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Zoomlion ZCC1300 Maintenance Manual

Crawler crane
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Crawler Crane Maintenance Manual
 
                                           
ZCC1300
ZCC1800
ZCC2600
Edition 1
Jan 2020

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Table of Contents
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Summary of Contents for Zoomlion ZCC1300

  • Page 1 Crawler Crane Maintenance Manual                                               ZCC1300 ZCC1800 ZCC2600 Edition 1 Jan 2020...
  • Page 3 Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science and Technology Co., Ltd.

  • Page 4: Safety Instructions

    Maintenance Manual for Crawler Crane Safety Instructions DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this manual to show important instructions. In this manual, the labels follow the paragraph or item they apply to. The markers are as follows: Refers to a dangerous situation which, if you do not prevent, will cause DANGER death or injury.

  • Page 5: Table Of Contents

    3.1.3 “Main boom with luffing jib” configuration ............. 3-3 3.2 Description of main components of basic machine ............3-4 3.2.1 Basic machine of ZCC1300 crawler crane ............3-4 3.2.2 Basic machine of ZCC1800 crawler crane ............3-5 3.2.3 Basic machine of ZCC2600 crawler crane ............3-6 Chapter 4 Maintenance 4.1 General ..........................
  • Page 6 Maintenance Manual for Crawler Crane 4.3 Inspection of the crane ..................... 4-6 4.4 Explanation of maintenance interval ................4-7 4.5 Maintenance plan ......................4-8 4.6 Power system ......................... 4-12 4.6.1 Engine ......................... 4-12 4.6.2 Fuel system ......................4-14 4.6.3 Cooling system ....................4-17 4.6.4 Air intake system ....................
  • Page 7 Maintenance Manual for Crawler Crane 4.12 Maintenance of load hooks and pulleys ............... 4-61 4.12.1 Daily inspection and maintenance of load hook ..........4-61 4.12.2 Inspection of load hook ..................4-62 4.12.3 Inspection of pulley ................... 4-63 4.12.4 Pulley lubrication ....................4-64 4.13 Maintenance of wire ropes ...................
  • Page 8 Maintenance Manual for Crawler Crane 5.4 Troubleshooting of electrical system ................5-11 5.4.1 Troubleshooting of cab electrics ................. 5-11 5.4.2 Troubleshooting of slewing table electrics ............5-12 5.4.3 Troubleshooting of boom electrics ..............5-13 5.4.4 Troubleshooting of load moment limiter ............. 5-14 5.5 Troubleshooting of air conditioning system ..............

  • Page 9: Chapter 1 About This Manual

    Maintenance Manual for Crawler Crane Chapter 1 About this Manual...

  • Page 11: General

    CAUTION If you find any cracks in the steel structure of the crane, please contact with “customer service department” of Zoomlion and describe the position and shape of the crack.

  • Page 12: Product Identification

    The serial number on the name plate is for crane identification. The users can confirm the crane components and relevant technical data by this serial number. For example, the serial number of the crane is ZCC1300-001.

  • Page 13: Illustration And Symbols

    Maintenance Manual for Crawler Crane 1.3 Illustration and symbols 起 This manual has a mass of illustrations, which are schematic. The meanings of illustrations are 重 as follows: 机 Position of working mechanism to be operated on the crane; 说 明...

  • Page 15: Chapter 2 Safety Guidelines And Environmental Protection

    Maintenance Manual for Crawler Crane Chapter 2 Safety Guidelines and Environmental Protection...

  • Page 17: Safety Guidelines

    Maintenance Manual for Crawler Crane Chapter 2 Safety Guidelines and Environmental Protection 起 重 2.1 Safety guidelines 机 说 2.1.1 General 明 Since various dangerous factors exist during maintenance and service of the crane, this section will talk about the safety guidelines for service technician to maintain and service crane.

  • Page 18: Qualification And Selection Of The Personnel

    Maintenance Manual for Crawler Crane WARNING Follow the safety guidelines about maintenance and service before conducting any maintenance and service work. 2.1.2 Qualification and selection of the personnel Only professionals can conduct maintenance and service work. This regulation is especially applicable for electrical system, hydraulic system, engine system and brake system of crane.
  • Page 19 Maintenance Manual for Crawler Crane Parts involved: Wire ropes/rope pulleys/load hooks/slings All winches 起 重 Crawler travel gear 机 2.1.3.3 Dangers caused by slipping, stumbling and falling 说 明 Figure 3-3 Danger sign – slipping, stumbling and falling Only use specified thoroughfare and ladders, because the thoroughfare adopts anti slipping design and has handrails to help you keep balance.

  • Page 20: Preparations Before Maintenance And Service Work

    Maintenance Manual for Crawler Crane 2.1.3.6 Dangers caused by the residue energy in the hydraulic system When hydraulic elements such as pipe, hose and hydraulic valve are damaged, the crane will stop working. However, some part of the system will still bear pressure and the pressure may be not released.
  • Page 21 Maintenance Manual for Crawler Crane 2.1.4.2 Measures to prevent fire Keep the crane clean, especially removing combustion materials. Clean the crane 起 completely after maintaining and servicing the hydraulic system, engine and fuel system. 重 机 Remove all residual lubrication oil, fuel or cleaning agent. 说...

  • Page 22: Instructions About Maintenance Work

    2.1.5 Instructions about maintenance work Maintenance Manual doesn’t include information about how to carry out maintenance work. If in need, please contact the customer service department of Zoomlion. Relevant safety instructions for maintenance work are as follows: Without permission, welding, combustion or grinding operation on the crane is prohibited.

  • Page 23: Environmental Protection

    Maintenance Manual for Crawler Crane 2.2 Environmental protection 起 Some harmful substances such as engine oil, lubricating grease, fuel, antifreeze coolant, 重 hydraulic oil and refrigerant will be produced during maintenance. These substances and 机 relevant contaminated rags will pollute the environment and do harm to people’s health, 说...

  • Page 25: Chapter 3 Description Of Crane

    Maintenance Manual for Crawler Crane Chapter 3 Description of Crane...

  • Page 27: Description Of Main Components Under Different Boom Configurations

    Maintenance Manual for Crawler Crane Chapter 3 Description of Crane 3.1 Description of main components under different boom 起 重 configurations 机 说 3.1.1 “Main boom” configuration 明 Figure 3-1 “Main boom” configuration Names of the components Names of the components Tip boom Crane undercarriage Load hook...

