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Zoomlion ZCC1100 Operator's Manual

Crawler crane
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Zoomlion Heavy Industry Science and Technology Co., Ltd
Add: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Economic and
Technological Development Zone, Changsha, Hunan Province, China.
PC: 410131
www.zoomlion.com
CRAWLER CRANE
OPERATOR'S MANUAL
Zoomlion Heavy Industry Science and Technology Co., Ltd.
For reference only.
Operators manual should be
consulted and adhered to.
Vision creates future

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Summary of Contents for Zoomlion ZCC1100

  • Page 1 Vision creates future CRAWLER CRANE OPERATOR’S MANUAL Zoomlion Heavy Industry Science and Technology Co., Ltd Add: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Economic and Technological Development Zone, Changsha, Hunan Province, China. PC: 410131 www.zoomlion.com...
  • Page 2 For reference only. Operators manual should be consulted and adhered to.
  • Page 3 For reference only. Operators manual should be consulted and adhered to. ZCC1100H Crawler Crane Operator’s Manual Edition 1 5, 2014...
  • Page 4 For reference only. Operators manual should be consulted and adhered to.

  • Page 5: To Users

    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 6 For reference only. Operators manual should be consulted and adhered to.

  • Page 7: Table Of Contents

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Contents To Users ............................I Safety Instructions ........................II Chapter 1 Safety 1.1 Important instructions ....................1-1 1.1.1 Notes ....................... 1-1 1.1.2 Alarms and warnings ..................
  • Page 8 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.3.4 Overall dimensions..................2-12 2.4 Technical data ......................2-13 2.4.1 Main technical parameter ................2-13 2.4.2 Specification of load hook and selection of rope reeving ......... 2-15 2.4.3 Performance of wire rope and winch...............
  • Page 9 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 3.4 Requirements for operating site ................. 3-28 3.4.1 Slopes and trenches..................3-28 3.4.2 Permissible ground pressure ................3-29 3.4.3 Travel on level ground or slope without a load ..........3-30 3.4.4 Travel on level ground or slope with a load .............
  • Page 10 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.1.6 Control panel on the roof of operator’s cab ............4-9 4.2 Instruction for digital display system ................4-12 4.2.1 Load moment limiter ..................4-12 4.2.2 Electrical system ....................
  • Page 11 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Chapter 5 Assembly and Dismantling 5.1 Safety-technical notes ....................5-1 5.1.1 Notes on assembly ................... 5-1 5.1.2 Checking safety measures ................5-1 5.1.3 Checking wire rope, load hook, rope pulley and anchoring rod ......
  • Page 12 For reference only. Operators manual should be consulted and adhered to.

  • Page 13: Chapter 1 Safety

    For reference only. Operators manual should be consulted and adhered to. 履带起重机操作手册 Operator’s Manual for Crawler Crane 第一章 安全操作说明 Chapter 1 Safety...
  • Page 14 For reference only. Operators manual should be consulted and adhered to.

  • Page 15: Important Instructions

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Chapter 1 Safety 安 全 操 1.1 Important instructions 作 说 1.1.1 Notes 明 Read this manual and familiarize yourself with any associated documents before operating this crane.

  • Page 16: Safety Tips

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 1.2 Safety tips 1.2.1 Safety precautions Do not use this equipment with guards removed or incorrectly fastened. Do not use this equipment with safety devices maladjusted or removed. 1.2.2 Precautions for operator safety Safety component –...

  • Page 17: Organizational Safety Measures

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Hard hat Safety glasses/Goggles 安 全 Hearing protection device 操 作 Close fitting overalls 说 Safety boots 明 Industrial gloves High visibility vest or jacket 1.5 Organizational safety measures...

  • Page 18: Safety Advice Regarding Specific Operation Phases

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 1.7 Safety advice regarding specific operation phases Standard operation Take necessary precautions to ensure that the crane is used in a safe and reliable state.

  • Page 19: Gas, Dust, Steam, Smoke And Noise

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 This crane is wired on a negative earth. Always observe correct polarity. Battery 安 全 Always disconnect battery leads before carrying out any maintenance to the electrical 操...
  • Page 20 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 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.

  • Page 21: Chapter 2 Description Of Crane

    For reference only. Operators manual should be consulted and adhered to. 履带起重机操作手册 Operator’s Manual for Crawler Crane 第二章 起重机的描述 Chapter 2 Description of Crane...
  • Page 22 For reference only. Operators manual should be consulted and adhered to.

  • Page 23: Product Model

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Chapter 2 Description of Crane 2.1 Product model 2.1.1 Product name plate and its position Position of product name plate Figure 2-1 Position of product name plate Figure 2-2 Product name plate ZCC1100H Crawler Crane...

  • Page 24: Engine Type And Its Manufacturer

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.1.2 Engine type and its manufacturer QSL9-C 280, American Cummins (Imported) 2.1.3 Intended use of the crane This crawler crane is designed for lifting loads! It is prohibited to transport people with this equipment! In many cases, there have been serious injuries when people have been transported using this equipment (or even on the hook or on loads).
  • Page 25 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.1.4.2 Classification of the crane The crane group of the crane is A1, operating class is U2 and the load collective class is Q1. All important components of the crane are designed and manufactured for normal assembly operation.
  • Page 26 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Where, is the i value appearing in the whole service life of the crane. is the max. load value appearing in the crane’s entire service life. is the crane’s load cycles corresponding to load in the crane’s entire service life.

  • Page 27: Terminology

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.2 Terminology 2.2.1 Crane modes 2.2.1.1 Working mode The boom configurations of ZCC1100H crawler crane in working mode are shown in the table 2-2.
  • Page 28 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane The boom configurations are shown in the figure 2-3. SF-1 SF-2 Figure 2-3 Boom configurations DANGER It’s prohibited to lift a load by use of two hooks (twin hook operation) without the permission of the manufacturer under the boom configurations S-2, S-3, SF-2, otherwise, the crane may topple over.
  • Page 29 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Note: L is the working radius in assembly mode. Figure 2-4 Assembly mode CAUTION Whenever using mounting cylinder on the boom to lift the load, be sure to make the crane in assembly mode.

  • Page 30: Description Of Main Components

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.2.2 Description of main components 2.2.2.1 Components on superstructure The positions of components on slewing table are shown in the figure 2-5, and the description of components is shown in the table 2-3.
  • Page 31 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.2.2.2 Components on undercarriage The positions of components on undercarriage are shown in the figure 2-6, and the description of components is shown in the table 2-4.

  • Page 32: Product Description

    7872’ (2400m). For details, please consult the local service provider of the engine or technological department of crawler crane of Zoomlion. 2-10 ZCC1100H Crawler Crane...
  • Page 33 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Crane drive The driving force is supplied by diesel engine, and it is transmitted by a coupling to A piston variable pump, which provides oil for travel gear and winches; A piston variable pump, which provides oil for slewing mechanism;...

  • Page 34: Overall Dimensions

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.3.4 Overall dimensions Unit: ft (mm) 30° ~82.5° 3'3" (1000) 2'7" 17'10" (800) (5440) 20'10" Extended/retracted 16'5"/11'2" (6340) Extended/retracted (5000/3400) R15'5" (4700) Figure 2-7 Overall dimensions of the crane 2-12 ZCC1100H Crawler Crane...

  • Page 35: Technical Data

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4 Technical data 2.4.1 Main technical parameter Table 2-5 Technical parameter of ZCC1100H crawler crane Item Unit Value Remarks 110/10’6”...
  • Page 36 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Item Unit Value Remarks Rear 61740 (28) Counterweight Counterweight Lbs (t) Central 22050 (10) counterweight 15’5” (4.7) Slewing radius ft (m) 45’3”×11’2”×11’ Overall dimensions (L×W×H) ft (m) (13.8×3.4×3.35) Ground clearance of the...

