swing switch (No. 7
in Figure 4.1.2) clockwise at the time of operating the control lever. Now, the boom
forces the slewing table to turn to the center of gravity of the weight under the lateral
force of wire rope until the hoisting rope is straight. Stop operating when the hoisting
rope is straight.
(1) In case of free swing, the hook must be hoisted at the same time so that a
lateral force will be generated for wire rope to hoist the hook to a position
vertical to the boom.
(2) Before proceeding to crane slewing, the operator must confirm that there
is no obstruction within the slewing zone and honk the horn to warn
surrounding personnel to ensure safe operation.
(3) Operation shall be stable. Its very dangerous to suddenly stop slewing or
reverse, which must be avoided; lifted weight shall not swing.
(4) Long boom slow slewing speed.
(5) Heavy load slow slewing speed.
04 - 42
(6) Slewing on the trailer is forbidden.

(7) For the purpose of safe operation, users must inspect the slewing ring bolt
after 100 h of primary use. Its tightening moment is 1,800 N.m. Then inspect
and fasten as above after 300 h of operation. After that, inspecting and
fastening shall be done every 500 h of operation.
(1) When the crane is during driving, transportation or when the operator is not
on the crane, its not allowed to use slewing brake switch as a lock.
(2) Avoid using slewing brake for sudden slewing stopping operation because it
may damage the superstructure.
4.5.4 Operation of simultaneous movement
4.5.4.1 Working condition of the main boom
a)
Slewing + derricking:
Operate the slewing control lever and derricking control lever at the same time.
Derricking + hoisting winch 1:
Operate the hoisting winch 1 control lever and derricking control lever at the same
time.
c)
Slewing + hoisting winch 1:

Operate the hoisting winch 1 control lever and slewing control lever at the same
time.
d)
Hoisting winch 1 + hoisting winch 2:

Operate the hoisting winch 1 control lever and hoisting winch 2 control lever at the
same time.
e)
Slewing + travelling:
Operate the slewing control lever and travel gear pedal at the same time.
f)
Hoisting winch 2 + derricking:

Operate the hoisting winch 2 control lever and derricking control lever at the same
time.
4.5.4.2 Working condition of the fixed jib

a)
Slewing + hoisting winch 2

Operate the slewing control lever and hoisting winch 2 control lever at the same
time.
b)
Slewing + derricking
Operate the slewing control lever and derricking control lever at the same time.
04 - 43
Chapter 4
b)
4.5.5 Operation of the crawler carrier extending & retracting mechanism

4.5.5.1 Composition and features of the crawler carrier extending & retracting
mechanism
The extending & retracting mechanism of the crawler carrier consists of a folding
bracket, a horizontal cylinder, a crawler, an anchoring rod and a pin etc. Its connected
to the frame with the folding bracket extending outside the frame and extending &
retracting are driven by the cylinder.
4.5.5.2 Operation method for the crawler carrier extending & retracting mechanism
(see the following figure)
a)
After the basic machine has arrived at the operation position, manually pull out the
pin.
Frame
Chapter 4
Horizontal cylinder
Pin
b)
Pull out the lower structure control lever. The ground surface shall be level and free
of large obstruction.
c)
Pull out the upper pin spindle of the anchoring rod before crawler telescoping. Be
sure to install the pin spindle on the anchoring rod after horizontally telescoping in
place and before travelling.
Note: The disassembly procedure is opposite to the above procedure.
(1) Under any circumstances, there shall be at least 2 people for crawler
telescoping. Its not allowed for one person to operate alone. When
telescoping the cylinder, one person of the installation team shall operate the
04 - 44
handle and the other shall observe whether the folding bracket or crawler is
telescoped in place.
(2) Connect the folding bracket and the frame with a pin before extending the
crawler.
(3) Be sure to install the pin after horizontally extending or retracting in place
and before travelling.
(4) Crawler telescoping is forbidden with boom, counterweight, lifting weight
installed.
(5) During crawler telescoping, the speed of the engine shall be kept at
intermediate or low speed (1,000-1,500 rpm).
(6) Crawler telescoping shall be carried out on level and solid ground. Pay
attention to the balance of crane body.
(7) Hoisting is forbidden while crawler extending is not in place yet.
4.6 Reeving of the wire rope
See section 2.4.3 for specific wire rope reeving ratio and specification.
Chapter 4
4.6.1 Reeving of the hoisting rope

4.6.1.1 Preparation for installation
a)
Horizontally align the crane.
b)
There shall be one assistant to guide the wire rope.
4.6.1.2 Hook installation

a)
Place the required hook pulley block under the pulley head of the boom.
b)
Take off the spring clip and pull out the securing pins on the wire rope on the hook
pulley block.
c)
Start the crane engine.
d)
Place the hoisting rope on the top wire rope pulley and reeve the wire rope
between the pulley head and hook pulley block (see section 4.6.1.3 for specific
operation).
e)
Put the wire rope securing pins back and secure them with spring clip.
When the assistant is guiding the wire rope to the pulley head, the crane driver
must operate the winch mechanism to ensure that the wire rope on the winch
drum is secure.
04 - 45
(1) This must be completed on safe ground. If its not evitable to guide wire rope
from the boom to the pulley head manually, special care must be taken when
walking on the boom.
(2) There might be a hazard leading to serious accident if the person guiding the
wire rope slips on the boom because the crane is not properly operated.
4.6.1.3 Reeving of wire rope on hooks
a)
b)
Number of pulleys of hook pulley blocks

1)
80 t hook: hook for 6 pulleys.
2)
3)
4)
8 t hook: hook for 0 pulley.
Reeving of wire rope on hooks (see section 2.4.3.1 for corresponding reeving
ratios of hooks)
80 t hook, with corresponding rope reeving ratios of 12, 10 and 8.
Chapter 4
1)
12
04 - 46
10
2)
50 t hook, with corresponding rope reeving ratios of 7, 6 and 5.
Chapter 4
04 - 47
Chapter 4
3)
30 t hook, with corresponding rope reeving ratios of 4 and 3.
04 - 48
4)
6 t hook, with a corresponding rope reeving ratio of 1.
a)
Figure 1: insert the wire rope into the rope lock as indicated in the figure.
b)
Figure 2: place the wire rope around the rope thimble and then insert the rope back
into the rope lock.
c)
Figure 3: tension the wire rope with effort so that its appressed between the rope
thimble and rope lock.
d)
Figure 4: secure the wire rope with rope clips. (Two rope clips are required)
e)
Based on the reeving, secure the rope lock on the boom head or hook pulley block
with pins and secure them with spring clips.
The pins must be installed from the inside to the outside and secured outside,
so as to prevent the hoisting rope from rubbing with the pins or spring clips.
04 - 49
Chapter 4
4.6.1.4 Wire rope end fixing
Figure 1
Figure 2
Rope
lock
Figure 3
Figure 4
Rope thimble
Wire
end
rope
Wire rope
Chapter 4
Rope clip
4.6.1.5 Installation of the height limit switch weight

a)
Secure the switch wire rope with rope clips so as to form a knot.
b)
Put the switch weight on the hoisting rope.
c)
Secure the weight and wire rope with weight securing pins and spring clamps.
04 - 50
Axle pin and spring

pin
Goose head
frame
Wedge sleeve
and wedge
Rope
clip
Wire rope
Chapter 4
Auxiliary
hook
Main boom head

Main
hook
Rope
clip
Weight
Hoisting wire rope
Figure 04-29
Height limit switch weight
(1) Height limit switch weight consists of two connected components. When
releasing or installing weight, make sure that the two components are secure.
Otherwise, there is a possible hazard of damaging your feet when the weight
falls off.
(2) The crane driver must confirm that the reeving has been correctly done, and
that the load indicator has been properly set. Incorrect reeving or incorrect
entered reeving number will lead to serious accidents.
04 - 51
4.6.2 Reeving of the derricking wire rope
Chapter 4
456
Figure 04-30 Reeving of the derricking wire rope

Table 04-13 Parts related to the derricking wire rope
S/N
Code
Description
Qty.
Weight
00663000100001210
Pin spindle
0.9 kg
006340000001
Retaining spring (D40,45)
0.053 kg
00663002100001140
Washer
0.12 kg
1090100446
Rope lock 20
8.156 kg
1090100453
Rope thimble
1.513 kg
1090100001
Rope clip
0.624 kg
00663022100001021
Derricking wire rope
264 kg
The method for securing derricking wire rope end is the same as that for hoisting rope.
(1) Do not stay person around hook pulley block.