  • Page 28: Main Boom With Fixed Jib" Configuration

    Maintenance Manual for Crawler Crane 3.1.2 “Main boom with fixed jib” configuration Figure 3-2 “Main boom with fixed jib” configuration Names of the components Names of the components FA-frame Rear tilting-back support of fixed jib Fixed jib Fixed jib rear anchoring rods Fixed jib front anchoring rods Main boom Front tilting-back support of fixed jib...

  • Page 29: Main Boom With Luffing Jib" Configuration

    Maintenance Manual for Crawler Crane 3.1.3 “Main boom with luffing jib” configuration 起 重 机 说 明 Figure 3-3 “Main boom with luffing jib” configuration Names of the components Names of the components Luffing jib WA-frame 1 Tilting-back support for luffing jib Luffing rope Tilting-back support for WA-frame 2 WA-frame 2...

  • Page 30: Description Of Main Components Of Basic Machine

    Maintenance Manual for Crawler Crane 3.2 Description of main components of basic machine 3.2.1 Basic machine of ZCC1300 crawler crane Figure 3-4 ZCC1300 basic machine Names of the components Names of the components Crawler carrier assy. Derricking winch Undercarriage central section...

  • Page 31: Basic Machine Of Zcc1800 Crawler Crane

    Maintenance Manual for Crawler Crane 3.2.2 Basic machine of ZCC1800 crawler crane 起 重 机 说 明 Figure 3-5 ZCC1800 basic machine Names of the components Names of the components Crawler carrier assy. Main boom derricking winch Central counterweight Fuel tank Undercarriage central section Hydraulic oil tank Hoisting winch 1...

  • Page 32: Basic Machine Of Zcc2600 Crawler Crane

    Maintenance Manual for Crawler Crane 3.2.3 Basic machine of ZCC2600 crawler crane Figure 3-6 ZCC2600 basic machine Names of the components Names of the components Crawler carrier assy. Main boom derricking winch Central counterweight Fuel tank Undercarriage central section Hydraulic oil tank Hoisting winch 1 Oil pump device Slewing mechanism...

  • Page 33: Chapter 4 Maintenance

    Maintenance Manual for Crawler Crane Chapter 4 Maintenance...

  • Page 35: General

    If repair is necessary, contact the local office of our company. In order to ensure the performances of a crane, use the accessories and lubricating grease designated by Zoomlion. Replace consumables, such as filter cartridges, in time as specified to avoid faults.

  • Page 36: Safety Precautions

    Maintenance Manual for Crawler Crane 4.2.2 Safety precautions Before inspecting and maintaining the crane, lower the boom on the ground, stop the engine, lock all safety devices and remove the key from ignition switch to prevent unauthorized persons from starting up the engine. DANGER Failing to follow this instruction may cause personnel injury or death.
  • Page 37 Maintenance Manual for Crawler Crane CAUTION (1) When cleaning the crane, do not spray water on the electrical elements and 起 connectors. 重 (2) After cleaning the crane, lubricate the rotating parts on slewing table. 机 说 (3) Clean the operating console, control panel, floor, and the stained decorations in the 明...
  • Page 38 Maintenance Manual for Crawler Crane Pay attention to water temperature and oil temperature It is very dangerous to drain water, oil or replace filter cartridge immediately after the engine stops. Therefore, these operations can be done only when the temperature of engine has fallen down.
  • Page 39 Maintenance Manual for Crawler Crane 起 重 机 说 明 Figure 4-7 Pay attention to pressure inside m) Precautions for the welding process Cut off power supply. Disconnect power lead of battery. Never apply a voltage of more than 200V constantly. Set up grounding device 1m away from the welding point.

  • Page 40: Inspection Of The Crane

    Maintenance Manual for Crawler Crane 4.3 Inspection of the crane The crane shall be inspected by the manufacturer before delivery according to GB/T3811-2008 and relevant standards at home and abroad. Experienced professionals shall inspect the crane at least once a year after its delivery according to the working environmental change or application conditions.

  • Page 41: Explanation Of Maintenance Interval

    Maintenance Manual for Crawler Crane 4.4 Explanation of maintenance interval 起 The maintenance interval means that the crane maintenance work is carried out at regular 重 intervals. 机 The maintenance interval can be determined by: 说 明 Operating time of crane component (in hours) Calendar time (date, month and year) when the crane is in operation and storage Generally speaking, the maintenance intervals are determined by the operating time of crane components.

  • Page 42: Maintenance Plan

    Maintenance Manual for Crawler Crane Maintenance plan Table 4-2 Maintenance intervals Maintenance intervals Components / Actions Power system Refer to Operating Instructions provided by engine 4.6.1 Engine manufacturer. (as required in the maintenance manual of the 4.6.1.1 Daily inspection engine) Inspection of the engine ★...
  • Page 43 Maintenance Manual for Crawler Crane Maintenance intervals Components / Actions Inspection of oil level of 起 ★ 4.7.1 winch reducer 重 机 Change of gear oil of winch ▲ ★ 4.7.2 说 reducer 明 Inspection of tightening bolts ★ 4.7.3 of the winch reducer Inspection of brakes of the ★...
  • Page 44 Maintenance Manual for Crawler Crane Maintenance intervals Components / Actions 4.10.2 Hydraulic oil tank Inspection of hydraulic oil ★ 4.10.2.1 tank Change of oil return filter ▲ ★ 4.10.2.2 cartridge ▲ ★ 4.10.2.3 Change of air filter ★ 4.10.2.4 Cleaning of filter cartridge ★...
  • Page 45 Maintenance Manual for Crawler Crane Maintenance intervals Components / Actions ★ Change it according to inspection status and 起 4.13.3 Change of wire rope 重 take-down standard. 机 4.14 Air conditioning 说 ★ 4.14.1 Daily inspection 明 Maintenance of air ★...

  • Page 46: Power System

    Maintenance Manual for Crawler Crane 4.6 Power system 4.6.1 Engine Figure 4-8 Appearance of engine Position of the engine: at the rear part of the slewing table. 4.6.1.1 Daily inspection Inspect the appearance of the engine components to ensure that they are intact and function normally.
  • Page 47 Maintenance Manual for Crawler Crane 4.6.1.2 Inspection of engine operation status Inspect the engine oil pressure gauge, water temperature gauge, tachometer and warning 起 indicator to make sure that the engine operates normally. 重 机 Inspection steps: 说 Start engine with ignition start switch and run it at idle speed for 3-5 minutes. 明...