  • Page 37: Specification Of Load Hook And Selection Of Rope Reeving

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4.2 Specification of load hook and selection of rope reeving There are four types of load hooks available for ZCC1100H crawler crane. In actual operation, choose appropriate load hook according to the weight of load and the length of boom.
  • Page 38 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION If the crane is working with hoisting rope reeving less than the value listed in the above table, single hoisting rope load and rope layers on the drum must be checked to make sure that they satisfy the rated single rope force in the tables 2-9, 2-10, and 2-12 in section 2.4.3.3.
  • Page 39 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-10 Parameters for hoisting winches 1 and 2 without free-fall function Permissible Working Maximum Winch speed Rated single Winch speed length of wire layer of...

  • Page 40: Lifting Height

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.4.4 Lifting height 2.4.4.1 Lifting height on main boom 70° 60° 50° 80° 219’10” (67) 220’ 210’ (64) (67.1) 200’2” (61) 200’ 190’4” (58) (61) 180’5”...
  • Page 41 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4.4.2 Lifting height on fixed jib 10° 180’5”+59’ (55+18) 240’ 180’5”+39’4” (73.2) (55+12) 220’ 180’5”+19’8” (67.1) (55+6) 200’ (61) 180’...
  • Page 42 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 180’5”+59’ 30° (55+18) 240’ 180’5”+39’4” (73.2) (55+12) 220’ 180’5”+19’8” (67.1) (55+6) 200’ (61) 180’ 101’9”+59’ (54.9) (31+18) 160’ 101’9”+39’4” (48.8) (31+12) 140’ 101’9”+19’8” (42.7) (31+6) 120’...

  • Page 43: Lifting Capacity Chart

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4.5 Lifting capacity chart 2.4.5.1 Lifting capacity on main boom The value given in the lifting capacity chart is the permissible maximum lifting capacity, which is obtained from the calculation when the load is suspended (according to the standard ASME/ANSI B30.5).
  • Page 44 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-13 Lifting capacity on S-1 boom Unit: kip (ton) Main boom length ft(m) Radius Radius ft(m) ft(m) 42'8" 52'6" 62'4" 72'3" 91'11" 101'9" 111'6"...
  • Page 45 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-13 Lifting capacity on S-1 boom Unit: kip (ton) Main boom length ft(m) Radius Radius ft(m) 131'3" 141'2" 150'11"...
  • Page 46 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION (1) The values in bold are the lifting capacity determined by the strength of the machine, while the values that are not in bold are the lifting capacity determined by the stability of the machine.
  • Page 47 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4.5.2 Lifting capacity on S-2 boom Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 101’9"(31) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 48 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 111’6"(34) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 49 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 121’5"(37) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 50 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 131’3"(40) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 51 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 141’2"(43) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 52 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 150’11"(46) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 53 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 160’10"(49) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 54 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 170’8"(52) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 55 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-14 Lifting capacity on S-2 boom Unit: kip (ton) 180’5"(55) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 56 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane (4) The values in the chart are the lifting capacity when the crane is working with 61740 Lbs (28t) rear counterweight and 22050lbs (10t) central counterweight in 360° range. (5) The value in the chart is the maximum lifting capacity of the crane, including the weight of lifting device, hook, wire rope at the end of hook and so on.
  • Page 57 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 2.4.5.3 Lifting capacity on S-3 boom Table 2-15 Lifting capacity on S-3 boom Unit: kip (ton) Radius Radius Main boom length ft(m) 42'8"...
  • Page 58 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-15 Lifting capacity on S-3 boom Unit: kip (ton) Radius Radius Main boom length ft(m) 131'3" 141'2" 150'11" 160'10" 170'8" 180'5" 190'4" 200'2" (40) (43) (46)
  • Page 59 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane (3) Do not lift a load in the area which is not in the lifting capacity range, otherwise the crane may topple over or be damaged.
  • Page 60 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.4.5.4 Lifting capacity on SF-1 boom Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 101’9"(31) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 61 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 111’6"(34) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 62 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 121’5"(37) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 63 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 131’3"(40) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 64 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 141’2"(43) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 65 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 150’11"(46) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 66 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 160’10"(49) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 67 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 170’8"(52) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 68 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-16 Lifting capacity on SF-1 boom Unit: kip (ton) 180’5"(55) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 69 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane (3) Do not lift a load in the area which is not in the lifting capacity range, otherwise the crane may topple over or be damaged;...
  • Page 70 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 2.4.5.5 Lifting capacity on SF-2 boom Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 101’9"(31) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 71 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 111’6"(34) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 72 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 121’5"(37) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 73 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 131’3"(40) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 74 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 141’2"(43) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 75 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 150’11"(46) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 76 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 160’10"(49) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" 59'1" Radius Radius (12) (18) Fixed jib angle(°...
  • Page 77 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 170’8"(52) Main boom length ft(m) Fixed jib length ft(m) 19'8"...
  • Page 78 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 2-17 Lifting capacity on SF-2 boom Unit: kip (ton) 180’5"(55) Main boom length ft(m) Fixed jib length ft(m) 19'8" 39'4" Radius Radius (12) Fixed jib angle(°...

  • Page 79: Lifting Capacity In Assembly Mode

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane (3) Do not lift a load in the area which is not in the lifting capacity range, otherwise the crane may topple over or be damaged;...
  • Page 80 For reference only. Operators manual should be consulted and adhered to.

  • Page 81: Chapter 3 Safety Guidelines

    For reference only. Operators manual should be consulted and adhered to. 履带起重机操作手册 Operator’s Manual for Crawler Crane 第三章 安全准则 Chapter 3 Safety Guidelines...
  • Page 82 For reference only. Operators manual should be consulted and adhered to.

  • Page 83: Operational Planning

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 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.

  • Page 84: Correct Use Of The Crane

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.1.1 Correct use of the crane Using the crane correctly is a fundamental safety requirement, and slackness is not allowed. No unauthorized use of crane for other purpose besides its designed function is allowed. The manual lists the precautions and protective measures in the process of dismantling, test and maintenance of the crane.

  • Page 85: Responsibility Of Relevant Personnel

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.1.3 Responsibility of relevant personnel Responsibility of the manufacturer: Ensure the completeness of the equipment, accessories and the related technical documents upon its first delivery.

  • Page 86: Work Area

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.1.4 Work area Only the operator is allowed to stay on the equipment when the crane is working. The operator can’t leave the cab at any time when the crane is working. In order to build a safe and comfortable working environment, the following requirements should be followed: Keep the cab clean.

  • Page 87: Safety Technical Notes

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.2 Safety technical notes 3.2.1 Safety instructions for crane operator The crane operator’s primary responsibility is to control, operate and adjust the crane in a manner that is safe for both himself and others.

  • Page 88: Safety Instructions For The Rigger

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Driving (or slewing) too fast with a load, or setting up and loading on an uneven surface; Diagonally pulling the load, or loosing of the lifted load; Swinging of suspended load;...

  • Page 89: Safety Instructions For The Signalman

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 CAUTION Operate the crane correctly for the sake of safety and be familiar with the possible dangers caused by the work. 3.2.4 Safety instructions for the signalman The main job of a signalman is to assist crane operator to carry out operation safely.

  • Page 90: Electromagnetic Influences

    (2) Danger of burns or inflammation due to too high temperature. (3) Spark or electric arc formation. In any case, before working with the crane near transmitters, contact Zoomlion representatives. In addition, consult a high - frequency specialist. The whole crane must be “totally” grounded. Check visually or with a simple tester to ensure that the ladder, cab and cable pulleys are grounded.