(2) When coiling the winch, throw out the wire rope like a whip. Make sure that
there is no loose wire rope on the winch.
When coiling a wire rope on the winch, reserve at least 2 m of wire rope, and fix
the end of the wire rope. Do not coil the end onto the winch.
04 - 52

Chapter 5 Assembly & dismantling
5.1 Technical instructions for safety
a)
Confirm that the crane complies with the operation standard. Check the position of
the A-frame, derricking anchoring rod, A-frame, boom intermediate section, and
related components against the table of boom length combination modes.
b)
Route the hoisting ropes between the boom head pulley block and the hook pulley
block that correspond to the tables of working conditions as required.
c)
Install the counterweight as required.
d)
Remove the obstructions at the site in advance to facilitate the disassembling and
assembling work. In addition, use ropes to enclose the work site to avoid access of
unauthorized personnel.
e)
Choose a flat work site. After assembling a boom, lift it from the ground right in front
of or in rear of the lower part of the crane body.
f)
Install the fixed jib to fulfill the permissible length of the boom, and install the
hoisting ropes to fulfill their reeving capacity.
g)
Do not use chains, hook or wire ropes to directly touch the chord member or web
member of the boom. Instead, fix them to the hoisting pile of the boom sections by
using protection pads or fiber woven sling before the lifting and installation work.
h)
Support a boom section with a suitable and secure article upon no contact with the
ground during the installation and dismantling work.
i)
Ensure that nobody stands below the boom, and exercise caution to ensure safety
when extracting or inserting a pin.
(1) Use a safe platform for installation, because a danger of falling down may
result from a temporarily constructed (unsafe) platform.
(2) Before operating the slewing mechanism, pull out the pins from the fastening
device to avoid continuously sounding of the buzzer and ensure slewing of
the slewing mechanism.
5.1.2 Examination of the safety measures
a)
Assign the relevant operators and their responsibilities.
b)
Confirm that the crane is in level operating state.
c)
Confirm that the distance between the crane and the slope/groove is far enough for
safety.
d)
Confirm and verify the voltage of the electrical cables in vicinity of the work area
and make sure that the crane does not collide with the electrical cables during
05 - 1
Chapter 5
5.1.1 Notes on assembly
operation.
e)
Confirm that the crane is placed at a proper site to ensure the maximum and
minimum working radius.
f)
Confirm that no obstruction exists in the work site to hinder the movement of the
crane.
g)
Confirm that sufficient load bearing capacity is available at the work site.
h)
Fully learn about the type and working mode of the lifting operation.
i)
Check the distance between the lifting point and the ambient structures.
j)
Check the impact of public facilities (including the height of high- and low-voltage
cables and coal gas pipelines) in vicinity of the operation location.
k)
Check the restrictions imposed on the operating range by the ambient environment
(e.g. whether there is any other crane operating).
l)
Check the quantity, material, shape, size and weight of the object to be lifted.
Chapter 5
m) Check the lifting height and slewing radius required.

n)
Check the height and width of the access to the work site.
o)
Check the method for communication between signalers and the operator.
p)
Take proper measures to keep unauthorized personnel and equipment out of the
work area.
Check the safety measures against the preceding requirements. Prepare a plan in
accordance with Chapter 2 to grasp the accurate and detailed conditions of the
lifting operation and ensure the work safety.
5.1.3 Examination of the wire ropes, hook, pulley and anchoring rod
5.1.3.1 Inspection of the wire ropes
Before each time of installation and after a certain period of operation, carry out a
professional inspection on wire ropes to learn about the damage and abrasion of these
wire ropes in time.
Remove a wire rope from the crane if the wire rope has any of the following
defects:
(1) A strand of the wire rope is broken.
(2) The steel wire in the wire rope is broken.
(3) A set of wire ropes are broken.
05 - 2
(4) The diameter of a wire rope is less than 10% of the normal diameter value or
even smaller.
(5) The wire rope is deformed.
Replace the defective wire rope with a new one in accordance with the original design
specification subject to the same rated elongation rate for the length and diameter. After
installing the new wire rope, reset the lowering limit switch for the winch wire rope.
Before replacing a wire rope with a new one, repair or replace the damaged pulley
(if any) with a new one to avoid damage of the new wire rope.
See the Maintenance Manual for the details of inspection and maintenance of wire
ropes.
a)
Check the hook for deformation, e.g. expansion at the bottom of the hook.
b)
Check all bolts and screws to ensure that all cotter pins are available and the splits
are open.
c)
Ensure that the rotating parts of the hook rotate freely and the gaps are not
excessively large.
d)
Checking the rotary joint of the hook: Rotate it by hand. Difficult rotation or jam
indicates that the swivel bearing is damaged.
e)
Checking the safety catches: They must be complete and intact.
f)
Check the corrosion and abrasion on the hook.
g)
See the Maintenance Manual for the details of inspection and maintenance of the
hook.
5.1.3.3 Inspection of the pulley

a)
Check for damage and fissure around the wire rope pulley.
b)
Before using a wire rope pulley, fully inspect it upon collision (e.g.: collision with a
building) or other stresses during operation.
c)
Replace a pulley when the pulley grooves whose abrasion depth reaches 1/4 of the
diameter of the wire rope.
d)
Replace the pulley of the damaged or fissured lifting wire rope (if any) immediately.
The damage or fissure on the pulley of the lifting wire rope may result in a serious
accident.
05 - 3
Chapter 5
5.1.3.2 Inspection of the hook
e)
Check whether a pulley is loose or sways. A loose or swaying pulley indicates that
the bearing or shaft sleeve is damaged.
pulley.
5.1.3.4 Inspection of the anchoring rod
a)
Properly fix the anchoring rod on the boom for transportation.
b)
After dismantling the anchoring rod for transportation, reinstall it on the boom in
accordance with the installation drawing for future use.
c)
Check the anchoring rod for damages such as fissure, abrasion and rusting.
d)
Inspect the anchoring rod regularly.
anchoring rod.
5.1.4 Raising and lowering of the boom
Chapter 5
Before raising or lowering the boom, ensure that the following requirements are fulfilled.
a)
Adjust the crane to a horizontal state.
b)
Install the counterweight on the slewing platform according to the instructions in

section 5.3 of Chapter 5.
c)
Install the boom and jib in accordance with the working status table and operating
manual.
d)
Set every limit switch correctly to make it work properly.
e)
Ensure that all pin connections are safe.
f)
Correctly route the lifting wire rope into the pulley, and tightly seize the wire rope
clip to avoid springing out from the pulley groove.
g)
Ensure that all the parts of the boom and the fixed jib are secure.
h)
Ensure that the boom, balancing frame and all parts (including limit switches, wire
rope drum, aviation warning signal light, and anemometer) are free from
accumulated snow and icing in winter.
Incorrect installation or ineffective limit switch and falling of the parts (bolts,
resilient clip and ice cubes, etc) will result in a danger and lead to a safety
accident.
05 - 4
5.2 Unloading and installation of the basic crane

