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XCMG QAY220 Operation Manual

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QAY220 All Terrain Crane Operation Manual
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  • Page 1 QAY220 All Terrain Crane Operation Manual Courtesy of CraneMarket.com...
  • Page 2 Courtesy of CraneMarket.com...
  • Page 3 QAY220 All Terrain Crane Operation Manual QAY220 All Terrain Crane Operation Manual Date The operation manual is part of the crane. Always keep on hand!. Please read it carefully before operating the crane. This equipment is designed and manufactured by complying with the standards of GB 6067.1-2010 Safety rules for lifting appliances,...
  • Page 4 Courtesy of CraneMarket.com...

  • Page 5: Table Of Contents

    QAY220 All Terrain Crane Operation Manual Contents Preface ..............................ⅤII Chapter 1 General safe operating practices ....................1-1 1-1 Highway traffic regulations ......................1-1 1-2 Axle load ............................1-1 1-3 Transport of hook block ....................... 1-2 1-4 Crew ............................. 1-2 1-5 Safety technical notes ........................
  • Page 6 2-1 Composition and meaning of crane model .................. 2-1 2-2 Main application and working scope ................... 2-1 2-3 Operating conditions ........................2-1 2-4 Main features of QAY220 All terrain crane ................. 2-2 2-5 Terminology ..........................2-3 2-6 Main parts ............................ 2-5 Chapter 3 Main technical specifications ....................
  • Page 7 QAY220 All Terrain Crane Operation Manual 4-5-2 Boom extending and retracting procedure ................4-13 4-5-3 Notes on operation ....................... 4-16 4-6 Boom elevating operation ......................4-17 4-6-1 Operating method (right lever) .................... 4-17 4-6-2 Relationship among boom angle, total rated load and working radius ........ 4-18 4-6-3 Notes on operation .......................
  • Page 8 QAY220 All Terrain Crane Operation Manual 5-6 Re-reeving winch rope ......................5-21 5-6-1 Working conditions ......................5-21 5-6-2 Reeving method ........................5-23 5-6-3 Installation of the weight ...................... 5-27 Chapter 6 Crane electric system ........................ 6-1 6-1 Safety control ..........................6-1 6-2 Operation control .........................
  • Page 9 QAY220 All Terrain Crane Operation Manual 8-1-5 Notes ............................8-2 8-2 Lowering limiter (counter) ......................8-3 8-3 Safety switch of electric proportional system ................8-4 8-4 Electronic level gauge........................8-5 8-5 Hydraulic safety valve ........................ 8-6 8-6 Hydraulic oil filter clogged warning lamp.................. 8-6 8-7 Low oil pressure warning lamp ....................
  • Page 10 Courtesy of CraneMarket.com...

  • Page 11: Preface

    This manual is suitable for QAY220 All terrain crane. Methods about operation, inspection and adjustment of QAY220 All terrain crane as well as erecting and transporting accessories are supplied in the manual. Lifting operation is a work that may be involved with risk, in order to ensure safety while give full rein to the crane high performance, please read, understand and use the operating instructions in this manual.
  • Page 12 QAY220 All Terrain Crane Operation Manual Symbols and their meanings are as follows: ——It means there is an imminent danger, serious injury or death will be caused if it could not be avoided. ——It means there is a potential danger, injury or death may be caused if it could not be avoided.

  • Page 13: Chapter 1 General Safe Operating Practices

    2. Short distance job site transfer During short distance job site transfer, the deadweight of QAY220 All Terrain Crane does not include the weight of all optional parts and parts transported along with the machine. In special case, a counterweight slab of 22 t, jib, auxiliary winch or various hook blocks may be taken on board.

  • Page 14: Transport Of Hook Block

    QAY220 All Terrain Crane Operation Manual 1-3 Transport of hook block Chapter 1 1. Transport of hook block for short distance transfer A hook block may be carried on board when the crane is transferred for short distance to another job site. The hook should be held...

  • Page 15: Job Site Requirements

    QAY220 All Terrain Crane Operation Manual 1-5-2 Job site requirements Chapter 1 The following should be met on job site: 1. Supports (outrigger floats) should be The crane must be set up on a firm and level supporting surface, no risk of extended in place stipulated in load charts;...

  • Page 16: Planning The Job

    QAY220 All Terrain Crane Operation Manual 1-5-4 Planning the job Chapter 1 As well as a fully functioning crane and well qualified personnel, operational planning is an important precondition for safe and reliable crane operation. If the crane operator does not possess...