  • Page 91: Safety Signs

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 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 large metal parts. Use only conductive rubber hoses to refuel.
  • Page 92 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 安 全 准 则 Figure 3-2 Arrangement of safety signs on the other side of the crane (near the operator’s cab) Table 3-1 Description of safety signs near the ladder and operator’s cab Figure Figure Safety signs...
  • Page 93 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Table 3-1 Description of safety signs near the ladder and operator’s cab Figure Figure Safety signs Description Moving parts can crush and cut.
  • Page 94 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Table 3-1 Description of safety signs near the ladder and operator’s cab Figure Figure Safety signs Description Open flame prohibited. Do not stand under the jib during assembling...
  • Page 95 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Table 3-1 Description of safety signs near the ladder and operator’s cab Figure Figure Safety signs Description Risk of falling. Keep off folding 12,14 brackets/additional...
  • Page 96 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 The arrangement of safety signs on the slewing table is shown in the figure 3-3, and the description of safety signs is shown in the table 3-2. Figure 3-3 Arrangement of safety signs on the slewing table 安...
  • Page 97 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Arrangement of safety signs in the front of slewing table is shown in the figure 3-4, and the description of safety signs is shown in the table 3-3.
  • Page 98 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Arrangement of safety signs at the rear side of slewing table is shown in the figure 3-5, and the description of safety signs is shown in the table 3-4. Figure 3-5 Arrangement of safety signs at the rear side of slewing table Table 3-4 Description of safety signs at the rear side of slewing table Safety signs...

  • Page 99: The Potential Dangers Existing In Crane Operation

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Table 3-5 Description of safety signs on the derricking traveling block Safety signs Description After the derricking travelling block is fastened to the main boom pivot section, fold and secure the crossing coupling of guy...

  • Page 100: Injuries Due To Hydraulic Energy

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Before starting operation, check that – All protective covers and casings are fitted correctly, – All the engine compartment doors are locked, – All the safety devices are operational.

  • Page 101: Scald

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.2.10 Scald These safety instructions and preventive measures protect against burns: Always wear protective gloves when working near hot components. The engine cooling system is pressurized and the escaping steam can cause scald injuries.

  • Page 102: Risk Of Fire And Explosion

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Never short circuit the battery. Never place any tools on the batteries. Discharged battery: – Can burst open upon freezing. – Stored in frost-proof rooms. In storage: –...
  • Page 103 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 While filling the fuel tank or the hydraulic tank: smoking and the use of fire or open flames is strictly prohibited.

  • Page 104: Risk Of Poisoning And Asphyxiation

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 (3) During high-rate charging or discharging, batteries can produce a explosive gas, even an explosion. 3.2.13 Risk of poisoning and asphyxiation Symptoms of carbon monoxide poisoning, with increasing intensity: Slight: headaches, short of breath without much exertion, heart palpitations.

  • Page 105: Endangering The Environment

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.2.14 Endangering the environment Follow these safety instructions and precautionary measures: Fix any leaks on the machine immediately. Neutralize escaped hydraulic oil, fuel or lubricating oil straight away with a binding agent.

  • Page 106: Slings

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.3 Slings 3.3.1 Hooks Usage: The hook must be selected to work with the cable, the chain or the strap used in the lifting device.

  • Page 107: Slings Introduction

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.3.3 Slings introduction The predominant characteristics of a sling are determined by the components of that sling. For example, the strengths and the weaknesses of a wire rope sling are essentially the same as those of the wire rope from which it is made.

  • Page 108: Sling Safety Guide

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 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. Never allow anyone to ride on the hook or load.

  • Page 109: Load Center Of Gravity

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 CAUTION (1) Never stand directly underneath a lifted load. Observe the instruction “No person is allowed to stand under the boom when the crane is operated”. (2) Tail the load by tagline with proper force.

  • Page 110: Requirements For Operating Site

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.4 Requirements for 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: Crane movement can be carried out within the smallest possible radius.

  • Page 111: Permissible Ground Pressure

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.4.2 Permissible ground pressure The ground upon which the crane works must be flat and firm The recommended ground endurance: 50t/m The following table 3-6 shows the bearing capacity of various grounds, for reference only.

  • Page 112: Travel On Level Ground Or Slope Without A Load

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.4.3 Travel on level ground or slope without a load The ground must be firm and flat and can provide adequate load-bearing capacity; Pay attention to trenches and hunches on the ground;...
  • Page 113 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 CAUTION To travel crawler crane uphill, the following conditions must be observed: (1) The ground must be able to support possible ground pressure. (2) The friction coefficient between roadway and track pad must be large enough to produce enough drive forces.

  • Page 114: Operation Weather

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.5 Operation weather 3.5.1 Snow and ice DANGER (1) Danger of accidents (due to ice falling down); (2) Increased danger of damage due to frozen height limit switches on the main boom, the fixed jib heads.

  • Page 115: Electrical Safety

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Lay down the boom and examine for damage; repair damage to the paint work at the point where the lightning struck. WARNING When lightning strikes the equipment, there is danger of serious injury or even death to all personnel in the immediate vicinity.

  • Page 116: Underground Cables

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.7 Underground cables With special equipment, the crane can also be used for underground working. 3.7.1 In underground working, it is possible to damage: Underground electric cables Gas pipes Telephone, TV, and data cables...

  • Page 117: Notes In Connection With Gas Pipes

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Operate the equipment with particular care near underground cables, all applicable local safety guidelines as well as the special guidelines and safety measures of the utility companies must be noted and obeyed.

  • Page 118: Measures Adopted If A Gas Pipe Is Damaged And The Gas Escapes, Or A Leak Is Suspected

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.7.5 Measures adopted if a gas pipe is damaged and the gas escapes, or a leak is suspected Stop work immediately. Leave the crane after shutting down the engine and all additional fuel powered units. Alert all site personnel, avoid producing any sparks and maintain a strict no-smoking policy.

  • Page 119: Notes In Connection With Underground Electric Cables

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Do not attempt to put out the fire before the fire department arrives unless lives are in danger or there is a risk of major damage to property. If the gas fire is not causing any immediate danger, it is sometimes better to let the gas burn.
  • Page 120 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 – At least 33ft (10 m) in the case of a high-voltage cable, or if uncertain about the voltage of the underground cable. Inform the relevant power station of the accident.

  • Page 121: Checking Safety Measures

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.8 Checking safety measures 3.8.1 Daily inspection of the crane The crane must be checked daily to ensure safe and good state, the items to be inspected includes: Check the daily record of work to ensure that all regular inspections, maintenance, and repair work have been performed.

  • Page 122: Crane Operation With A Load

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.9 Crane operation with a load Before beginning any work, the crane operator must be convinced that the crane is in safe operating condition. All safety devices, such as load moment limiter, hoist limiter switches, and brakes, etc., are in good working order.

  • Page 123: Crane Operation

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.9.2 Crane operation 3.9.2.1 Operating conditions The crane must satisfy the conditions in the table 3-8 when working. Table 3-8 Operating conditions Conditions Examples...
  • Page 124 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Conditions Examples When the crane is working near the high-voltage power line, safe clearance between any part of the crane and overhead power line should comply with regulations in table 3-9.
  • Page 125 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Table 3-10 Safe clearance when the crane is working near high-voltage power line Output voltage of V ≤ 1 1<...
  • Page 126 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Instructions Examples It is forbidden to lift the load hidden in the ground or frozen on the ground. The crane can travel with a load of 100% of the rated load when the gradient is equal to or less than1/100 and the travelling speed is less than 0.4...
  • Page 127 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Instructions Examples Under any condition, there must be at least three windings of wire rope left on the hoisting drum. When a load is suspended in the air, the operator is not allowed to leave the cab.
  • Page 128 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Instructions Examples It is prohibited to make any modifications to the crane without permission; otherwise you should take the consequences. Stop the crane operation if one of the conditions in the table 3-12 occurs: Table 3-12 Conditions to stop and inspect the crane Conditions to stop the crane 安...
  • Page 129 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Conditions to stop the crane In case of poor visibility and /or darkness, it is difficult to identify the load or signal There is defect or damage of configuration or components which will impair safe operation, for example, the brake and safety equipment...
  • Page 130 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Conditions to stop the crane Serious accident may occur when climbing the crane. Make sure that climb the crane after the crane stops stably, with two hands and ensuring firm stepping. Make sure the crane clean and dry because wet platform, ladder, tools, rubbish or other loose parts may cause falling.
  • Page 131 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.9.2.3 Preparation for crane operation Crane operator should perform the following checks before operating the crane: Check the daily record of work to ensure that all regular inspections, maintenance and repair works are performed.
  • Page 132 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 When the boom is less than 275’6”(84 m), the centre of load hook must/should be aligned with the centres of slewing table and boom frame. If a deviation of load hook is detected, measure the crane inclination via a inclinometer on the edge of slewing ring, and make sure the inclination is not more than 1% (±...
  • Page 133 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 – Apply brake or lock winch and slewing gear – Switch off the crane engine and cut off the power of load moment limiter and limit switch –...
  • Page 134 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 3.9.2.5 Checks after operation When the 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 away by water.