Following the disassembling principles and methods, disassemble QUY80H crawler
crane into several parts for transportation. The basic crane contains main boom bottom
section, frame, rotary table, crawler frame, A-frame and derricking pulley block,
weighing totally about 42 tons.
5.2.1 Inspections before operation
5.2.1.1 Site
a)
The site is flat, secure, and covered with steel plates if necessary.
b)
A sufficient area is available for travelling of trailer truck and operation of the
auxiliary crane.
5.2.1.2 Implementation of the operation procedures and safety rules

Prior to an operation, all personnel must master the operation procedures and safety
rules and learn about their responsibilities.
5.2.1.3 Inspection before operation
Check the basic crane before operating it.
5.2.2 Unloading of the basic crane
After arrival of the basic crane at the site, remove the fastening devices and
package.
Chapter 5
a)
05 - 5
b)
Drive the basic crane off the flat-bed trailer. Alternatively, use a truck crane to lift
the basic crane off the flat-bed trailer, and then drive the flat-bed trailer out of the
site.
c)
Handle the adjustable folding bracket and crawler frame to the required position.
See 4.5.5 of Chapter 4 for the detailed information.
(1) During transportation, retract the crawler, lower the A-frame, and then level
and lock the base section by using the slew securing pin spindle.
(2) Use a ramping plate of 8 gradient when the basic crane travels onto or off
the flat-bed trailer. Ensure that the angle of the main boom pivot section is
less than 30 to avoid tip-over.
(3) Before operating the slewing mechanism, pull out the pin from the fastening
device to avoid continuous sounding of the buzzer and ensure slewing of the
slewing mechanism.
Chapter 5
5.3 Installation of the counterweight

The counterweight system weighs totally 26.8 t and consists of one 5.2 t counterweight
base plate, four 3.35 t side counterweight plates and two 4.1 t central counterweight
plates. When operating the counterweight system, stably suspend all counterweight
plates at the afterbody of the superstructure. Install the counterweight plates only after
the crawler frame reaches the maximum range. When installing the counterweight, use
the auxiliary crane to unload the counterweight plates from the transportation vehicle,
and then install the counterweight plates in proper sequence. After installing the
counterweight, use the counterweight locking bolts and nuts to secure the
counterweight. The process of dismantling the counterweight is contrary to that of
installing it.
05 - 6
Weigh
t (t)
Qty.
(Pcs.
)
Heigh
t (mm)
Counterweight
pedestal,
1090900075
5.21
605
Counterweight plate
1090900079
3.35
560
Counterweight plate
1090900078
3.35
560
Counterweight plate
1090900080
4.1
560
Locking bolt,
0066302490020000
0
28.3 kg
Plate
0066302490000101
0
1.32 kg
Name and code
Nut
1040200272
Washer
1040300010
Outline dimension
Specification: M30-8
GB/T56-1988
Specification: 30
GB/T93-1987
0.277
kg
0.011
kg
05 - 7
Chapter 5
Table 05 - 1 List of counterweight plates
Weigh
t (t)
Qty.
(Pcs.
)
Heigh
t (mm)
Pin spindle
0066302490000102
0
3.78 kg
Retaining spring
0066330010000109
0
0.185
kg
Chapter 5
Name and code
05 - 8
Outline dimension
Chapter 5
Top View
05 - 9
(1) Install the counterweight plates in proper sequence to avoid confusion.

(2) Do not install or disassemble the counterweight when the crawler frame has
not stretched in position (when the crawler frame has stretched in position,
the track gauge between the left crawler and the right crawler is 4.2 m).
Chapter 5
(3) Under any circumstances, install and dismantle the counterweight by at least
two persons.
05 - 10
Chapter 5
5.4 Available working conditions of the product
Figure 05 1
SF
Working conditions of the product
05 - 11
Table 05-2
Code
S
Chapter 5
SF
05 - 12
Explanation of the codes of the booms

Type
Working condition of the

main boom
Working condition of the
fixed jib
Working condition parameter

Main boom length: 13 m to 58 m
Main boom length: 37 m to 49 m
Fixed jib: 6 m to 18 m
5.5 Combination of the boom and anchoring rod
Chapter 5
5.5.1 Working condition of the main boom
Figure 05 2
Working condition of the main boom
05 - 13
5.5.1.1 Structural composition of the main boom

The main boom is 13 - 58 m long, consisting of the basic boom and the intermediate
section.
The basic boom is 13 m long, consisting of the boom pivot section, boom head and tip
boom.
Chapter 5
The intermediate section is classified into three types: 3 m, 6 m, and 9 m, with each 3 m
being an increment in length.
Figure 05 3
Structural composition of the main boom
Table 05 - 3 Structural composition of the main boom

S/
N
Code
Descriptio
n
Qty
.
Weigh
t
006630001000010
31
Pin spindle
28
2.12
kg
006340000001
Retaining
spring
(D40, 45)
56
0.053
kg
05 - 14
Outline dimension (unit: mm)
S/
N
Code
Descriptio
n
Qty
.
Weigh
t
006630201000010
10
Pin spindle
1.1 kg
006633001000012
30
Spring bolt
50
0.1 kg
0066300010000116
2
Pin spindle
2.32
kg
1090100448
Rope lock
4.58
kg
1090100455
Rope
thimble
2.38
kg
006630201000010
40
Pin spindle
1.87
kg
1090100022
Steel wire
rope clip
1.25
kg
24 (GB5976-1986)
05 - 15
Chapter 5
S/
N
Code
10
006630201000010
50
11
1040300094
GB/T96.1-2002 (ISO7093-1-2000)
12
1040100069
GB/T70.1-2000 (ISO4762-2004)
13
006630201014000
00
Rope
support
10.84
kg
14
006633001022000
00
Angle
indicator
2.57
kg
Descriptio
n
Qty
.
Weigh
t
Nylon
board
23
1.62
kg
Washer,
8-140HV
Screw,
M820-8.8
46
46
0.006
kg
0.015
kg
Chapter 5
5.5.1.2 Methods and principles for assembling and dismantling of the main boom
When assembling different booms in length, disconnect the joints at the boom pivot
section and at boom head, and fix the intermediate sections between them to achieve
the required length.
Installation principle: When combining booms, connect the shortest intermediate
sections to the boom pivot section in a proper sequence.
Table 05 - 4 Main boom assembly chart
Main boom length
(m)
Sequence of the boom

sections
Main boom
length (m)
Sequence of the 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
05 - 16
Table 05 - 5 Codes of the components of the main boom

Code
Description
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
0.255
0.44
0.63
G13
G14
G15
Main boom intermediate

section
section
section
Chapter 5
Based on the preceding principle, the installation Schematic diagrams are shown as
follows:
05 - 17
Chapter 5
05 - 18
Chapter 5
05 - 19
Chapter 5
(1) Connect main booms in strict accordance with the main boom assembly
charts.
(2) When assembling the main booms, do not stand or operate below or inside
the main booms.
05 - 20
Table 05 - 6 Explanation of the codes of the main boom sections

Code
G10
Description
Qty.
Weight
00663050100600000
Tip boom
assembly
0.12 t
G11
00663020100200000
Boom pivot
section
0.93 t
G12
00663050100400000
Boom head
assembly
1.2 t
G13
00663020100800000
3-m section
0.26 t
G14
00663020101000000
0.44 t
G15
00663020101200000
0.63 t
6-m section
9-m section
Chapter 5
S/N
05 - 21
5.5.1.3 Boom head assembly
Chapter 5
Figure 05 4
05 - 22
Boom head assembly
12
3
4
13
7
14
15
11
Figure 05 5 Section view of the boom head
05 - 23
Chapter 5
10
Chapter 5
Table 05 - 7 Parts of the main boom head