  • Page 48: Fuel System

    Maintenance Manual for Crawler Crane 4.6.2 Fuel system Engine oil return hole Engine oil inlet Oil-water separator Fuel tank Figure 4-9 Fuel system 4.6.2.1 Inspection of fuel pipeline Besides visual inspection (for example, oil level inspection), inspect fuel system of the engine annually.
  • Page 49 Maintenance Manual for Crawler Crane 4.6.2.2 Discharge of water from oil-water separator 起 Manual pump button 重 机 说 Oil water separator 明 Water reservoir Water drainage knob Figure 4-10 Oil-water separator The water contained in the fuel is separated in the oil-water separator. When the water is accumulated to 1/3 of the total volume, it shall be discharged outside to prevent it from entering the engine cylinder together with the fuel.
  • Page 50 Maintenance Manual for Crawler Crane Demount the filter cartridge with inspection window from the head of fuel filter, and then clean the surface of O-ring. Apply O-ring and seal ring of filter with new oil or lubricating grease. Screw the inspection window on the new filter cartridge and then tighten them on the head of filter.

  • Page 51: Cooling System

    Maintenance Manual for Crawler Crane CAUTION (1) Treat the collected waste diesel according to relevant environmental protection 起 regulations, and do not discharge it into the environment. 重 (2) Take preventive measures to avoid fires when cleaning the fuel tank. 机...
  • Page 52 Maintenance Manual for Crawler Crane As for the performance of coolant, please refer to section 6.1. CAUTION (1) Before adding the coolant, stop engine and cool it down for some time. Only after the engine cools down, can you open the sealing cover of the cooling system. Otherwise, the system will be full of pressure, which will result in accident.

  • Page 53: Air Intake System

    Maintenance Manual for Crawler Crane For the change interval of the coolant, refer to section 4.5. For the performance requirements of the coolant, refer to section 6.1. 起 重 CAUTION 机 Do not drain the coolant to the natural environment. 说...
  • Page 54 Maintenance Manual for Crawler Crane a) Shake off the dust from the filter b) Blow the outer surface of filter cartridge cartridge. with compressed air. c) Blow the inner surface of filter cartridge d) Clean the sealed supporting surface. with compressed air. Figure 4-14 Cleaning of air suction filter WARNING Do not start up the engine during the cleaning work.

  • Page 55: Exhaust System

    Maintenance Manual for Crawler Crane 4.6.4.2 Replacement of air filter cartridge When the external filter cartridge is cleaned for many times, its filtering performance will be 起 degrade. At this time, the external filter cartridge must be replaced. 重 机 When changing the external filter cartridge, replace the internal filter cartridge (safety filter 说...

  • Page 56: Hoisting Winch And Derricking Winch

    Maintenance Manual for Crawler Crane 4.7 Hoisting winch and derricking winch 4.7.1 Inspection of oil level of winch reducer Stop the machine on the level ground, and unscrew the oil level plug. If you can see the oil level, it means that the oil is sufficient. Otherwise, gear oil is needed to refill. Always inspect the oil level when the transmission has stopped and the oil has cooled down.

  • Page 57: Inspection Of Tightening Bolts Of Winch Reducer

    Maintenance Manual for Crawler Crane During operation, the gear box should be allotted a great amount of oil. As a result, once the system has completed debug, it’s suggested that inspect the oil level again when the gear has stopped and refill the oil according to requirements. 起...
  • Page 58 M24×80-8.8 ZCC2600 √ Bolt M16×50-8.8 4.7.3.2 Derricking winch reducer Figure 4-18 Installation of bolts of derricking winch reducer (for ZCC1300 crawler crane) Table 4-4 Bolts of derricking winch reducer of ZCC1300 crawler crane Product Use loctite glue Names Specification Remarks...
  • Page 59 Maintenance Manual for Crawler Crane 起 重 机 说 明 Figure 4-19 Installation of bolts of derricking winch reducer (for ZCC1800/ZCC2600 crawler crane) Table 4-5 Bolts of derricking winch reducer of ZCC1800/ZCC2600 crawler crane Product Use loctite Names Specification Remarks type glue or not √...

  • Page 60: Inspection Of Brakes Of The Winch Reducer

    Maintenance Manual for Crawler Crane Table 4-6 Bolts of luffing jib derricking winch reducer of ZCC2600 crawler crane Product Use loctite Names Specification Remarks type glue or not √ As to tightening torque Bolt M24×80-8.8 ZCC2600 of bolt, refer to section √...

  • Page 61: Inspection Of Hoisting Winch Reducer And Derricking Winch Reducer

    Maintenance Manual for Crawler Crane 4.7.5 Inspection of hoisting winch reducer and derricking winch reducer Both hoisting winch reducer and derricking winch reducer are designed using integrated 起 planetary gears. The gears are designed for long service life and the drive shaft and drive 重...

  • Page 62: Theoretical Service Life Of Winches

    Maintenance Manual for Crawler Crane DANGER Once violate the standard configuraton when determining the residual service lift, the winch may stop suddenly or unexpected fault may occur. This will cause property loose, even death. Inspection of brake of drive device Check the brake and drive device at the same time.
  • Page 63 Maintenance Manual for Crawler Crane Hidden damage from accidents Extreme environmental conditions: Extremely low or high temperatures 起 重 Corrosive atmosphere 机 Dust and dirt 说 明 4.6.7.2 Used portion of theoretical service life The crane operator is obligated to have the crane inspected at least once a year. The actual operating conditions (load collective) and the winch operating hours at each inspection interval are required to determine the proportion of the theoretical service life that has actually been used.
  • Page 64 Maintenance Manual for Crawler Crane Load Load collective Definition Service life collective Graph classification factor Engine or other Load (%) relevant parts are 50% of the running time at frequently Heavy-duty maximum load (dead load subjected to load and 1/1 working load); max.
  • Page 65 Maintenance Manual for Crawler Crane 4.7.6.5 Determining the actual used portion of theoretical service life The actually used proportion Si of the theoretical service life is given by the following formula: 起 × 重 机 说 Where: 明 - the used portion of theoretical service life - load collective factor - load collective factor for inspection interval i - effective operating hours for inspection interval i...
  • Page 66 Maintenance Manual for Crawler Crane Remaining theoretical service life =3200h-216h=2984h Second inspection 0.25 When , the load collective is . The operating hours of the engine is 3400h during this period: 3400h-1800h=1600h (1800h were used during the first year of operation) The winch operated about 12% of the time, i.e., =192h.