  • Page 135: Hand Signals For Controlling Crane Operations

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 3.10 Hand signals for controlling crane operations The hand signals for controlling crane operations are shown in the table 3-13. Table 3-13 Hand signals for controlling crane operations Ser.
  • Page 136 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Ser. No. Signal Rotate Lower load slowly Turn left: With right Turn right: With left With arm extended forearm vertical, the palm forearm vertical, the palm downwards with a 30°...
  • Page 137 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 履带起重机操作手册 Ser. No. Signal Raise boom Lower boom Raise boom slowly With arm stretched With arm stretched sideways horizontally, Bend the left arm.
  • Page 138 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Ser. No. Signal End of a movement With fingers extended, Description cross both hands before the forehead. Illustration 安 全 准 则 The crane operator must watch the load before carrying out any movements and especially pay attention to the hook or hook pulley when moving the crane without load.

  • Page 139: Chapter 4 Crane Operation

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 履带起重机操作手册 Chapter 4 Crane Operation 第四章 起重机的操作...
  • Page 140 For reference only. Operators manual should be consulted and adhered to.

  • Page 141: Operating And Control Instruments

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Chapter 4 Crane Operation 4.1 Operating and control instruments 4.1.1 Operator’s cab, overview Figure 4-1 Operator’s cab, overview The arrangement of operating and control instruments in the operator’s cab is shown in the figure 4-1.
  • Page 142 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of Remarks instruments Electrical control box Arrange the electric elements. Arrange the switches for electric elements. (For details, please Operating console see section 4.1.2.) Control the movements of hoisting winches 1 and 3, derricking Right control lever winch and mounting cylinder.

  • Page 143: Operating Console

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.1.2 Operating console Set Up Overl o wer Rel e ase On Overroll Release Derrick Release Figure 4-2 Operating console The switches on the operating console are detailed in the table 4-2. Table 4-2 Description of switches on the operating console Names of the Remarks...

  • Page 144: Control Lever

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of the Remarks switches After lowering warning is sent, never reel off hoisting winch. Lowering bypass Turn the switch clockwise and keep it there at this time. When switch the icon appears on the load moment limiter, the...
  • Page 145 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane As shown in the figure 4-3, the left is the operating board for left control lever. It is stuck on the left glass of the cab. The four directions shown on the right means that the control lever can be moved forwards, backwards, leftwards and rightwards.
  • Page 146 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.1.3.2 Right control lever Front Right Figure 4-4 Illustration of right control lever operation As shown in the figure 4-4, the left is the operating board for right control lever. It is stuck on the left glass of the cab.

  • Page 147: Left Control Panel

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION The horn can only be actuated in emergency condition to warn the person in the vicinity of the crane. 4.1.4 Left control panel Free Fall Chief H1 Free Fall H3 Free Fall...

  • Page 148: Right Control Panel

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane DANGER (1) If free-fall operation is not finished (i.e. the wind drum does not stop rotating), never set the free-fall switch of corresponding winch to the initial position. (2) When the hoisting winch is controlled by control lever, never switch on any free-fall switches.

  • Page 149: Control Panel On The Roof Of Operator's Cab

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION (1) Before starting the engine each time, first set the ignition key switch in initial position. (2) The engine will be started after automatic preheating when it is cold. Moreover, delay start of the engine is normal.
  • Page 150 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Figure 4-8 Switches on the control panel As to the functions of switches on the control panel, refer to figure 4-7. Table 4-7 Description of switches on the control panel Names of switches Functions Washer switch...
  • Page 151 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of switches Functions Turn on this switch to operate mounting cylinder on main Mounting cylinder boom pivot section, and turn off H2 winch switch at the same switch time.

  • Page 152: Instruction For Digital Display System

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2 Instruction for digital display system Figure 4-9 Digital display system The description of digital display system is shown in the table 4-8. Table 4-8 Description of digital display system Names of the Remarks components...

  • Page 153: Electrical System

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2 Electrical system The main screen of electrical system is shown in the figure 4-10. Res:0.0 Max:0.6 Free fall alarm +Y:0.0 1500 1000 2000 +X:0.0 0 hour 2500...
  • Page 154 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2.1 Alarm functions Figure 4-11 Screen of alarm functions The screen of alarm functions will be described in details in the table 4-9. Table 4-9 Description of alarm functions screen Meaning of the icons Remarks Icon “Engine oil...
  • Page 155 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2.2 Engine information 1500 1000 2000 0 hour 2500 0 rpm 3000 Speed WaterTEMP Oil Pressure Fule Lever 0.0Bar 0.0% 0℃ Figure 4-12 Screen of engine information The screen of engine information will be described in detail in the table 4-10.
  • Page 156 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2.3 Monitored additional functions Res:0.0 Max:0.6 Free fall alarm +Y:0.0 +X:0.0 Voltage Angle: Y:0.0 X:0.0 Gradient: X:0.0% Y:0.0% Figure 4-13 Screen of monitored additional functions The screen of monitored additional functions will be described in detail in the table 4-11.
  • Page 157 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2.4 Pressure monitoring of hydraulic system 0.0 MPa 0.0 MPa 0.0 MPa Pump 0.0 MPa Derricking 0.0 MPa Slewing 0.0 MPa Control 0.0 MPa Return Oil 0.0 MPa Figure 4-14 Pressure monitoring of hydraulic system...
  • Page 158 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.2.2.5 Function key area Main Page Enter I\O Watch PAR ADJ PAR Rst Work Status Figure 4-15 Function key area The function key area will be described in the table 4-13. Table 4-13 Description of function key area Function keys Remarks...

  • Page 159: Startup Of The Crane

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.3 Startup of the crane 4.3.1 Adjustment of crane operator’s seat Vertical adjustment of headrest The height of headrest is adjusted manually with proper strength. Figure 4-16 Adjustment of headrest Adjustment of armrest The height of armrest can be adjusted by the adjusting knobs.
  • Page 160 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Horizontal adjustment of seat Pull the lever upwards; Move the seat to required position; Release the lever. Figure 4-18 Horizontal adjustment of seat Adjustment of seat height There are two levers to adjust the seat height.

  • Page 161: Checks Before Startup

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Adjustment of backrest Pull the horizontal adjustment lever upwards, pull the backrest to proper position and release the lever. Figure 4-20 Adjustment of backrest 4.3.2 Checks before startup The following checks should be performed before startup of the engine.

  • Page 162: Turn On Power Supply

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane DANGER (1) Never check the coolant level before the engine is cooled down. Otherwise, you may get scalded. (2) Before carrying out any boom movements, make sure that there are no loose parts on the boom such as pin, or retaining spring.
  • Page 163 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Items to be inspected Check engine oil level; Check if slewing fixing pin is pulled out; Check hoisting limit switches on H1, H2; Check if free-fall switches are switched off; Check the maximum main boom angle;...