S/N
Code
00663020100401010
Rope guard
1.86 kg
00663020100401020
Cover
0.3 kg
00663020100401030
Pulley
spindle
27.77
kg
00663020100401040
Shaft sleeve
1.84 kg
00663020100401050
Single
anchoring
rod
8.34 kg
00663020100401060
Shaft sleeve
4.44 kg
05 - 24
Description Qty. Weight
Code
00663020100401070
Shaft sleeve
1.66 kg
00663020100401080
Shaft sleeve
1.13 kg
006340000056
Baffle 120
0.42 kg
10
00663020100401100
Shaft
48.8 kg
11
00663020100401120
Spacing
sleeve
0.23 kg
12 00663020100401090
Screw
1.27 kg
13 00663024100200000
Pulley
assembly
15.73
kg
14 00663027800420000
Pulley
assembly
13.3 kg
PD0406
05 - 25
Chapter 5
S/N
S/N
Code
15
00663020100401110
Spacing
sleeve
2.1 kg
5.5.1.4 Specifications and combination modes of the anchoring rods in the main
boom
Each boom length matches the length of an anchoring rod, which must be connected in
the specified method. For the basic boom (13 m), the anchoring rod is 6.22 m long.
If the main boom length increases by 3 m, extend the main boom anchoring rod with
two 0.3 m long double anchoring rods and two 2.7 m long single anchoring rods.
two 0.3 m long double anchoring rods and two 5.7 m long single anchoring rods.
four 0.3 m long double anchoring rods, two 2.7 m long single anchoring rods, and two
5.7 m long single anchoring rods.
Chapter 5
The assembly charts are shown in the following figures (unit: mm).
05 - 26
Chapter 5
05 - 27
Chapter 5
05 - 28
5.5.1.5 Parts in the main boom anchoring rod (unit: mm)
Chapter 5
Boom top single

anchoring rod
Connected to the
derricking movable
pulley block single
anchoring rod
Figure 05 6
Parts in the main boom anchoring rod

05 - 29
Chapter 5
Table 05 - 8 Parts in the main boom anchoring rod

S/N
Code
00663005400201022
Pin spindle
52
1 kg
00663300100001230
Spring bolt
52
0.1 kg
00663025400210000
Double
anchoring
rods
26
5.1 kg
00660515400001030
Single
anchoring
rod
47.4 kg
00663055400210000
Transition
anchoring
rod
47.01
kg
00663025400201020
Single
anchoring
rod
10
55.5 kg
00663025400201010
Single
anchoring
rod
10
27.43
kg
05 - 30
Chapter 5
5.5.2 Working conditions of the fixed jib
Figure 05 7
Working conditions of the fixed jib

05 - 31
5.5.2.1 Composition and structure of the fixed jib

The fixed jib is 6 - 18 m long.
The intermediate section is 6 m long.
Chapter 5
Each 6 meter is an increment in length.
Figure 05 8
Composition and structure of the fixed jib
Table 05 - 9 Parts for the composition of the fixed jib

S/N
Code
1040000169
GB/T5783-2000 (ISO4017-1999)
1040300054
GB/T93-1987 ()
006340000019
PD0406
00663000200001011
05 - 32
Name, weight
Weight
Qty.
and code
Bolt
0.048
8
M1245-8.8
kg
0.001
Washer 12
8
kg
0.144
Baffle 60
4
kg
Pin spindle
3.42 kg
Name, weight
Weight
Qty.
and code
S/N
Code
00663000200001022
Pin spindle
12 0.67 kg
006340000029
Retaining
spring (D30,
32, 35)
24
0.045
kg
5.5.2.2 Methods and principles for assembling and dismantling the fixed jib
The fixed jib is installed in angles (the angles between the center line of the fixed jib and
the center line of the main boom) of 10 and 30. When assembling different jibs in
length, disconnect the joints between the jib pivot section and the jib head, and fix the
intermediate sections between them to achieve the required length.
When connecting the sections in the fixed jib, use the same method as that of
connecting the sections in the main boom.
Table 05 10
Fixed jib assembly chart
Jib length (m)
Sequence of jib
sections
Jib length (m)
Sequence of jib sections
3+3
18
3+6+6+3
12
3+6+3
Code
Description
Length (m)
Weight (t)
G31
Fixed jib pivot section
0.17
G32
Fixed jib head
0.21
G34
Fixed jib intermediate

section
0.17/piece
FA-frame
0.26
1.6 - 2.8
0.046/piece
1.5 - 2.33
0.034/piece
G37
G74
G75
Fixed jib front tilting-back

support
Fixed jib rear tilting-back
support
Chapter 5
Table 05 - 11 Explanation of the codes of the parts in the fixed jib
05 - 33
G32
G32
G32
G34
G34
G34
G74
G31
G31
G75
G37
Figure 05 9
Chapter 5
Table 05 - 12
G31
Codes of the sections in the fixed jib
Explanation of the codes of the sections in the fixed jib
Code
G31
00663020200
200000
Jib pivot
section
0.17 t
G32
00663020200
400001
Jib head
0.21 t
G34
00663020100
400000
6m
section
0.17 t
G37
00663027800
000000
FA-frame
0.26 t
05 - 34
Descripti Qty
Weight
on
.
S/N
Descripti Qty
Weight
on
.
S/N
Code
G74
00663003100
600001
Jib front
tilting-bac
k support
0.046 t
G75
00663053100
200000
Jib rear
tilting-bac
k support
0.035 t
Figure 05 - 10
Chapter 5
5.5.2.3 Parts in the fixed jib head
Parts in the fixed jib head
Table 05 - 13 Parts in the fixed jib head

S/N
Code
00663020200401030
1040200102
GB/T6170-2000
Name,
weight and
code
Qt
y.
Weight
Screw
1.5 kg
Nut M24-8
0.089 kg
05 - 35
S/N
Code
Name,
weight and
code
Qt
y.
Weight
Assembling
of
installation
wheels
9.77 kg
Oil cup
M101
0.01 kg
Pipe
0.67 kg
Pin
0.095 kg
00663020200420000
1080000002
00663020200401040
1040500057
00663027800420000
Pulley
assembly
13.3 kg
00663020200401050
Spacing
sleeve
2.27 kg
00663100200401040
Top cover
2.27 kg
10
00663020200401060
Shaft
13 kg
11
00663100200401080
Plate
0.31 kg
12
1040000090
GB/T5783-2000 (ISO4017-1999)
Bolt
M1030-8.8
0.025 kg
13
1040300067
GB/T93-1987
Washer 10
0.001 kg
GB1152-1989
Chapter 5
GB/T91-2000
05 - 36
S/N
Code
14
00663100200401070
15
1040100038
16
1040200096
Name,
weight and
code
Qt
y.
Weight
Shaft
6.36 kg
GB/T70.1-2000
Screw
M1250-8.8
0.048 kg
GB/T6170-2000
Nut M12-8
0.012 kg
5.5.2.4 Specifications and combination modes of the anchoring rods in the fixed jib
5.5.2.4.1 Combination of rear anchoring rods in the fixed jib
If the fixed jib is installed in an angle of 10, the anchoring rod is 7.16 m long.
If the fixed jib is installed in an angle of 30, the anchoring rod is 8.06 m long.
Specifically, add two 0.3 m long double anchoring rods and two 0.6 m long single
anchoring rod.
Chapter 5
The combination chart is shown in the following figure (unit: mm):
FA-frame
anchoring rod
Figure 05 - 11
Fixed jib rear anchoring rod
05 - 37
Chapter 5
Table 05 14
S/N
Code
00663025400401010
1040500005
Parts in the fixed jib rear anchoring rod