  • Page 67: Maintenance Of The Slewing Reducer And Slewing Ring

    Maintenance Manual for Crawler Crane 4.8 Maintenance of the slewing reducer and slewing ring 4.8.1 Slewing reducer 起 重 4.8.1.1 Inspection of oil level of slewing reducer 机 说 It’s normal if the oil level is higher than the oil inspection hole. Otherwise, adding gear oil is 明...
  • Page 68 4.8.1.4 Inspection of mounting bolts of slewing reducer Because all mounting bolts use Loctite glue, there is no need to tighten it again. Visual inspection is enough. Figure 4-22 Mounting bolts of slewing mechanism for ZCC1300 crawler crane 4-34...
  • Page 69 Maintenance Manual for Crawler Crane Table 4-8 Mounting bolts of slewing mechanism for ZCC1300 crawler crane Use loctite Names Specification Quantity Remarks glue or not 起 重 √ Bolt M16×70-8.8 As to tightening 机 说 √ torque for bolt, Bolt M16×110-8.8...
  • Page 70 Maintenance Manual for Crawler Crane Figure 4-24 Mounting bolts of slewing mechanism for ZCC2600 crawler crane Table 4-10 Mounting bolts of slewing mechanism for ZCC2600 crawler crane Product Use loctite Names Specification Quantity Remarks type glue or not √ Bolt M16×90-8.8 As to tightening torque for bolt,...

  • Page 71: Slewing Ring

    Figure 4-25 Installation of slewing ring bolts Table 4-11 Mounting bolts of slewing ring Product Use loctite Names Specification Quantity Remarks type glue or not √ Bolt M30×200-10.9 ZCC1300 √ Bolt M30×210-10.9 As to tightening √ Bolt M30×260-10.9 ZCC1800 torque for bolt, √ Bolt M30×300-10.9...
  • Page 72 Maintenance Manual for Crawler Crane Inspect the bolts on the slewing ring visually before the crane works each time or at least once a week. When the slewing ring has been used for 100 working hours for the 1 time, inspect whether the bolts are loose.
  • Page 73 Maintenance Manual for Crawler Crane 4.8.2.4 Lubrication of raceway of slewing ring Raceways must be injected with lubricating grease regularly according to the working 起 environment. After having worked for 50hs, raceways shall be injected with the lubricating 重 grease. After that, it should be injected with lubricating grease again every 300 working hours. 机...

  • Page 74: Crawler And Traveling Reducer

    Maintenance Manual for Crawler Crane 4.9 Crawler and traveling reducer 4.9.1 Crawler carrier assy. Crawler carrier assy. is composed of crawler carrier, track roller, track carrier roller, drive sprocket, driven sprocket and track pad. It has crawler tension device. When the crawler has travelled for a long time, the crawler will come loose.
  • Page 75 (L) around 40 ± 5 millimeter (for ZCC1300/ZCC1800 crawler crane) and 50±5 mm (for ZCC2600 crawler crane) after proper cleaning and strengthening, and the crawler components must be tightened or loosened subject to their tightness.

  • Page 76: Travelling Reducer

    Maintenance Manual for Crawler Crane CAUTION Slightly move the crane forwards before adjusting to concentrate the loose parts of the crawler on the top of drive sprocket, so that it can be easily adjusted. CAU TION (1) Before checking the tension of track pad, clean the track pad first. (2) The tension of crawler must be adjusted when the machine is on level ground.
  • Page 77 Maintenance Manual for Crawler Crane 4.9.2.2 Replacement of gear oil of travelling reducer A view 起 重 机 说 明 Figure 4-28 Position to add and replace gear oil of travelling reducer Replacement steps: Unscrew and remove oil drain plug and oil filler plug on the travelling reducer, and drain original gear oil into proper vessel.
  • Page 78 Figure 4-29 Mounting of travelling reducer bolts Table 4-12 Travelling reducer bolts Product Use loctite Names Specification Quantity Remarks type glue or not √ Bolt M24×140-10.9 ZCC1300 √ Bolt M24×80-10.9 As to tightening √ Bolt M33×200-10.9 torque for bolt, ZCC1800 √ please refer to Bolt M33×110-10.9...

  • Page 79: Maintenance Of Hydraulic System

    Maintenance Manual for Crawler Crane 4.10 Maintenance of hydraulic system 4.10.1 Routine inspection of hydraulic system 起 重 To ensure that the hydraulic system is in a good status for long-term operation, maintain the 机 hydraulic system on time. For the inspection interval of hydraulic system, see the following 说...
  • Page 80 Maintenance Manual for Crawler Crane Pay special attention to the following terms in the routine maintenance and service of hydraulic system: Proper choice of hydraulic oil can pass on pressure, lubricate, cool or seal the system. Improper hydraulic oil is the main reason causing premature breakdown of hydraulic system and reducing in durability.

  • Page 81: Hydraulic Oil Tank

    Maintenance Manual for Crawler Crane Refueling personnel should wear clean gloves and overalls; The brand of the cleaning oil of the hydraulic system should be the same with the hydraulic oil used by the system. The oil temperature should be between 45℃ to 80℃. 起...
  • Page 82 Maintenance Manual for Crawler Crane Do inspect the hydraulic oil amount before staring the engine. When the crane is placed levelly, if the oil level is under the inspection level, it means that the hydraulic oil is insufficient. Only after refueling the hydraulic oil to inspection level, the engine can be started. If the oil amount is fast reduced in the hydraulic oil tank, it means that the pipe or hydraulic elements may leak.
  • Page 83 Maintenance Manual for Crawler Crane Take out the spring and permanent magnet steel assembly. 起 重 机 说 明 Replacement of oil return filter cartridge Figure 4-32 Take the filter cartridge out and change it; Install the spring and the permanent magnet steel assembly, finally put the filter cover. Change and /or replace the oil return filter cartridge when the hydraulic system has worked for 50 hours after maintenance and service.
  • Page 84 Maintenance Manual for Crawler Crane Open the cover of the air filter before adding the hydraulic oil. Check the air filter after adding the hydraulic oil. Figure 4-33 Air filter 4.10.2.4 Cleaning of the filter cartridge Inspect the filter, find the dirt on it, and then clean the filter in time. Steps for cleaning: Turn off the engine and depressurize the hydraulic system;...

  • Page 85: Exhaust Of Hydraulic System

    Maintenance Manual for Crawler Crane Start the engine, run the engine at low speed to energize the oil pump. Manipulate each mechanism respectively and drain the used oil of each loop of the system one by one on the basis of fresh hydraulic oil. The used oil drained cannot flow into the hydraulic oil tank. 起...