  • Page 17: Operation Precautions

    QAY220 All Terrain Crane Operation Manual 1-7 Operation precautions Chapter 1 1. Mistakes in calculating lifting capacity can cause accidents. So the following should be taken into consideration: • The lifting load listed in load chart includes the weight of the hook, rope and slings.

  • Page 18: Operations Under Special Working Conditions

    QAY220 All Terrain Crane Operation Manual 1-8 Operation under special working conditions Chapter 1 1-8-1 Slopes and trenches The crane must not be set up too close to slopes or trenches, and depending on the type Safe distance D is measured from the...

  • Page 19: Influence Of Wind

    QAY220 All Terrain Crane Operation Manual 4. An insulator must always be between the load hook of the crane and the tackle, and it is Chapter 1 prohibited to remove the insulator; 5. If possible, transport larger loads in horizontal direction, to reduce high frequency absorption;...

  • Page 20: Safety Information

    QAY220 All Terrain Crane Operation Manual 1-9 Safety information Chapter 1 1-9-1 Minimum distance between any part of the crane and electrical overhead wires When operate crane near power electrical lines, the safe clearances keeping boom, slings, auxiliary tool, rope, tag line and load from the lines should comply with those shown in table 1-1.

  • Page 21: Permissible Ground-Bearing Load

    QAY220 All Terrain Crane Operation Manual 1-9-2 Permissible ground-bearing load Chapter 1 When the crane is supported, the outriggers exert considerable pressure F onto the ground. In certain cases, individual outrigger must take up the weight of the crane as well as the weight of the load and this is transferred to the ground.

  • Page 22: Wind Speed Description

    QAY220 All Terrain Crane Operation Manual 1-9-3 Wind speed description Chapter 1 During operation, the instantaneous wind velocity at the working height is taken as the velocity of wind that works against the crane. The instantaneous wind speed for 3 seconds is converted by the average wind velocity for 10 minutes at a height of 10 meters above the ground multiplying 1.5 of conversion factor.

  • Page 23: Wind Pressure-Height Conversion Factor K

    QAY220 All Terrain Crane Operation Manual 1-9-4 Wind pressure-height conversion factor K Chapter 1 Influence of the wind on the crane: the higher the boom above the ground, the larger the wind pressure as well as the wind velocity. When calculating the wind pressure for crane operation, if the boom length is less than 50 m, 125N/m is taken as the wind pressure for calculation;...

  • Page 24: Emergency Methods

    QAY220 All Terrain Crane Operation Manual 1-10 Emergency methods Chapter 1 1-10-1 Emergency methods when natural disaster occurs When natural disaster comes, accident may occur if no proper and correct measures are taken, even if the crane is out of service. For example, thunderstorm, gale and earthquake will endanger the crane, i.e.

  • Page 25: Emergency Methods When Accident Occurs

    QAY220 All Terrain Crane Operation Manual 1-10-2 Emergency methods w hen Chapter 1 accident occurs Not observing the above points can lead 1. Fall from height: first avoid secondary to fatal accidents and damage. injury caused by moving the victim blindly, and...

  • Page 26: Safety Protective Equipments

    QAY220 All Terrain Crane Operation Manual 1-11 Safety protective equipments Chapter 1 Safety protective equipments (helmet) should be worn by operator, signaler and management working on or around the crane. Safety belt should be worn when perform work above the ground. In specified working...

  • Page 27: Indication Plates

    QAY220 All Terrain Crane Operation Manual 1-14 Indication plates Chapter 1 1-14-1 Nameplate Nameplate is fixed outside the door of the operator’s cab (refer to Fig. 1-1), chassis nameplate is fixed on the right front side of chassis frame, VIN is marked on the nameplate and below the chassis nameplate (refer to Fig.
  • Page 28 QAY220 All Terrain Crane Operation Manual Chapter 1 Fig. 1-2 Location of chassis nameplate and VIN 1-16 General safe operating practices Courtesy of CraneMarket.com...

  • Page 29: Indicating Plates

    QAY220 All Terrain Crane Operation Manual 1-14-2 Indicating plates Chapter 1 On reducer, hydraulic oil tank, etc. Indicating plate includes model, quantity, replacement time and notes of lubricating oil added for reducer. Fig. 1-3 Winch system indicating plate General safe operating practices 1-17 Courtesy of CraneMarket.com...
  • Page 30 QAY220 All Terrain Crane Operation Manual Chapter 1 Fig. 1-4 Hydraulic oil indicating plate 1-18 General safe operating practices Courtesy of CraneMarket.com...
  • Page 31 QAY220 All Terrain Crane Operation Manual Chapter 1 Fig. 1-5 Slewing system indicating plate General safe operating practices 1-19 Courtesy of CraneMarket.com...