Description
Qty.
Weight
Pin spindle
20
0.81 kg
Pin 545
20
0.088 kg
00663025400410000
Double
anchoring
rods
2.48 kg
00663025400420000
Widening
anchoring rod
11.68 kg
00663015410401050
Pin spindle
1.44 kg
1040500173
Pin 6.380
0.023 kg
00663025400401050
Transition
plate
11.44 kg
00663025400430000
Double
anchoring
rods
8.18 kg
05 - 38
GB/T91-2000
GB/T91-2000
S/N
Code
Description
Qty.
Weight
00663025400440000
Transition
connection
13.46 kg
10
00663025400401030
Single
anchoring rod
21.6 kg
11
00663025400401040
Single
anchoring rod
4.2 kg
5.5.2.4.2 Combination of front anchoring rods in the fixed jib

If the fixed jib is 6 m long, the anchoring rod is 6.34 m long.
If the fixed jib increases by 6 m, add two 0.3 m double anchoring rods and two 5.46 m
single anchoring rods.
Chapter 5
The combination chart is shown in the following figure (unit: mm):
05 - 39
6m
12m
18m
Chapter 5
Parts in the fixed jib front anchoring rod (unit: mm)

Fixed jib head
05 - 40
FA-frame
anchoring rod
Figure 05 - 12
Table 05 15
S/N
Code
00663025400401010
1040500005
Fixed jib anchoring rod
Parts in the fixed jib front anchoring rod

Description
Qty. Weight
Pin spindle
20
0.81
kg
Pin 545
20
0.088
kg
00663025400410000
Double
anchoring rods
10
2.48
kg
00663025400601010
Plate
26.11
kg
16.1
kg
GB/T91-2000
Single anchoring
rod
00663025400601030
5.5.2.5 Fixed jib tilting-back support
Chapter 5
5.5.2.5.1 Fixed jib front tilting-back support (2 pieces)
23
Figure 05 - 13
Fixed jib front tilting-back support
05 - 41
5.5.2.5.2 Fixed jib rear tilting-back support (2 pieces)
9, 10, 7
67
11
Figure 05 - 14
Chapter 5
Table 05 16
Fixed jib rear tilting-back support
Parts in the fixed jib tilting-back support
S/N
Code
Description
Qty.
Weight
00663003100610000
External tilting-back support
18.63 kg
00663308000001020
Pin spindle
1.15 kg
1040500057
GB/T91-2000 pin 550
0.095 kg
00663303100401010
Spring
1.22 kg
00663003100620000
Internal tilting-back support

assembly
23.98 kg
00663003100401010
Pin spindle
1.15 kg
00663604100001050
Spring bolt
0.99 kg
00663053100210000
Outer pipe
18.11 kg
00663053100201010
Pin spindle
0.67 kg
10
1040100682
Screw GB/T825-1988-M8
0.234 kg
11
00663053100220000
Inner pipe
13.14 kg
05 - 42
5.6 Assembling and dismantling of the main boom

5.6.1 Preparation for installing the main boom
a)
To fulfill the work plan, select an appropriate combination of booms and the
corresponding combination of anchoring rods from the tables of working
conditions.
b)
To meet the operation requirements, select appropriate hook and corresponding

reeving capacity in accordance with section 4.6.1 of Chapter 4.
c)
Ensure that the auxiliary crane for installation and operators are available.
result from a temporarily constructed (unsafe) platform. Remove the
obstructions at the site in advance to facilitate the disassembling and
assembling work. In addition, use ropes to enclose the work site to avoid
access of unauthorized personnel.
(2) Do not use any random combination of booms and combination of anchoring
rods unspecified in the instructions.
(3) Do not use chains, hook or wire ropes to directly touch the chord member or
web member of the boom. Instead, fix them to the hoisting pile of the boom
sections by using protection pads or fiber woven sling before the lifting and
installation work.
(5) In addition to the load bearing requirements under the working conditions,
ensure that the parts to be disassembled meet the process requirements of
the self-dismantling/assembling process. Self-dismantling/assembling is a
complicated lifting process, which should proceed in strict accordance with
the design requirements.
(6) When assembling a boom, do not stand on a moving boom.
(7) When dismantling or connecting pin spindles, do not stay below the boom.
(8) Do not support the middle part in the main chord of the boom and the web
member by using a pad block or timber to avoid damage of the boom section.
5.6.2 Installation of the main boom
After unloading the basic crane and installing the counterweight, assemble the boom
sections and anchoring rods as per the operation requirements.
05 - 43
Chapter 5
(4) When lifting the section head by using the auxiliary crane, use at least two
slings, each with pulling force of not less than 15 t.
5.6.2.1 Connection of the boom

a) Preassemble the boom in accordance with the combination of the main boom in
section 5.5.1.2 in advance. Install the boom in the following method: when
connecting the 3 m section, 6 m section, and 9 m section to each other, place the
head lug and tail lug of the boom in proper positions, align them with the connection
pin holes (as shown in the following figure), insert connection pin spindle 1, place
the pin hole for the connection pin in the up-down direction, and insert retaining
spring 2. Use the same method to connect them in other pin holes.
9 m boom
section
6 m boom
section
3 m boom
section
Chapter 5
Retaining spring 2
Up-down direction
Pin spindle
1
Figure 05 - 15
Fixed jib front tilting-back support
b) When connecting the intermediate sections and jib head, align them to the upper
connection pin holes, insert connection pin spindle 1, place the pin hole for the
connection pin in the up-down direction, and then insert retaining spring 2 for
locking.
05 - 44
Install the two upper pin

spindles
Intermediate
section
Boom head
Adjust the derricking winch (if necessary, use the auxiliary crane to lift the
intermediate section connected to the boom pivot section), align the boom pivot
section to the lug hole below the adjacent intermediate section, use pin spindle 1
and retaining spring 2 to lock both ends, and then disconnect the derricking pulley
block and the boom pivot section.
05 - 45
Chapter 5
c) Drive the basic crane slowly to right front of the preassembled boom, adjust the
derricking winch slowly (see 4.5.2.2 of Chapter 4), joint the boom pivot section to
the lug hole above the adjacent section, use pin 1 to connect the main boom pivot
section to the intermediate boom and use retaining spring 2 to lock both ends of the
pin spindle.
Retaining
spring 2
Pin spindle
1
Install the upper pin

spindle followed by the
lower pin spindle.
Table 05 - 17 Parts for connecting the boom

Code
Description
Code
Pin spindle
00663000100001031
Retaining spring
006340000001
(1) During installation, fix the connection pins outside followed by those inside,
and smear the pin spindles with lubricating grease or similar lubricant.
(2) During installation, do not reach your hands or fingers into the pin holes.
Chapter 5
(3) When knocking out the connection pins, do not stand below or inside the
boom section.
(4) Do not climb to the boom sections, and do not stand or walk on the boom
sections.
(5) For installation, use ladder or other similar tools.
5.6.2.2 Anchoring rod assembling and rope reeving for the main boom
a) Detach the upper anchoring rods of the derricking pulley block from the boom pivot
section, connect them to the upper anchoring rods of the intermediate section
successively, and then fix them by using pin spindles and retaining springs (see
5.5.1.4 of Chapter 5 for the details about connecting and combining the main boom
anchoring rods).
05 - 46
b) Operate the hoisting winch 1 control lever to put the hoisting winch 1 in reel-out
state, draw the hoisting rope to let it reach the tower head at the main boom head,
and reserve the length required for reeving the hook.
c) Operate the right handle (see 4.1.3 of Chapter 4 for the detailed information) to the
left, enabling the derricking winch reel in the rope to lift the boom head to a proper
height (slightly higher than the hook).
d) Place the hook below the tower head, pass the hoisting rope through the hook and
tower head in the selected manner (see 4.6 of Chapter 4 for the detailed
information), and fix the ends of the wire rope by using the rope thimble and rope
lock.
05 - 47
Chapter 5
For the staggered arrangement between the main hoisting rope and the main
boom anchoring rod, refer to section 4.6 Reeving of wire ropes.
When walking on the boom, exercise caution to avoid a serious injury or death
caused by slipping.
5.6.3 Electrical connection of the main boom
5.6.3.1 Line connection
Chapter 5
Table 05 18
2, 3
Components for line connection
S/N
Code
Description
Qty.
1020701369
Electric cable drum assembly (main

boom)
1021400132
Air velocity transducer
1020400233
Solar lamp
1020500140
Over-wind protection switch
1020701370
Electric cable drum assembly (fixed

jib)
1029900040
Weight assembly
05 - 48
5.6.3.2 Wiring of the main boom

Pull out the plug of the main boom wire winding reel (code 1 in the preceding figure).
Bind the wire along the main boom, and fix the boom sections with chains. Plug the wire
to the connector clip on the top of the distribution box at the main boom head, and then
make electrical connections between the distribution box and the parts at the main
boom head. See the following figure.
A direction
Main
Connected to
the fixed jib
over-wind
distribution
protection
switch Anemometer
box
Connected to the main

boom wire winding reel
A direction
Figure 05 - 16
Auxiliary
over-wind
protection
switch
Wiring of the main boom
Chapter 5
Connect wires in the sequence shown in the preceding figure.