  • Page 164: Operation Of Air Conditioning In Operator's Cab

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.3.4 Operation of air conditioning in operator’s cab The crane operator’s cab can be heated or cooled according to the expected temperature, and the control panel is located above the wallboard on the right side of the cab. Refer to figure 4-23.

  • Page 165: Start Of Engine

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.3.6 Start of engine Insert ignition key into ignition lock and turn it clockwise to the 2 position, the engine can be started. Start engine 启动发动机...
  • Page 166 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION (1) Compared with routine conditions, it takes longer time to preheat the engine automatically in cold weather. This is a normal phenomenon. (2) Do not use accelerator when starting engine. If the engine fails to start after approx.

  • Page 167: Safety Device

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4 Safety device The crane operator must check all safety devices for functional work before every crane operation. DANGER Operating crane with faulty safety devices is prohibited! 4.4.1 Emergency stop button As soon as this emergency stop button is pressed, The electrical control system is switched off and the diesel engine shuts down;...

  • Page 168: Battery Master Switch

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.2 Battery master switch Battery master switch is located in the battery box on the slewing table. Set battery master switch in “OFF” position during long-time work breaks so as to prevent the electricity of battery from discharging excessively.

  • Page 169: Flashing Light

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.3 Flashing light When the crane is electrified via ignition key switch, the flashing light will light up. It will warn people around and shows that the crane is working. Flashing light Figure 4-30 Position of flashing light 4.4.4 Load moment limiter...
  • Page 170 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.4.1 Moment percent between 100%-110% If the moment percent shown on the load moment limiter is between 100% and 110%, it means that the actual load of crane reaches 100% - 110% of the rated load. At this time, crane movements “spool up H1, H2 and H3”, “derrick boom up and down”...

  • Page 171: Boom Angle Indicator

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.4.2 Moment percent more than 110% If the moment percent shown on the load moment limiter is more than 110%, it means that the actual load of crane exceeds 110% of the rated load.

  • Page 172: Derricking Limiter

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Figure 4-32 Position of boom angle indicator 4.4.6 Derricking limiter It is used to detect main boom angle in real time according to the data collected by angle sensors.

  • Page 173: Lowering Limiter

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.7 Lowering limiter Figure 4-33 Lowering limiter In order to prevent wire rope from being wound in the opposite direction after it is unwound completely, the lowering limit switches fitted on H1, H2 and H3 are triggered when there are only three windings of wire rope left on the drums.

  • Page 174: Hoisting Limiter

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.8 Hoisting limiter Figure 4-34 Hoisting limiter The hoisting limiter is installed to prevent the hook pulley from colliding with the boom head. Before using the crane every time, inspect the switch by lifting the hook to the upper limit and colliding with the hoisting limit switch weight.

  • Page 175: Anemometer

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.9 Anemometer The anemometer fitted on the main boom or fixed jib head can detect the wind speed on the top of the boom in real time. When the in-service wind speed exceeds 9.8m/s, the crane operation should be stopped immediately.

  • Page 176: Checklist Of Safety Device

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.4.11 Checklist of safety device Table 4-14 Checklist of safety device Prerequisite limited movements Bypass methods Movement speed 1. Turn the bypass switch clockwise until the icon 1.
  • Page 177 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Prerequisite limited movements Bypass methods Movement speed 1. Turn the bypass switch clockwise until the icon appears on the load moment 1. When bypass limiter.
  • Page 178 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Prerequisite limited movements Bypass methods Movement speed 1. Turn the bypass switch 1. When bypass clockwise until the icon switch is turned 1. The crane appears on the load moment on, the speed of movements “lift...
  • Page 179 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION (1) Once the limited movements are bypassed by bypass switch, their speeds will be reduced to about 15% of original speed. (2) Press “Setup” switch, the bypass of cutoff is valid. After the limited movement is bypassed, return the control lever for 10s, or press “Setup”...

  • Page 180: Crane Operation

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5 Crane operation 4.5.1 Preparation for operation Assemble boom sections and rear counterweight according to load capacity charts, and retract crawler carriers completely. The gradient of the ground is less than 1%, and the ground has sufficient load-bearing capacity.

  • Page 181: Valid Area Of Control Lever

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.3 Valid area of control lever To carry out a single movement, the operator must move control lever within -60°-60° areas at front, rear, left and right sides. The gridding area in the following figure is the valid area of the control lever.

  • Page 182: Setting Of Work Mode

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.4 Setting of work mode For detailed steps of setting work mode, please see Load Moment Limiter Operating Manual. CAUTION Set correct work mode in load moment limiter in accordance with actual conditions. Setting of work mode will affect the winch by the control system, otherwise accidents may occur.
  • Page 183 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Turn to left with a crawler Turn to right with a crawler Figure 4-39 Turning with a crawler CAUTION The high speed is not allowed when the crane is turning with a crawler. Differential steering Figure 4-40 Differential steering Differential steering to right:...
  • Page 184 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Turning on the spot Figure 4-41 Turning on the spot Turning to right on the spot: Depress right travel gear pedal downwards heavily, then right crawler will turn to left. Depress left travel gear pedal downwards heavily, then left crawler will turn to right.
  • Page 185 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane If crawler crane needs to turn on the slope, some treatments should be taken to the undulations to form a gentle slope curve (see the following figure), which can prevent crane’s center of gravity from deviating and load from concentrating on a section of crawler when crawler crane is traveling over undulations.

  • Page 186: Operation Of Crane Winches

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.6 Operation of crane winches 4.5.6.1 Hoisting winches Components of hoisting winch The hoisting winch consists of hydraulic motor, winch reducer, brake, lowering limiter, hoisting limiter, wire rope, main and auxiliary load hooks etc..
  • Page 187 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane (7) When the system sends out the alarm, the operator should operate the crane towards safe directions. If it is necessary to operate the crane towards dangerous directions, the operator can refer to Section 4.4.
  • Page 188 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.6.3 Derricking mechanism Components of derricking mechanism Through changing the length of wire rope reeved between derricking pulley blocks (includes derricking crown block and derricking traveling block), the derricking mechanism, via derricking winch, can adjust boom angle so as to change the working radius.
  • Page 189 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane The components of derricking mechanism will be described in the table 4-16. Table 4-16 Components of derricking mechanism Names of the components Anchoring rods Derricking traveling block Derricking crown block A-frame assy.
  • Page 190 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane If derricking mechanism does not work for a long time, turn on derricking ratchet pawl switch, and then reel off derricking winch slowly until ratchet pawl is engaged into the ratchet wheel completely.

  • Page 191: Operation Of Slewing Mechanism

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.7 Operation of slewing mechanism 4.5.7.1 Components of slewing mechanism The slewing mechanism consists of hydraulic motor, planetary gear reducer, brake, drive gear and slewing ring, etc. The superstructure can carry out 360° continuous rotation via the slewing ring which is driven by drive gear.
  • Page 192 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Figure 4-45 Fixation of slewing table Detecting device for slewing fixing pin When the fixing pin is not pulled out, it will damage the support or do an injury to the person in the vicinity of the crane if slewing motion is carried out.
  • Page 193 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Bypass switch Detecting switch for slewing fixing Slewing fixing pin Support Figure 4-46 Detecting device for slewing fixing pin 4-53...
  • Page 194 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.5.7.4 Operation of swing free running If a load hook is not positioned vertically over the load’s center of gravity before lifting operation, the operator can operate left control lever and press the “Swing free running” button on the control lever at the same time.

  • Page 195: Auxiliary Remote Control Box

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane (7) For the sake of safety, the user must check slewing ring bolts with 1800N.m tightening torque after the initial 100 operating hours. Then check and tighten them after 300 operating hours.
  • Page 196 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane The function of auxiliary remote control box is shown in the following figure. Left counterweight up Counterweight mounting Right counterweight up Spare Left counterweight down Right counterweight down Undercarriage control Spare...