  • Page 86: Inspection Of Hydraulic Pipes For Damage

    Maintenance Manual for Crawler Crane 4.10.4 Inspection of hydraulic pipes for damage Change the damaged pipes and fittings of hydraulic pumps on the slewing table due to mechanical failure, heat energy or other influences. Keep enough distance between all pipes, hoses and high-temperature engine parts (for example, turbocharger), which will not result in friction.

  • Page 87: Inspection Of Hydraulic Hoses

    Maintenance Manual for Crawler Crane 4.10.6 Inspection of hydraulic hoses Inspect whether all hydraulic hose are damaged regularly. Replace all the damaged hoses 起 even though slight damage is detected in these visual inspections. 重 机 The hydraulic hoses may have the following problems: 说...
  • Page 88 Maintenance Manual for Crawler Crane Ensure sufficient radius of bending. Make sure smooth flow of fluids and avoid pipe damage effectively. Too small curving radius will reduce the service life of hose. Incorrect Incorrect Correct Correct Figure 4-34 Hose illustration (II) Use elbow and other connectors when necessary.

  • Page 89: Safe Connection And Dismantling Of Quick-Release Coupling In Hydraulic Pipes

    Maintenance Manual for Crawler Crane Ensure fixed position of a hose with a clamp: Reduce the wear between the hose and relevant parts effectively. 起 重 机 Incorrect 说 明 Correct Figure 4-34 Hose illustration (V) Arrangement of the hose: Avoid too hot surface and sharp edges.
  • Page 90 Maintenance Manual for Crawler Crane If quick-release coupling is screw-type coupling, screw the coupling until a firm and tight fit is attained. At this time, the quick-release coupling is screwed. Screw the dust cap in time to prevent the impurities such as dust from entering when the quick-release coupling is not connected.

  • Page 91: Maintenance Of The Electrical System

    Maintenance Manual for Crawler Crane 4.11 Maintenance of the electrical system 4.11.1 Inspection of the illumination system 起 重 Check for normal operation of the illumination system. If any faults are detected, repair them at 机 说 once. 明 4.11.2 Inspection of hoisting limit switch When load hook comes into contact with the limit weight during its upward movement, the hoisting limit switch is triggered, the buzzer sounds and the crane movement “lift the load hook”...
  • Page 92 Maintenance Manual for Crawler Crane This series of lead-acid batteries for cars is produced in accordance with JIS Japan and DIN Germany. They can start the crane in 30 minutes after injecting the electrolyte. If possible, charging for 3 - 5 hours before use will result in a better starting performance. 4.11.5.1 Preparation for battery use Make sure the level of electrolyte is 10 mm higher than the minimum waterline.

  • Page 93: Prevention Of Electrical Parts Or Cables From Catching Fires

    Maintenance Manual for Crawler Crane 4.11.6 Prevention of electrical parts or cables from catching fires 4.11.6.1 Reasons to start the fire 起 The fires of electrical parts or cables of electrical system result from wrong operation of relevant 重 机 components or circuit, or carelessness of operator, rather than technology failure.

  • Page 94: Circuit Breaker

    Maintenance Manual for Crawler Crane Check all cables, connectors and terminals for tight fit or damages (see if there is any oxides formed on both poles of the terminal or battery), and rectify all confirmed faults immediately. Use the original spare parts and original fuse in compliance with the specified rigidity only. Close the crane immediately in case the power fails.

  • Page 95: Maintenance Of Load Hooks And Pulleys

    Maintenance Manual for Crawler Crane 4.12 Maintenance of load hooks and pulleys 4.12.1 Daily inspection and maintenance of load hook 起 重 Since the service condition of the main load hook and auxiliary load hook varies from day to day, 机...

  • Page 96: Inspection Of Load Hook

    Maintenance Manual for Crawler Crane 4.12.2 Inspection of load hook Check load hook once a year by professionals so that the failures of load hook can be found early, thus preventing accidents. Record all the failures and repair methods. Then check whether the faults are repaired later.

  • Page 97: Inspection Of Pulley

    Surplus of grease. Position of sealing seat for pulley spindle. Running noise and rolling resistance. Spindle clearance. The pulley spindle must be replaced in case defects are detected. In this situation, please inform the customer service department of Zoomlion. 4-63...

  • Page 98: Pulley Lubrication

    Maintenance Manual for Crawler Crane 4.12.4 Pulley lubrication Oil filling nozzle Oil passage Spindle Figure 4-37 Sectional view of metal pulley Oil filling nozzle Oil passage Spindle Figure 4-38 Sectional view of nylon pulley Metal pulley is mainly used for load hook. Nylon pulley is mainly used for crane and pulley block on the boom frame.

  • Page 99: Maintenance Of Wire Ropes

    Maintenance Manual for Crawler Crane 4.13 Maintenance of wire ropes 起 The service lives of wire ropes are different basing on the operating condition of the machine. 重 Both hoisting rope and derricking rope must be strictly inspected regularly to find abrasion and 机...

  • Page 100: Take-Down Criteria

    Maintenance Manual for Crawler Crane The original lubrication can only lasts for a certain period of time. You need to lubricate it regularly. Lubricating oil should be applied by many means, such as: Use the paintbrush or glove to paint the oil. Put the lubricating oil on the pulley area.
  • Page 101 Maintenance Manual for Crawler Crane Local aggregation of fractured wires: In case fractured lines cling together and aggregate in the range of the rope length less than 6d (d: diameter of wire rope) or exist almost in one strand, even though the number of fractured wires is small. 起...

  • Page 102: Comprehensive Introduction Of Wire Ropes

    Maintenance Manual for Crawler Crane Illustration Deformation form Dealing methods When the wires are loosened, Loosening of single wires the wire rope must be taken down. The wire rope with pronounced Contractions contractions must be taken down. The wire rope with flattened Flattening areas must be taken down.
  • Page 103 Maintenance Manual for Crawler Crane The wire rope may come across some problems even in delivery stage: the fork of the forklift truck may move under the scroll or get into the rope bundle, which will damage the surface of the wire rope.
  • Page 104 Maintenance Manual for Crawler Crane 4.13.4.3 Installation procedure of wire rope The best way to install a wire rope is different depending on the system. In each case, choose appropriate method according to typical work progress table, which is the method most unlikely to make the wire rope distort or damage through contacting with the structural members.
  • Page 105 Maintenance Manual for Crawler Crane the new one. This kind of connection may distort the installed old wire rope during operation, which will pass down to the new wire rope, and damage the new wire rope to a large extent even in installation stage.
  • Page 106 Maintenance Manual for Crawler Crane 4.13.4.6 Cutting of wire rope There are many ways to cut a wire rope. Use a cutterbar to cut wire rope with a diameter of 8mm. For wire ropes with a diameter more than 8mm, use mechanical or hydraulic cutterbar. If possible, use pneumatic or electrical right-angled grinder.