5.6.3.3 Functional inspection
a)
Check the anemometer.

Sway the vane of the anemometer, and observe the display screen in the
operators cab. The anemometer now shows the value correctly.
b)
Check the solar lamp.

Turn on the switch (below the lamp) for the solar lamp, and block the top of the
solar lamp with a cover to make it unable to sense light. The lamp now keeps
flickering.
c)
Check the hoisting winch 1 over-wind protection switch.

Raise the weight of the over-wind protection switch of the hoisting winch 1, ensure
that the switch is in the over-wind state and observe the display screen in the
operators cab. The hoisting winch 1 alarm lamp now flickers and the alarm buzzer
sounds.
05 - 49
d)

Raise the weight of the over-wind protection switch of the tip boom, ensure that the
switch is in the over-wind state and observe the display screen in the operators
cab. The hoisting winch 2 alarm lamp now flickers and the alarm buzzer sounds.
5.6.4 Raising of the main boom
Chapter 5
5.6.4.1 Requirements for raising the boom

a)
The crane is propped properly and placed horizontally.
b)
Confirm that the counterweight has been installed as required.
c)
Select a combination of boom in accordance with the object to be lifted and the
table of lifting weights, and confirm that the boom has been securely installed.
d)
Confirm that all the limit switches have been correctly installed and are functioning
well.
e)
Confirm that all the pin spindles have been securely connected.
f)
The lifting wire rope must be in a correct position in the wire rope pulley and is fixed
by a wire rope safety pin to avoid fall-off from the pulley.
g)
Nobody stays in the hazardous area.
h)
The boom is free of loose parts.
i)
The boom, jib and parts (main boom maximum angle limit switch, over-wind
protection switch, electric cable drum, solar lamp and anemometer) are free from
ice and snow in winter.
An accident may result from incorrect installation, failures, or loose parts (such
as pin, spring clip and ice) of a limit switch.
5.6.4.2 Raising of the boom
Set the load moment limiter to the working condition of the main boom according to the
table of working conditions.
Operate the right handle (see 4.5.2.2 of Chapter 4) leftward to slowly tighten the boom
derricking reel in the rope and the main boom anchoring rod. Continuously tighten the
derricking wire rope to raise the main boom. When the main boom reaches the selected
position, move the right handle back to the middle position and stop raising the boom.
05 - 50
Chapter 5
Figure 05 - 17
Working condition of the main boom
(1) The boom angle varies from 0 to 80. When it changes to 78, the complete
vehicle generates an audible alarm. When the derricking reel moves upward
until the boom angle changes to 80, the upward movement of the main
boom automatically stops. At this time, only downward movement is allowed
regardless of any disabling methods.
05 - 51
(2) When raising the main boom, monitor the wire rope to ensure that it always
remains in the pulley groove.
(3) When raising the boom, ensure that the movement maintains steady. The
operator observes the real-time variation of the data on the display screen,
and other personnel pay attention to the changes of the ambient
environment all the time.
(4) Do not stand below the boom.
(5) Fulfill the working radius specified in the table of lifting characteristics, even
if no load is applied to the boom hook, to avoid the collapse of the crane.
5.6.5 Lowering and dismantling of the main boom
5.6.5.1 Lowering of the boom
Operate the right handle (see 4.1.3 of Chapter 4) rightward to make the boom
derricking move downward. Slowly lower the main boom to enable the hook to touch
the ground. Continue releasing the derricking wire rope until the main boom tower head
touches the ground. Move the right handle back to the middle position to stop the
movement.
(1) In the lowering process, release the ropes of the main derricking and
auxiliary derricking to avoid collision between the hook and the pulley head.
Chapter 5
(2) Do not stand within the range of the boom movement.

(3) In the lowering process, ensure that the movement maintains steady. The
operator observes the real-time variation of the data on the display screen,
and other personnel pay attention to the changes of the ambient operation
environment all the time.
5.6.5.2 Disassembling of the boom sections and anchoring rods
a)
After the anchoring rod falls onto the anchoring rod support, remove the pin
spindles on the anchoring rods between the boom sections, fasten the pin spindles
on the anchoring rod support, and fix the anchoring rods for easy transportation.
b)
Use the assembling equipment or auxiliary crane to remove the boom sections.
c)
Place the A-frame on the slewing platform.
(1) Disassemble the boom in a sequence inverse to the assembling sequence.

(2) In the disassembling process, observe the instructions on warning and
danger for assembling.
05 - 52
5.7 Assembling and disassembling of the fixed jib

5.7.1
Preparation for installing the fixed jib
(1) The crane is propped properly and placed horizontally.

(2) The main boom is properly connected.
(3) The auxiliary crane and working platform are available.
(4) Set the safety device of the load moment limiter according to the table of working
conditions and make sure it is correct.
(5) To fulfill the work plan, select an appropriate combination of booms and
corresponding combination of anchoring rods from the tables of working
conditions.
(6) To fulfill the work requirements, install the hook in accordance with section 4.6.1.
result from a temporarily constructed (unsafe) platform. Remove the
obstructions at the site in advance to facilitate the disassembling and
assembling work. In addition, use ropes to enclose the work site to avoid
access of unauthorized personnel.
(3) Do not use chains, hook or wire ropes to directly touch the chord member or
web member of the boom. Instead, fix them to the hoisting pile of the boom
sections by using protection pads or fiber woven sling before the lifting and
installation work.
(4) In addition to the load bearing requirements under the working conditions,
ensure that the parts to be disassembled meet the process requirements of
the self-dismantling/assembly process. Self-dismantling/assembly is a
complicated lifting process, which should proceed in strict accordance with
the design requirements.
(5) When assembling a boom, do not stand on a moving boom.
(6) When dismantling or connecting pin spindles, do not stay below the boom.
(7) Do not support the middle part in the main chord of the boom and the web
member by using a pad block or timber to avoid damage of the boom section.
05 - 53
Chapter 5
(2) Do not use any random combination of booms and combination of anchoring
rods unspecified in the instructions.
5.7.2 Installation of the fixed jib

To facilitate transportation, assemble the fixed jib pivot section G31, FA-frame G37,
fixed jib rear tilting-back support G74, and FA-frame rear tilting-back support G75
together, as shown in the following figure.
Figure 05 - 18
Installation of the fixed jib
5.7.2.1 Installation sequence