  • Page 197: Rope Reeving

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.6 Rope reeving 4.6.1 Hoisting rope guidance and reeving Preparation Choose a correct rope reeving in accordance with section 2.4.3 in Chapter 2. The boom is placed straight ahead of the crane. An assistant is present to guide the hoisting rope.
  • Page 198 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane WARNING If wire rope is not reeved in according to the figure 4-50 to figure 4-52, the service life of wire rope will be shortened. Rope reeving: 10 Rope reeving: 9 Rope reeving: 8...
  • Page 199 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Rope reeving: 6 Rope reeving: 5 Rope reeving: 4 Rope reeving: 3 Figure 4-51 Reeving 55USt (50t) load hook Rope reeving: 4 Rope reeving: 3 Rope reeving: 2 Figure 4-52 Reeving 33USt (30t) load hook 4-59...
  • Page 200 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Deflection pulley on the boom head Lifting pulley on the boom head Figure 4-53 Rope reeving between deflection pulley and lifting pulley Hoisting rope guidance for tip boom is shown in the figure 4-54. The load hook on main boom is reeved in according to the Figure 4-50 –...

  • Page 201: Derricking Rope Reeving

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Rope reeving for main boom with fixed jib Rope reeving for main boom with fixed jib is shown in the figure 4-56. Rope pulley on A-frame Rope pulley on fixed jib...
  • Page 202 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Derricking traveling block Derricking crown block Note: Rope pulleys 1, 2, 3, 4, 9, 10 are the derricking upper pulleys, while rope pulleys 5, 6, 7, 8, 11 are the derricking lower pulleys.

  • Page 203: Fixation Of Rope End Point

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 4.6.3 Fixation of rope end point The rope end point must be fixed in accordance with the following steps: Step 1: insert wire rope (1) into rope lock (2) Step 2: put wire rope (1) around rope thimble (3) and then insert them together into rope lock (2) again Step 3: pull wire rope (1) tightly to make it fixed between rope thimble (3) and rope lock (2)
  • Page 204 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Right Wrong Rope length (T) is six times as much as rope diameter and it should be no less than 150mm. Rope length (S) is three times as much as rope diameter or it is 75mm.

  • Page 205: Chapter 5 Assembly And Dismantling

    For reference only. Operators manual should be consulted and adhered to. 履带起重机操作手册 Operato r’s Manual for Crawler Crane 第五章 安装说明 Chapter 5 Assembly and Dismant ling...
  • Page 206 For reference only. Operators manual should be consulted and adhered to.

  • Page 207: Safety-Technical Notes

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Chapter 5 Assembly and Dismantling 5.1 Safety-technical notes 5.1.1 Notes on assembly Make sure that the crane complies with operating requirements. Then check the positions of A-frame, anchoring rod, FA-frame and assembly sequence of boom intermediate sections one by one according to combination mode of boom.
  • Page 208 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane In transit with no load and boom lowered, the equipment clearance shall be a minimum of 4 feet for voltages less than 50 kV., and 10 feet for voltages over 50 kV., up to and including 345 kV., and 16 feet for voltages over 345 kV.

  • Page 209: Checking Wire Rope, Load Hook, Rope Pulley And Anchoring Rod

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.1.3 Checking wire rope, load hook, rope pulley and anchoring rod 5.1.3.1 Checking wire rope The ropes must be checked by an expert before assembly and after certain working period in order to detect possible damage or wear and tear at an early stage.
  • Page 210 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.1.3.4 Checking anchoring rod Check if the length of anchoring rod complies with the nominal size. Check if the surface of anchoring rod has defects. 5.1.3.5 Erecting and lowering the boom Before erecting or lowering a boom combination, ensure that the following prerequisites are met:...

  • Page 211: Assembly Of Basic Machine

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.2 Assembly of basic machine 5.2.1 Unloading of basic machine 5.2.1.1 Checks before operation Check the jobsite The ground on the jobsite must be firm and flat. If necessary, a steel plate should be padded.
  • Page 212 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Drive basic machine down off the low-loader (see the figure 5-2), or lift the basic machine away from the lower-loader with the help of an auxiliary crane, and then drive the low-loader away.
  • Page 213 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane (3) The slewing fixing pin must be unpinned prior to operating the slewing mechanism. Otherwise, the fixing device for slewing table may be damaged. 5.2.1.3 Unloading of basic machine (without crawler carriers) After basic machine reaches the jobsite, remove related fixing devices and package.
  • Page 214 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Unit: ft (mm) Figure 5-5 Raising basic machine via support cylinders Unit: ft (mm) 8'8" 2637 Figure 5-6 Supporting basic machine via support cylinders CAUTION If support cylinders are not lifted high enough, the operator can put the solid squared timbers underneath the support plates.
  • Page 215 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Push “Counterweight lifting/undercarriage auxiliary device selector switch” on the control box down to choose “undercarriage auxiliary device”. Operate horizontal cylinders and support cylinders according to the operating board as shown in the figure 5-7.

  • Page 216: Self-Assembly And Dismantling Of Crawler Carrier (Optional)

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.2 Self-assembly and dismantling of crawler carrier (optional) 5.2.2.1 Components of crawler carrier self-assembly and dismantling mechanism Crawler carrier self-assembly and dismantling mechanism consists of mounting cylinder, main boom pivot section, main boom tilting-back support, support cylinder, derricking mechanism and so on.
  • Page 217 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane (2) After crawler carrier is assembled on the undercarriage central section via mounting cylinder, the angle of main boom pivot section is large. At this time, pivot section may not be lowered by unwinding the derricking rope.
  • Page 218 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.2.3 Assembly of left crawler carrier Procedure for assembling left crawler carrier: Figure 5-10 Assembly of left crawler carrier Affirm that four pairs of folding brackets have been positioned by retaining plates (part 4 in the figure 5-17), and the adjusting blocks on the folding brackets have been removed to the lowest position.
  • Page 219 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-11 Assembling crawler carrier with the help of horizontal cylinder Table 5-2 Parts used for assembly of crawler carrier Names of the parts Names of the parts Horizontal cylinder...
  • Page 220 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.2.4 Assembly of right crawler carrier The process of assembling right crawler carrier: Confirm that left crawler carrier is in contact with the ground (see the figure 5-14). At this time, the crane is inclined slightly, and the superstructure can slew freely.
  • Page 221 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.2.2.5 Follow-up operation After left and right crawler carriers are attached on the crane, dismantle folding brackets so that the horizontal anchoring rods can be connected, and central counterweight can be assembled.

  • Page 222: Extending And Retracting Of Crawler Carrier

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.3 Extending and retracting of crawler carrier 5.2.3.1 Components of crawler carrier extending & retracting mechanism Crawler carrier extending & retracting mechanism consists of folding brackets, horizontal cylinder, crawler carrier, anchoring rods, pin spindles and so on.
  • Page 223 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-18 Enlarged view of crawler carrier extending & retracting mechanism WARNING Inspect the hose of traveling motor before extending and retracting crawler carrier, and ensure the hose is not damaged during crawler carrier extending and retracting.
  • Page 224 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.3.2 Use of adjusting block of folding bracket Adjusting block is located at the upper side of folding bracket. It is used to adjust the clearance between folding bracket and crawler carrier.
  • Page 225 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane The locked status of adjusting block is shown in the figure 5-20. Figure 5-20 Locking of adjusting block Screw out reverse bolt for enough distance via socket wrench. Screw two forward bolts by turns to push adjusting block into the required position.
  • Page 226 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.2.3.3 Operation of crawler carrier extending & retracting mechanism The crawler carriers of this crane can be extended and retracted completely. When the crane is working, the crawler carriers are usually extended completely. See the figure 5-21.
  • Page 227 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane The operation of retracting crawler carriers is shown as follows: Figure 5-22 Crawler carrier retracted completely Lower the adjusting blocks of eight folding brackets via socket wrench to proper positions where the adjusting blocks are in the same level with the upper plane of folding brackets.