  • Page 107: Maintenance Of Air Conditioning

    Maintenance Manual for Crawler Crane 4.14 Maintenance of air conditioning 4.14.1 Daily maintenance 起 Regularly inspect the refrigeration equipment of the air conditioning system, especially 重 机 check whether pipe fittings are fixed tightly, whether oil stains exist at the oil seal of a 说...

  • Page 108: Operator's Cab

    Maintenance Manual for Crawler Crane 4.15 Operator’s cab 4.15.1 Inspection of the windshield wiper and cleaning solution in the operator’s cab Inspect whether the windshield works properly every week. The sprinkler is located at the rear left side of the operator’s seat. Add water frequently into the sprinkler and add little cleaning agent if necessary.

  • Page 109: Lubrication System

    Maintenance Manual for Crawler Crane 4.16 Lubrication system 起 Lubricate the parts that need lubricating regularly by hand to make sure that the equipment can 重 operate properly. The lubrication work is done by oil gun manually. 机 Table 4-16 Lubrication instructions 说...

  • Page 110: Lubrication Of Boom Pin

    Maintenance Manual for Crawler Crane 4.16.1 Lubrication of boom pin Main boom Attachment points of slewing table Pin spindles used to connect boom sections Oil cup Figure 4-46 Lubrication of boom pin Make sure that all pins (including pivot section bolting cylinder and pin spindles used to connect boom sections) are lubricated completely before raising the boom.

  • Page 111: Key Structural Member

    Maintenance Manual for Crawler Crane 4.17 Key structural member 4.17.1 Visual inspection 起 重 Some components must be inspected visually before operation every day. (See the following 机 说 figure) 明 I H L F E G K F E G K Figure 4-47 Visual inspection point (I) 4-77...
  • Page 112 F E G F E G Figure 4-47 Visual inspection point (II) CAUTION (1) ZCC1300 has no luffing jib working condition. (2) The following steel structural members are main components of the crane, and check them according to actual configuration. 4-78...

  • Page 113: Periodic Inspection

    Maintenance Manual for Crawler Crane 4.17.1.1 Visual inspection of boom A - Check boom parts, connecting pins and retaining pins for tight fit and damage. 起 B - Check main boom tilting-back support, tilting-back supports of jib for damage and functional 重...
  • Page 114 Maintenance Manual for Crawler Crane 4.17.3.1 Crawler carrier Figure 4-48 Crawler carrier 4.17.3.2 Undercarriage central section and folding bracket Figure 4-49 Undercarriage central section 4-80...
  • Page 115 Maintenance Manual for Crawler Crane 起 重 机 说 明 Figure 4-50 Folding bracket 4.17.3.3 Slewing ring Figure 4-51 Slewing ring 4-81...
  • Page 116 Maintenance Manual for Crawler Crane 4.17.3.4 Slewing table Figure 4-52 Slewing table 4.17.3.5 A-frame Figure 4-53 A-frame 4-82...
  • Page 117 Maintenance Manual for Crawler Crane 4.17.3.6 Boom and anchoring rods The straightness tolerance of main chord of boom section must be in line with the following 起 table: 重 Table 4-17 The straightness tolerance of main chord of boom section 机...
  • Page 118 Maintenance Manual for Crawler Crane Main boom pivot section Figure 4-55 Main boom pivot section 3m main boom intermediate section Figure 4-56 3m main boom intermediate section 4-84...
  • Page 119 Maintenance Manual for Crawler Crane 6m main boom intermediate section 起 重 机 说 明 Figure 4-57 6m main boom intermediate section 9m main boom intermediate section Figure 4-58 9m main boom intermediate section 4-85...
  • Page 120 Maintenance Manual for Crawler Crane Tip boom Figure 4-59 Tip boom Main boom anchoring rods Figure 4-60 Anchoring rods 4-86...
  • Page 121 Maintenance Manual for Crawler Crane Fixed jib head 起 重 机 说 明 Figure 4-61 Fixed jib head Fixed jib pivot section Figure 4-62 Fixed jib pivot section 4-87...
  • Page 122 Maintenance Manual for Crawler Crane Fixed jib intermediate sections Figure 4-63 Fixed jib intermediate sections Luffing jib pivot section Figure 4-64 Luffing jib pivot section 4-88...
  • Page 123 Maintenance Manual for Crawler Crane Luffing jib head 起 重 机 说 明 Figure 4-65 Luffing jib head m) 3m luffing jib intermediate section Figure 4-66 3m luffing jib intermediate section 4-89...
  • Page 124 Maintenance Manual for Crawler Crane 6m luffing jib intermediate section Figure 4-67 6m luffing jib intermediate section 9m luffing jib intermediate section Figure 4-68 9m luffing jib intermediate section 4-90...
  • Page 125 Maintenance Manual for Crawler Crane 4.17.3.7 Tilting-back support and other parts FA-frame 起 重 机 说 明 Figure 4-69 FA-frame WA-frame 1 Figure 4-70 WA-frame 1 4-91...
  • Page 126 Maintenance Manual for Crawler Crane WA-frame 2 Figure 4-71 WA-frame 2 Main boom tilting-back support Figure 4-72 Main boom tilting-back support 4-92...
  • Page 127 Maintenance Manual for Crawler Crane Front tilting-back support of fixed jib 起 重 机 说 明 Figure 4-73 Front tilting-back support of fixed jib Rear tilting-back support of fixed jib Figure 4-74 Rear tilting-back support of fixed jib 4-93...
  • Page 128 Maintenance Manual for Crawler Crane Tilting-back support for luffing jib Figure 4-75 Tilting-back support for luffing jib Tilting-back support for WA-frame 2 Figure 4-76 Tilting-back support for WA-frame 2 4-94...

  • Page 129: Inspection Of Counterweight

    Maintenance Manual for Crawler Crane 4.17.3.8 Winch support 起 重 机 说 明 Figure 4-77 Winch support 4.17.4 Inspection of counterweight 4.17.4.1 Counterweight base plate Inspect the welding seams at positioning blocks to ensure the counterweight plate can be positioned reliably. Figure 4-78 Counterweight base plate 4-95...