Connect the main boom as required (see 5.6 of Chapter 5 for the detailed
information).
b)
Use the auxiliary crane to lift the jib installation components, align the hinge joint
with the connection potion of the main boom head, and connect the main boom
head to the fixed jib pivot section by using pin spindle 1, shaft end baffle 2, washer
3, and bolt 4, as shown in the figure.
Chapter 5
a)
05 - 54
1
2
3
c)
Installation sequence
Based on the required boom length, select the 6 m intermediate section for
connection. For installation, align the boom lug hole properly, insert pin spindle 5,
and lock it by using retaining spring 6. Connect all the fixed jib sections in the way
of connecting main boom section pin spindle 1 and retaining spring 2, as shown in
the figure below.
05 - 55
Chapter 5
Figure 05 - 19
Chapter 5
Table 05 19
Parts used for connecting the fixed jib
S/N
Code
Description
Qty.
Weight
00663000200001011
Pin spindle
3.42 kg
006340000019
PD0406 baffle 60
0.144 kg
1040300054
GB/T93-1987 () washer 12
0.001 kg
1040000169
GB/T5783-2000 (ISO4017-1999)
Bolt M1245-8.8
0.048 kg
00663000200001022
Pin spindle
12
0.67 kg
d)
Connect the main boom anchoring rod subject to the selected main boom length
(see 5.3.1.6 of Chapter 5 for combining and connecting the anchoring rod). Fix the
anchoring rod in the rear of the preassembled part of the FA-frame (see 5.3.2.5.1
of Chapter 5 for combining and connecting the anchoring rod). Select proper front
A-frame length of the fixed jib based on the jib length (see 5.3.2.5.2 of Chapter 5
for combining and connecting the anchoring rod).
e)
Use the auxiliary crane to lift the FA-frame to largely straighten the front anchoring
rod of the jib, and use pin spindle 2 and pin 1 to splice the other end of the front
tilting-back support G74 to the fixed jib pivot section and lock it. Maintain the rear
tilting-back support G75 of the A-frame temporarily on the boom. Based on the
installation angle of the fixed jib, connect the rear anchoring rod of the fixed jib (see
5.3.2.5.1 of Chapter 5 for combining and connecting the anchoring rod).
05 - 56
G75
1, 2
G74
Parts for installing the front tilting-back support of the fixed jib
S/N
Code
Description
Qty.
Weight
00663308000001020
Pin spindle
1.15 kg
1040500057
GB/T91-2000 pin 550
0.095 kg
f)
Operate the hoisting winch 1 control lever to put the hoisting winch 1 in reel-out
state, draw the hoisting rope to let it reach the tower head at the main boom head,
and reserve the length required for reeving the hook.
g)
Operate the derricking winch control lever (see 4.5.2.2 of Chapter 4) to reel in the
derricking winch wire rope. When the main boom reaches to a proper height, use
pin spindle 2 and pin 1 to lock the rear tilting-back support of the A-frame onto the
main boom head.
05 - 57
Chapter 5
Table 05 20
1, 2
Table 05 - 21
Parts for installing the rear tilting-back support of the fixed jib
S/N
Description
Code
Weight
Qty.
Pin spindle
00663003100401010
1.15 kg
Spring bolt
00663604100001050
0.35 kg
(1) Ensure that the wire rope at the jib head is not squeezed.
Chapter 5
(2) Ensure that the pulley at the fixed jib head keeps rolling at the ground.
(3) When the main boom reaches a certain height, exercise caution to fix the
connection between the rear tilting-back support and the main boom head to
ensure safety.
h)
05 - 58
Operate the derricking winch control lever (see 4.5.2.2 of Chapter 4) to reel in the
derricking winch wire rope. Raise the main boom and jib to a height slightly higher
than the hook. Place the auxiliary hook right below the tower head of the jib, and
connect it to the main hoisting rope by using a shackle.
(1) For the staggered arrangement between the auxiliary hoisting rope and the
main boom anchoring rod, refer to section 4.6 "Reeving of the wire rope.
(2) When reeving the wire rope, use this method. Specifically, reel out the rope
from the auxiliary hoisting, draw the rope through the only pulley on the
FA-frame, draw the rope around the only pulley on the fixed jib head, and
connect the rope to the auxiliary hook.
5.7.3 Electrical connection of the fixed jib
5.7.3.1 Line connection
Figure 05 - 20
Table 05 22
Line connection
Parts for line connection
Code
Description
Code
Description
Code
Description
Anemoscope
Boom end lamp
Jib distribution box
After installing the main boom and fixed jib, draw the 16-core plug of the main boom
distribution box to the jib pivot section, connect it to the electrical cable drum of the fixed
jib (code 5 shown in the figure in section 5.6.3.1), and fix the electrical cable to the
boom by using a chain. Then, splice the other end of the electrical cable drum of the
fixed jib to the jib distribution box, remove the aviation warning signal light, anemometer
and auxiliary over-wind protection switch, and install them at proper positions on the jib
head. The jib distribution box is shown in the following figure.
05 - 59
Chapter 5
5.7.3.2 Wiring of the main boom and jib
A direction
Connected to the main

boom cable drum
Auxiliary
over-wind
protection switch
Anemometer
A direction
Figure 05 - 21
Jib distribution box
Connect wires strictly in the sequence shown in the preceding figure.

Chapter 5
5.7.3.4 Functional inspection

a)

Turn on the switch (below the lamp) for the solar lamp, and block the top of the
solar lamp with a cover to make it unable to sense light. The lamp now keeps
flickering.
b)

Sway the vane of the anemometer, and observe the display screen in the
operators cab. The anemometer now shows the value correctly.
c)

Raise the weight of the over-wind protection switch of the hoisting winch 2, ensure
that the switch is in over-wind state, and observe the display screen in the
operators cab. The hoisting winch 2 alarm lamp now flickers and the alarm buzzer
sounds.
05 - 60
5.7.4 Raising and lowering of the fixed jib

5.7.4.1 Preconditions
-
All the electrical connections have been made.
The control levers on the head position of the main boom maximum angle limit
switch have all been checked to act quickly and reliably.
Check the rotation and functions of the anemometer.
Check the over-wind protection switch.
Operate the hoisting winch, and adjust the over-wind protection switch at the boom
head. Requirement: at the limit position, the reel-in action of the hoisting winch
stops automatically. On the display screen, the over-wind indicator is lit and an
alarm is generated.
5.7.4.2 Requirements for raising the fixed jib
The crane is propped properly and placed horizontally.
Confirm that the counterweight has been installed as required.
The boom has been connected properly as per the needs of working conditions
and the boom connection requirements.
All the limit switches have been correctly installed and are functioning well.
All the pins have been provided with safety devices.
The lifting wire rope securely stays in the pulley groove and is firmly fixed by rope
guard to avoid fall-off from the pulley.
Nobody stays in the hazardous area.
No part on the main boom or jib is disengaged.
The main boom, jib and their parts (main boom maximum angle limit switch,
over-wind protection switch, electric cable drum, solar lamp and anemometer) are
free from ice and snow in winter.
Chapter 5
05 - 61
5.7.4.3 Raising of the fixed jib

a)
Set the load moment limiter to the working condition of the fixed jib according to the
table of working conditions.
Do not slew the boom before raising it above the ground.