  • Page 228: Assembly Of Central Counterweight

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane (4) The operation of extending and retracting crawler carrier must be performed on the flat and solid ground. And the crane must be leveled during operation. (5) Only one crawler carrier can be extended and retracted at a time.
  • Page 229 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Stop the transport vehicle with central counterweight attached at the side of basic machine, and lift the central counterweight from the vehicle via mounting cylinder. See the figure 5-23.
  • Page 230 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane When central counterweight is aligned with the undercarriage central section, attach the hooks at the upper side of central counterweight to the attachment points on the undercarriage central section.
  • Page 231 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-26 Attachment of central counterweight on the undercarriage central section Figure 5-27 Pulling down the main boom pivot section 5-25...

  • Page 232: Self-Assembly And Dismantling Of Counterweight

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane The assembly of central counterweight on the other side of crane is performed in the same way. See the figure 5-28. Figure 5-28 Assembly of central counterweight on the other side of the crane 5.2.5 Self-assembly and dismantling of counterweight 5.2.5.1 Components of counterweight self-assembly &...
  • Page 233 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-29 Counterweight self-assembly & dismantling mechanism Table 5-5 Counterweight self-assembly & dismantling mechanism Names of the components Names of the components Mounting cylinder Rear anchoring rods of A-frame Main boom pivot section...
  • Page 234 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane DANGER Make sure that the crawler carriers of the crane are extended completely before assembling rear counterweight. Unit: ft (mm) <14'9" <4500 Figure 5-30 Unloading of rear counterweight 5.2.5.3 Stacking of rear counterweight Stack counterweight plates on the counterweight base plate via mounting cylinder.
  • Page 235 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.2.5.4 Lifting of rear counterweight Move basic machine until the axes of slewing table in longitudinal direction, traveling direction and central line of counterweight are aligned with each other. See the figure 5-32. Figure 5-32 Moving basic machine Travel basic machine backwards until the counterweight lifting cylinder is positioned above the mounting hole of counterweight base plate.
  • Page 236 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane CAUTION The pin spindle of counterweight anchoring rods must be inserted towards counterweight plate. Check if the counterweight plates are stacked neatly and the counterweight anchoring rods are connected properly.
  • Page 237 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-34 Lifting of rear counterweight DANGER (1) The counterweight plates must be arranged neatly in a pile, otherwise accidents will occur.

  • Page 238: Fixation Of Mounting Cylinder

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane (2) At the initial stage, the counterweight anchoring rods must drop down under its own weight, and it must be aligned with the mounting hole of counterweight base plate.
  • Page 239 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-35 Fixation of piston rod of mounting cylinder 5.2.6.2 Fixation of mounting cylinder Procedure for fixing mounting cylinder: –...

  • Page 240: Available Boom Configurations

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.3 Available boom configurations There are two modes for ZCC1100H crawler crane: assembly mode and operating mode. For assembly mode, please refer to section 2.2. The operating mode will be described in the table 5-6.
  • Page 241 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane G15A SF-1 SF-2 Figure 5-37 Available boom configurations The components of boom frame in the figure 5-37 will be described in the table 5-7. Table 5-7 Description of components of boom frame Code Names of the components...
  • Page 242 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Code Names of the components Length Weight 6m fixed jib intermediate section 19'8" (6m) 362 lb (0.16t) FA-frame 545 lb (0.25t) Main boom tilting-back support 300 lb (0.14t) Front tilting-back support of fixed jib 102 lb (0.05t)

  • Page 243: Boom Configuration

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.4 Boom configuration 5.4.1 Main boom (S-1) 5.4.1.1 Components of main boom (S-1) Main boom, whose length varies from 42'8" (13m) to 219'10" (67m), consists of basic boom and main boom intermediate sections.
  • Page 244 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane When different length of main boom is required, crane operator only needs to disconnect main boom pivot section from main boom head, and then install main boom intermediate sections between them.
  • Page 245 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Main boom of different length can be assembled according to the figures 5-39, 5-40, 5-41. 42'8" (13m) 52'6" (16m) 62'4"...
  • Page 246 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 121'5" (37m) 131'3" (40m) 141'1" (43m) 150'11" (46m) Figure 5-40 Assembly of main boom 160'9" (49m) 170'7" (52m) 180'5" (55m) 190'4" (58m) 5-40...
  • Page 247 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane G15A G15A G15A 200'2" (61m) 210' (64m) 219'10" (67m) Figure 5-41 Assembly of main boom DANGER (1) The combination of 219'10" (67m) main boom in above figure is preferable combination.
  • Page 248 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.4.1.2 Combination of main boom anchoring rods Now, we will illustrate the connecting methods for 219'10" (67m) main boom anchoring rods. Please see the figure 5-42. 22’3''(700mm) To main boom head To derricking...
  • Page 249 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane The explanation of component numbers in the figure 5-42 is shown in the table 5-9. Table 5-9 Components of main boom anchoring rods Names of the Illustration components...
  • Page 250 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of the Illustration components 2.52’’(64mm) Ø1.97’’(50mm) Double anchoring rod 1.57’’(40mm) Ø 0.95’’(24mm) 4.41’’(112mm) Pin spindle Retaining pin 4.72’’(120mm) Pin spindle 2.76’’(70mm) Pin spindle DANGER (1) The component numbers of main boom anchoring rods given in the figure 5-42 “Combination of 219'10"...
  • Page 251 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Principle for determining the length of main boom anchoring rods: When basic boom is 42'8" (13m) long, the length of anchoring rods must be 20'6" (6240mm). There are three kinds of anchoring rods in accordance with main boom length: 9'10"...
  • Page 252 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Figure 5-43 Combination of main boom anchoring rods 5-46...
  • Page 253 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.4.1.3 Installation of intermediate tensioner Under main boom configuration, when main boom length is 210' (64m) or 219'10" (67m), the intermediate tensioner must be fitted.
  • Page 254 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Table 5-10 Components of intermediate tensioner Names of the Illustration components 2.28’’(58mm) 2-Ø1.57’’(40mm) Double anchoring rod 1.65’’(42mm) Ø1.18’’(30mm) Double anchoring rod Ø1.57’’(40mm) 0.47’’(12mm) 2-Ø1.18’’(30mm) Double anchoring rod Pin spindle 3.1’’(78mm)
  • Page 255 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Names of the Illustration components Retaining pin Pin spindle 2.64’’(67mm) DANGER The component numbers of intermediate tensioner given in the figure 5-45 “Installation of intermediate tensioner”...

  • Page 256: Main Boom With Fixed Jib (Sf-1)