  • Page 130: Other Inspection

    Maintenance Manual for Crawler Crane 4.17.5 Other inspection 4.17.5.1 Ladder Check whether the ladder is fastened or damaged, and whether there is oil stain, ice, snow on the surface. 4.17.5.2 Guard rail Check whether the guard rail is fastened or damaged, and whether there is oil stain, ice, snow on the surface.

  • Page 131: Inspection And Maintenance Under Special Working Environments

    Maintenance Manual for Crawler Crane 4.18 Inspection and maintenance under special working environments 起 重 4.18.1 Working in mud, snow and rain 机 说 Check whether various kinds of plug and pin are loose before operation. 明 After the operation, clean the machine. Check whether the bolts and nuts are loose. Put oil and grease into it.

  • Page 133: Chapter 5 Troubleshooting

    Maintenance Manual for Crawler Crane Chapter 5 Troubleshooting...

  • Page 135: Troubleshooting Of Mechanical Drive

    Maintenance Manual for Crawler Crane Chapter 5 Troubleshooting 5.1 Troubleshooting of mechanical drive 起 重 Some irregular phenomenon may occur during crane operation, therefore, checks must be 机 说 done in time to find causes, and maintain the crane if necessary. 明...

  • Page 136: Troubleshooting Of Power System

    Maintenance Manual for Crawler Crane 5.2 Troubleshooting of power system Table 5-2 Troubleshooting of power system Troubles Causes Solutions 1. The battery is charged 1. Charge the battery. insufficiently. The starting motor 2. Tighten the wire of terminal 2. The wire connected to on the motor.
  • Page 137 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The charge-air pressure 1. Make a check and consult sensor fails. the qualified repair plant. 起 重 2. The temperature of 机 charge-air is too high. 说 明 3. The temperature sensor 3.
  • Page 138 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The traveling control device 1. Show the fault record of fails. traveling control device, and consult the qualified repair plant. The engine braking 2. There is defect in 2. Inspect the controller, and force is not good.
  • Page 139 Maintenance Manual for Crawler Crane Troubles Causes Solutions 4. The fan is not turned on 4. Consult the qualified repair 起 重 correctly. plant. 机 5. The outside and inside of 5. Clean the radiator or remove 说 The temperature of radiator are dirty or the radiator the lime deposit.
  • Page 140 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. Some components may leak 1. Check the engine, oil antifreeze coolant. pipeline and radiator for leaks. Repair the leaking points by The consumption of professionals. antifreeze coolant is 2. The temperature of engine is 2.

  • Page 141: Troubleshooting Of Hydraulic System

    Maintenance Manual for Crawler Crane 5.3 Troubleshooting of hydraulic system 起 Table 5-3 Troubleshooting of hydraulic system 重 Troubles Causes Solutions 机 说 1. The pilot pump fails. 1. Check and repair the pilot 明 pump. Change it if necessary. 2.
  • Page 142 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The shutoff valve of oil 1. Open the shutoff valve. suction pipe is not opened. 2. The slewing valve 2. Check and adjust the malfunctions. overflow pressure of slewing valve. 3. The slewing pump fails. 3.
  • Page 143 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The pump or motor leaks oil. 1. Check and repair the pump or motor, or change them if 起 necessary. 重 机 2. The oil pipeline is blocked. 2. Clean the oil pipeline. The speed of actuating 说...
  • Page 144 Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The oil viscosity is too low. 1. Change hydraulic oil. 2. The oil temperature is too 2. Preheat the hydraulic The hydraulic system low. system. makes noise. 3. The back pressure of oil 3.

  • Page 145: Troubleshooting Of Electrical System

    Maintenance Manual for Crawler Crane 5.4 Troubleshooting of electrical system 5.4.1 Troubleshooting of cab electrics 起 Table 5-4 Troubleshooting of cab electrics 重 机 Troubles Causes Solutions 说 明 1. The wiper switch is 1. Change the wiper switch. damaged. 2.

  • Page 146: Troubleshooting Of Slewing Table Electrics

    Maintenance Manual for Crawler Crane Troubles Causes Solutions The switch on control 1. The circuit is out of order. 1. Check and repair the circuit. panel is not in 2. The switch is damaged. 2. Change the switch. functional work. 1.

  • Page 147: Troubleshooting Of Boom Electrics

    Maintenance Manual for Crawler Crane Troubles Causes Solutions 1. The circuit is out of order. 1. Check and repair the circuit. The basin-shaped 起 electric horn can not 2. The basin-shaped electric 2. Change the basin-shaped 重 sound. horn is damaged. electric horn.

  • Page 148: Troubleshooting Of Load Moment Limiter

    Maintenance Manual for Crawler Crane 5.4.4 Troubleshooting of load moment limiter Table 5-7 Troubleshooting of load moment limiter Troubles Causes Solutions 1. The safety fuse is broken. 1. Check and repair the safety fuse. The screen of load 2. The circuit is not connected 2.

  • Page 149: Troubleshooting Of Air Conditioning System

    Maintenance Manual for Crawler Crane 5.5 Troubleshooting of air conditioning system 起 Table 5-8 Troubleshooting of air conditioning system 重 Troubles Causes Solutions 机 说 1. The temperature control 1. Change the temperature 明 switch is damaged, or the control switch, or push the cooling/heating rocker switch is cooling/heating rocker switch not pushed to “heating”...

  • Page 151: Chapter 6 Oil And Medium Application

    Maintenance Manual for Crawler Crane Chapter 6 Oil and Medium Application...

  • Page 153: Antifreeze Coolant

    Cummins. If you want to use other brand, please consult the service centre of Cummins. Please buy the antifreeze coolant from Zoomlion. (3) The volume of antifreeze coolant is 44L. Change it every two years. If other kind of...

  • Page 154: Lubricating Oil

    Maintenance Manual for Crawler Crane 6.2 Lubricating oil Table 6-1 Temperature for lubricating oil Ambient temperature (°C) Brand of lubricating oil SAE15W-40 SAE10W-30 SAE5W-30 CAUTION (1) Please select high-quality Cummins lubricating oil. (2) The high-viscosity lubricating oil can reduce oil consumption and help the engine to run well in cold climate.

  • Page 155: Lubricating Grease

    Maintenance Manual for Crawler Crane The engine only uses vehicle diesel oil, which must comply with National Standard GB19147-2009. The sulfur content of vehicle diesel oil must not exceed 350 ppm. If this sulfur content is 起 重 exceeded, the diesel oil is not recommended to use. If you have to use this kind of diesel oil, 机...