Operate the right handle (see 4.1.3 of Chapter 4) leftward to raise the boom until
the boom reaches the required angle.
Chapter 5
b)
Figure 05 - 22
05 - 62
Raising of the fixed jib
For the working condition of the 58 m main boom and the 49 m boom and jib,
pay attention to the following points when raising the boom and climbing the
boom:
(1) The boom is right in front of the crawler crane (the drive sprocket is in
the rear).
(2) Before raising the jib, reel out a certain length of the hoisting rope, and
ensure that the hook does not leave the ground before the angle of the
boom is greater than 30. Before lowering the jib, reel out a certain length
of the hoisting rope, and ensure that the hook does not leave the ground
before the angle of the boom is less than 30.
Chapter 5
(3) Raise or lower the jib steadily at an even speed.
05 - 63
5.7.5 Dismantling of the fixed jib

a)
Operate the right handle (see 4.1.3 of Chapter 4) to release the derricking wire
rope rightward and make the pulley of the fixed jib head touch the ground.
Disconnect the pin spindle at the joint between the jib rear tilting-back support and
the main boom head (see the figure below).
Pull out the pin spindle

for connection here.
Figure 05 - 23
Chapter 5
b)
Dismantling of the fixed jib
Continue operating the right handle to release the derricking wire rope rightward.
The jib tower head will roll forward on the ground until the entire boom is laid down
on the ground. Move the control lever back to the middle position to stop the
movement.
(1) In the lowering process, ensure that the movement maintains steady.
The operator observes the real-time variation of the data on the display
screen, and other personnel pay attention to the changes of the ambient
operation environment all the time.
(2) Do not stand within the range of the boom movement.
(3) Move the hoisting rope avoid damage of the wire rope.
c)
Move the right handle backward to reel in the hoisting rope, and lock the wire rope
to the winch.
Assign a dedicated person to monitor the winch wire rope being reeled in,
and do not stand in the hazardous area.
d)
05 - 64
With the assistance of the auxiliary crane, make the A-frame lean forward to a
proper position, and then remove the front anchoring rod and rear anchoring rod
from the fixed jib.
e)
Dismantle the jib in sequence from the jib head until only the base section remains.
f)
Remove the entire assembly of the fixed jib at the head of the main boom head.
Ensure that the movement of the crane is steady and gentle, and observe the
operation and safety precautions to avoid an accident.
5.8 Assembling and dismantling of the tip boom
Parts for installing the tip boom
S/N
Code
Description
Qty.
Weight
00663300100001230
Spring bolt
0.1 kg
00663000100001162
Pin spindle
2.32 kg
00663020100001010
Pin spindle
1.1 kg
Chapter 5
Table 05 23
05 - 65
5.9 Weights and outline dimensions of the main parts (subject to the designed
values)
Table 05 - 24 Weights and outline dimensions of the parts
Chapter 5
Description
Dimension (mm)
Weight Qty. Remarks

(t)
(Piece)
(mm)
Basic crane
41.8
Width
3,400
Counterweight
pedestal
5.21
Height
605
Counterweight
plate
3.35
Height
560
Counterweight
plate
3.35
Height
560
Counterweight
plate
4.1
Height
560
Hook
(80T)
1.25
Width
650
05 - 66
Dimension (mm)
Weight Qty. Remarks

(t)
(Piece)
(mm)
Hook
(50T)
0.92
Width
484
Hook
(30T)
0.605
Width
405
Hook
(6T)
0.264
Width
350
Main boom
head (with tip
boom)
1.195
Width
1700
Main boom
3 m standard
boom
0.30
Width
1,700
mm
Main boom
6 m standard
boom
0.58
Width
1,700
mm
Main boom
9 m standard
boom
Single
piece:
0.68
Total
weight:
2.72
Width
1,700
mm
Jib head
(including rear
tilting-back
support and
FA-frame)
0.70
Width
740 mm
05 - 67
Chapter 5
Description
Description
Dimension (mm)
Weight Qty. Remarks

(t)
(Piece)
(mm)
0.17
Width
560 mm
Jib
Jib head
0.31
Width
560 mm
Chapter 5
Jib
6 m standard
jib
05 - 68
5.10 Methods and precautions for transportation

5.10.1 Methods and precautions for transportation
a)
This crawler crane must be disassembled for transportation. It can be transported

by flat-bed trailer, train, or other tools in long distance. During transportation, the
crane should be secured by ropes, with the door and window locked, and rain-proof
measures available. The crane should be transported in separate assemblies and
components in compliance with the load bearing capacity of the transportation
tools, the weights and sizes of the disassembled components. Overloaded
transportation is not allowed. For information about the weights and sizes of the
disassembled assemblies, see the Weights and Outline Dimensions of the Main
Parts.
b)
When transporting the crawler crane, securely fix the components to avoid collision
and slipping.
c)
Secure the adjustable folding brackets at the driven sprocket of the crawler frame.
d)
Secure the counterweight anchoring rod on the A-frame and the rear anchoring rod
of the A-frame at the rear end of the rotary table.
e)
Consult our company for detailed transportation solutions.
5.10.2 Other requirements

If the crawler crane is not used for long time (over half a year), take the following
measures for storage:
a) Wipe off the dust and oil sludge on the crane body, and keep the crane body clean.
c) Remove the battery, put it in a dry and ventilated place, and recharge it regularly.
d) Coat all exposed finished surfaces with lubricating grease to avoid rust.
e) Wipe off the dust sand on the wire ropes, and apply ZG3 calcium-based graphite
lubricating grease to the wire ropes once more.
f)
Place the crawler crane in a storehouse. When placing it in the open air, cover it
with raincloth, and inspect it frequently in rainy season to avoid rain intrusion and
rust. In winter, protect it against freeze.
g) Start up the crawler crane once a month, and run each mechanism without load to
check whether it functions properly.
h) Assign a dedicated person to ensure that the crawler crane is intact and ready to
use at any time.
05 - 69
Chapter 5
b) Retract all the piston rods in the oil cylinders to their shortest form.

Zcc800hwg Operation Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Zcc800hwg Operation Manual

Uploaded by

Copyright:

Available Formats

ZCC800H CRAWLER CRANE

The 1st edition (March, 2013)

ZCC800HWG Crawler Crane

For you .........................................................................................................................................I

ZCC800HWG Crawler Crane

ZCC800HWG Crawler Crane

ZCC800HWG Crawler Crane

Operating Manual for Crawler Crane

ZCC800HWG Crawler Crane

If this is not assured, the chance of causing a serious accident is greatly

Using these instructions in the manual:

makes you easier to become familiar with the crane

avoids malfunctions due to improper operation

Observing these instructions in the manual:

increases reliability in operations

extends the service life of the crane

reduces repair costs and downtime

ZCC800HWG Crawler Crane

ZCC800HWG Crawler Crane

If in doubt ask, do not take personal risk.

1.3 Alarms and warnings

Keep warnings and instruction labels clean.

Do not use this equipment with guards removed or incorrectly fastened.

Do not use this equipment with safety devices maladjusted or removed.

ZCC800HWG Crawler Crane

1.5 Features for operator safety

1.6 Environmental safety

Only use the lubricating oil recommended in the service manual.

Local and national regulations must be observed when disposing of waste.

Loose or baggy clothing can get caught in running machinery.

Correctly wear personal protective equipment.

Recommended personal protective equipment includes:

Close fitting overalls

High visibility vest or jacket

ZCC800HWG Crawler Crane

1.8 Measured noise level

ZCC800HWG Crawler Crane

1.11 Personnel qualification, requirements and responsibilities

Maintenance work must only be undertaken by suitable qualified engineers with

1.12 Safety advice regarding specific operational phases

Before starting the engine ensures it is safe to do so.

Stop the crane before removing any safety devices.

1.13 Special Hazards

External considerations and hazards

ZCC800HWG Crawler Crane

Vacate the area

Warn others against approaching and touching the crane.

Report the incident and have the live wire de-energized.

If your machine comes into contact with a live wire:

The electrical equipment of the crane must be inspected at regular intervals.

Use only original fuses with the specified current rating.

This crane is wired on a negative earth. Always observe correct polarity.

Recharge the battery in a well ventilated area.

No smoking when maintaining battery.

Wear appropriate PPE.

1.13.2 Gas, dust, steam, smoke and noise

Observe the rules and regulations at different working site.

1.13.3 Welding or naked flames

Avoid all naked flames in the vicinity of this crane.

ZCC800HWG Crawler Crane

1.13.4 Hydraulic equipment

Only fit replacement components of a type provided by the manufacturer.

Always practice extreme cleanliness servicing hydraulic components.

Operating Manual for Crawler Crane