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.4.2 Main boom with fixed jib (SF-1) 5.4.2.1 Components of fixed jib For “Main boom with fixed jib” configuration, main boom length varies from 101'9" (31m) to 180'5"...
  • Page 257 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Fixed jib can be assembled to required three lengths of 19'8" (6m), 39'4" (12m) and 59'1" (18m). See the figure 5-47 and table 5-11. Table 5-11 Assembly of fixed jib Assembly sequence of Assembly sequence of...
  • Page 258 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Fixed jib front anchoring rods: When fixed jib is 59' (18m) long, fixed jib front anchoring rods are composed of the following components as shown in the figure 5-48. 8.82''(224mm) To fixed jib To FA-frame...
  • Page 259 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 5-12 Components of fixed jib front anchoring rods Names of the Illustration components Pin spindle 2.1’’(53mm) Retaining pin 11.8''(300mm) Double anchoring rod 2- Ø1.38''(35mm)
  • Page 260 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of the Illustration components 1.34’’(34mm) Ø1.57’’(40mm) Double anchoring rod Ø1.38’’(35mm) 0.71’’(18mm) Pin spindle Ø1.57’’(40mm) CAUTION The component numbers of anchoring rods mentioned in “Figure 5-48 Combination of fixed jib front anchoring rods”...
  • Page 261 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 拉板组合 Anchoring rods combination 20’9’’ (6340mm) 19'8''(6m) 9'(2720mm) 9'(2720mm) 11.8''(300mm) 11.8''(300mm) 11.8''(300mm) 39'8''(12100mm) 20'9''(6340mm) 18'10''(5760mm) 39'4''(12m) 17'11''(5460mm) 9'(2720mm) 9'(2720mm) 11.8''(300mm) 11.8''(300mm) 11.8''(300mm)
  • Page 262 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane The explanation of component numbers in the figure 5-50 is shown in the table 5-13: Table 5-13 Components of fixed jib rear anchoring rods Names of the Illustration components...
  • Page 263 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Names of the Illustration components 10.9''(277mm) 2.75''(70mm) Ø1.38''(35mm) Reducing piece Ø2.36''(60mm) 4’7’’(1400mm) Double anchoring rod 2-Ø1.38’’(35mm) 5’ (1545mm) Coupling link 2- ∅1.38’’(35mm) 5’5’’(1665mm) 12’(3847mm)
  • Page 264 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane DANGER The component numbers of anchoring rods mentioned in “Figure 5-50 Combination of fixed jib rear anchoring rods (fixed jib angle = 30°)” are consistent with those in the above table, so the components of anchoring rods can be found by referring to the component numbers during assembling.

  • Page 265: Assembly And Dismantling Of Main Boom

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.5 Assembly and dismantling of main boom 5.5.1 Preparations for assembly Choose an appropriate boom configuration and corresponding anchoring rods combination according to the operational planning and load capacity charts.
  • Page 266 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Join the connecting holes with double tapered pins (1) and secure the pins with retaining pins (2). Join other connecting holes in the same way. –...
  • Page 267 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-53 Bolt preassembled main boom sections to main boom pivot section The components used in connecting main boom sections are shown in the table 5-14, and the serial numbers in the table is the same with those in figure 5-52, and figure 5-53.
  • Page 268 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.5.2.2 Assemble main boom anchoring rods and reeve in hoisting rope Connect anchoring rods of main boom intermediate sections and anchoring rods of main boom head with each other by pin spindles and secure them with retaining pins.
  • Page 269 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Move right control lever to the left to spool up derricking winch until the main boom head is raised by the derricking rope to a proper position a littler higher than the load hook, referring to figure 5-56.
  • Page 270 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.5.2.3 Fixation of derricking traveling block The machine is fitted with an automatic positioning device for derricking travelling block, which is convenient for dismantling of the pulley block. Taking the fixation of derricking travelling block as an example, illustrate the usage method of the device.
  • Page 271 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-59 Fixation of derricking traveling block Table 5-15 Fixation of derricking traveling block Description Description Guide rod Cross coupling Guide board Pin spindle Derricking travelling block...

  • Page 272: Electrical Connection To Main Boom

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.5.3 Electrical connection to main boom 5.5.3.1 Wire layout of main boom The arrangement of electrical parts on main boom is shown in figure 5-60: 3 4 5 Figure 5-60 Arrangement of electrical parts on main boom Functions of electrical parts are shown in the table 5-16:...
  • Page 273 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.5.3.2 Electrical connections to main boom To main boom cable drum A view H1 winch Anemometer To fixed jib cable drum Main boom junction box H2 winch A view...

  • Page 274: Erecting Main Boom

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Check hoisting limit switch for H2 Support and hold the hoisting limit switch weight for H2 to ensure that the switch is triggered, and then check that the icon “upper limit switch on H2” on the screen will flash and the buzzer will sound.
  • Page 275 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Figure 5-62 Raising main boom CAUTION (1) Always monitor the wire rope in process of raising main boom to make sure that the wire rope on boom head is kept in the rope groove all the time.

  • Page 276: Lowering And Dismantling Main Boom

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.5.5 Lowering and dismantling main boom 5.5.5.1 Lowering main boom – Move right control lever to the right to reel off derricking winch, and main boom will be lowered gradually.

  • Page 277: Assembly And Dismantling Of Main Boom With Fixed Jib

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.6 Assembly and dismantling of main boom with fixed jib 5.6.1 Preparation for assembly The crane is leveled. The main boom has been installed. The counterweight has been mounted according to requirements.
  • Page 278 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Figure 5-64 Assembly of fixed jib According to actual condition, choose and assemble several 6m fixed jib intermediate sections (G33). All fixed jib intermediate sections are connected with double tapered pins (5), secured the pins on both sides with retaining springs (6) as follows: Figure 5-65 Assembly of fixed jib The components used to assemble fixed jib are shown in the figure 5-17.
  • Page 279 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Table 5-17 Components used to assemble fixed jib Names of the Illustration components Pin spindle 4.49" (114mm) Retaining plate 3.23"...
  • Page 280 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Lift FA-frame using an auxiliary crane. Joint the rear tilting-back support (G75) and front tilting-back support (G74) respectively to hinge lug (A) on main boom head and hinge lug (B) on the fixed jib pivot section.
  • Page 281 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Outer pipe Inner pipe Pin spindle End of inner pipe Figure 5-67 Assembly of fixed jib CAUTION (1) Check whether the spring is mounted in the outer pipe of front tilting-back support of fixed jib.

  • Page 282: Electrical Connection To Fixed Jib

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.6.3 Electrical connection to fixed jib 5.6.3.1 Wire layout of fixed jib Mounting position of electrical parts on fixed jib is shown in the figure 5-68: Figure 5-68 Wire layout of fixed jib Description of electrical parts is shown in table 5-18: Table 5-18 Functions of electrical parts...
  • Page 283 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane To fixed jib cable drum A view H2 winch Fixed jib junction Anemometer A view Figure 5-69 Wire layout of fixed jib 5.6.3.2 Function check Put the key into the ignition key switch, and then turn it clockwise to the 1 position, the power...

  • Page 284: Erecting Main Boom With Fixed Jib

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.6.4 Erecting main boom with fixed jib 5.6.4.1 Prerequisites All electrical connections have been established correctly. Check limit switches for functional work. Check warning light on the boom head. Check hoisting limit switch.
  • Page 285 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.6.4.3 Raising main boom with fixed jib Move right control lever to the left to raise the boom until it reaches required position, which is shown in the figure 5-70.
  • Page 286 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.6.4.4 Lowering fixed jib Move right control lever to the right to unwind derricking rope, the boom will be lowered down. When main boom is lowered to 35°-30° position, stop lowering main boom. At this time, unwind hoisting rope to lower the hook down to the ground.

  • Page 287: Assembly And Dismantling Of Tip Boom

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.7 Assembly and dismantling of tip boom Figure 5-71 Assembly of tip boom The procedures for assembly of tip boom are shown in figure 5-71: –...

  • Page 288: Transport Weights And Dimensions Of Main Components

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane 5.8 Transport weights and dimensions of main components The transport weights and dimensions of main components of ZCC1100H crawler crane are shown in the table 5-19: Table 5-19 Transport weights and dimensions of main components Names of the Weight...
  • Page 289 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane Names of the Weight Dimensions Qty. Remarks components (lb*1000) Main boom pivot section (1.25t) Main boom head (1.2t) 3m main boom 0.55 intermediate...
  • Page 290 For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Names of the Weight Dimensions Qty. Remarks components (lb*1000) Load hook 3.35 (100T) (1.52t) Load hook 2.71 (50T) (1.23t) Load hook 1.72 (30T) (0.78t) Load hook 0.57 (8T)

  • Page 291: Transport Means And Safety Precautions For Transport

    For reference only. Operators manual should be consulted and adhered to. Operator’s Manual for Crawler Crane Operator’s Manual for Crawler Crane 5.9 Transport means and safety precautions for transport 5.9.1 Safety precautions for transport After crawler crane is dismantled, it can be transported by a low-loader, train or by other transport equipment for a long distance.

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