  • Page 156: Hydraulic Oil

    Maintenance Manual for Crawler Crane 6.5 Hydraulic oil Table 6-4 Working temperature of hydraulic oil The lowest The lowest The lowest The highest Ambient temperature for temperature working temperature Hydraulic oil temperature cold start for cold start temperature of hydraulic brand (without load) (with load)

  • Page 157: Gear Oil Of Reducer

    Maintenance Manual for Crawler Crane (4) If you find any special working conditions which are not listed in the above table, please consult the related departments of our company. (5) Check and measure oil temperature of the system at any time! 起...

  • Page 158: Oil Change Interval And Lubricating Interval

    Maintenance Manual for Crawler Crane 6.7 Oil change interval and lubricating interval Table 6-5 Gear oil change interval Volume (L) Inspection Type of gear change Components interval interval ZCC1300 ZCC1800 ZCC2600 L-CKD220 Reducer of industrial 1000 hoisting winch 1 closed gear oil L-CKD220...
  • Page 159 Maintenance Manual for Crawler Crane CAUTION (1) The volumes in above tables are approximate values. In order to obtain accurate 起 volume, the maintenance personnel must check the inspection points via oil 重 dipstick, inspection hole and inspection plug. 机 说...

  • Page 161: Chapter 7 Appendix

    Maintenance Manual for Crawler Crane Chapter 7 Appendix...

  • Page 163: Tightening Torque Of Threaded Parts

    Maintenance Manual for Crawler Crane Chapter 7 Appendix 7.1 Tightening torque of threaded parts 起 重 Table 7-1 Tightening torque of threaded parts 机 说 Tightening torque 明 Thread N•m Thread pitch diameter 8.8 grade 9.8 grade MIN. STD. MAX. MIN.
  • Page 164 Maintenance Manual for Crawler Crane Table 7-1 Tightening torque of threaded parts Tightening torque N•m Thread Thread pitch diameter 10.9 grade 12.9 grade MIN. STD. MAX. MIN. STD. MAX. Coarse 1.25 36.9 39.5 42.2 44.3 47.4 50.6 thread Fine 39.5 42.3 45.1 47.3...
  • Page 165 Maintenance Manual for Crawler Crane Table 7-1 Tightening torque of threaded parts Tightening torque 起 Thread N•m Thread pitch 重 diameter 8.8 grade 9.8 grade 机 说 MIN. STD. MAX. MIN. STD. MAX. 明 Coarse 597.8 640.5 683.2 672.5 720.5 768.6 thread Fine...
  • Page 166 Maintenance Manual for Crawler Crane Table 7-1 Tightening torque of threaded parts Tightening torque Thread N•m Thread pitch diameter 10.9 grade 12.9 grade MIN. STD. MAX. MIN. STD. MAX. Coarse 840.6 900.6 960.7 1008.7 1080.8 1152.8 thread Fine 881.2 944.1 1007.1 1057.4 1133.0...
  • Page 167 Maintenance Manual for Crawler Crane Table 7-1 Tightening torque of threaded parts Tightening torque Thread N•m 起 Thread pitch diameter 重 8.8 grade 9.8 grade 机 MIN. STD. MAX. MIN. STD. MAX. 说 明 Coarse 2633.1 2821.2 3009.3 2962.2 3173.8 3385.4 thread Fine...
  • Page 168 Maintenance Manual for Crawler Crane Table 7-1 Tightening torque of threaded parts Tightening torque Thread N•m Thread pitch diameter 10.9 grade 12.9 grade MIN. STD. MAX. MIN. STD. MAX. Coarse 3702.8 3967.3 4231.8 4443.4 4760.7 5078.1 thread Fine 3921.3 4201.4 4481.4 4705.5 5041.6...
  • Page 169 Maintenance Manual for Crawler Crane 7.2 Tightening torque of thread parts at pipe orifices 起 Table 7-2 Tightening torque of thread parts at pipe orifices (applicable to light pipe fittings) 重 机 1/8’’ 1/4’’ 1/4’’ 3/8’’ 1/2’’ 1/2’’ 3/4’’ 1’’ 11/4’’...

  • Page 170: Attached Tools

    Maintenance Manual for Crawler Crane 7.3 Attached tools Table 7-4 Attached tools for ZCC1300 crawler crane ID code Names of the tools Quantity Specification 1140102828 Pressure testing joint 1140102829 Pressure testing joint 1140207054 Testing hose 1140102826 Pressure testing joint 1140102830...
  • Page 171 Maintenance Manual for Crawler Crane Table 7-6 Attached tools for ZCC2600 crawler crane ID code Names of the tools Quantity Specification 起 1140102828 Pressure testing joint 重 1140102829 Pressure testing joint 机 说 1140207054 Testing hose 明 1140102826 Pressure testing joint 1140102830 Pressure testing joint 1140102954...

  • Page 172: Checklist For Periodic Inspection

    You can conduct the inspections according to the inspection category. This checklist is only for reference. The user can make your own checklist according to actual conditions. Crane type: Crane manufacturer: Zoomlion Serial Number: Serial Number of user: Company: Inspected by:...
  • Page 173 Maintenance Manual for Crawler Crane Table 7-8 Winch reducer Inspection Components inspected Result Remarks 起 intervals 重 Check if the load falls down 机 Status of load uncontrollably after engine stops. 说 明 Wire rope wound onto the drum Sound made by the reducer when it is running Brake Gear oil level...
  • Page 174 Maintenance Manual for Crawler Crane Table 7-10 Travel gear Inspection Components inspected Result Remarks intervals Check the convex teeth of track Track pad pad for wear Pin spindles of track pad Check them for cracks Check the slot of drive sprocket for Drive sprocket wear Track roller...
  • Page 175 Maintenance Manual for Crawler Crane Table 7-12 Electrical system Inspection Components inspected Result Remarks 起 intervals 重 Check if the value shown is correct 机 Load moment limiter and the warning icon flashes when 说 明 irregular condition occurs. Hoisting limit switch Check it for functional work Lowering limit switch Check it for functional work...
  • Page 176 Maintenance Manual for Crawler Crane Table 7-14 Wire rope Inspection Components inspected Result Remarks intervals Check rope end point, number of Wire rope for hoisting winch 1 wire breaks and strand breaks Check rope end point, number of Wire rope for hoisting winch 2 wire breaks and strand breaks Check rope end point, number of Derricking rope...

This manual is also suitable for:

Zcc1800Zcc2600

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