  • Page 32: Warning Plates

    QAY220 All Terrain Crane Operation Manual 1-14-3 Warning plates Chapter 1 Various warning plates are fixed on crane boom and counterweight, etc. so as to guide operator for safe operation and avoiding damage. 1-20 General safe operating practices Courtesy of CraneMarket.com...
  • Page 33 QAY220 All Terrain Crane Operation Manual Table 1-5 Explanation of warning plates Chapter 1 Graphic symbols Explanation Falling danger! It is forbidden to stand under boom. Keep away from the boom. Dangerous area. It is forbidden to stand under boom.
  • Page 34 QAY220 All Terrain Crane Operation Manual Graphic symbols Explanation Chapter 1 During lifting operation, no person is allowed to stay in the driver’s cab. Keep away from the extending outrigger. Be careful to avoid falling. Precautions. 1-22 General safe operating practices...

  • Page 35: Use The Manual Correctly

    QAY220 All Terrain Crane Operation Manual 1-15 Use the manual correctly Chapter 1 1. It is an integral part of the crane. 2. Keep it properly in the working life of the product. 3. Pass it to any successive owner of the product.
  • Page 36 QAY220 All Terrain Crane Operation Manual Chapter 1 1-24 Courtesy of CraneMarket.com...

  • Page 37: Chapter 2 Applications And Features

    QAY220 All Terrain Crane Operation Manual Chapter 2 Applications and features 2-1 Composition and meaning of crane model Chapter 2 QA Y220 Code designated by manufacturer Application code: All terrain crane (QA) Structural character code: lifting class Serial number, indicated by 0, 1, 2...

  • Page 38: Main Application And Working Scope

    2. The tilt of the slewing ring installation plane: it should be no more than 1% with no load; 3. Environmental temperature: -20℃～+40℃; 4. Working wind force: below grade 5 (wind velocity 14.1 m/s). 2-4 Main features of QAY220 All terrain crane QAY220 All terrain crane is mounted site. Large outrigger span, stable operation and excellent lifting performance.

  • Page 39: Terminology

    QAY220 All Terrain Crane Operation Manual and stable inching control. operating environment. It may be tilted 23°, 4. Hydraulic valve block of integrated widening the field of vision. Curtain, ultraviolet- module design and pump-controlled open proof glass and heater are optional to meet variable displacement system contribute to high various customer’s demands.
  • Page 40 QAY220 All Terrain Crane Operation Manual 2-5-6 Outrigger span It means the distance between two outrigger floats, such as transverse span b and longitudinal span a shown in the figure below. Transverse span b: the distance between outrigger vertical axes measured by the lines vertical to Chapter 2 the longitudinal moving direction of the crane.

  • Page 41: Main Parts

    QAY220 All Terrain Crane Operation Manual 2-6 Main parts Chapter 2 Applications and features Courtesy of CraneMarket.com...
  • Page 42 QAY220 All Terrain Crane Operation Manual Chapter 2 Name Name Name Driver’s cab Camera viewing systems Tire Special chassis Outrigger Outrigger float Slewing ring Operator’s cab Elevating cylinder Auxiliary winch Boom Turntable Cover Main winch Superstructure engine Applications and features...
  • Page 43 QAY220 All Terrain Crane Operation Manual Chapter 2 Courtesy of CraneMarket.com...
  • Page 44 QAY220 All Terrain Crane Operation Manual Chapter 2 Courtesy of CraneMarket.com...

  • Page 45: Chapter 3 Main Technical Specifications

    1. Refer to Fig. 3-1 and Fig. 3-2 for Outline; 2. Refer to Tables 3-1~3-4 for Technical specifications; 3. Refer to QAY220 All Terrain Crane Rated Lifting Load Manual for Rated lifting loads, Lifting height chart and Crane working areas.
  • Page 46 QAY220 All Terrain Crane Operation Manual Chapter 3 Fig. 3-1 XZJ5721JQAY220/XZJ5723JQZ220 All terrain crane outline in travel configuration (GVW 72 t) Main technical speciations Courtesy of CraneMarket.com...
  • Page 47 QAY220 All Terrain Crane Operation Manual Table 3-1 Main technical data of QAY220 AT in travel configuration Parameter Allowance Category Item Unit XZJ5721JQAY220 XZJ5721JQAY220 ±1% Overall length 15850 3000 -1%～0 Overall width 3970 -1%～0 Overall height Dimension ±1% 1650+3200+1650+2300+1650 Wheel base 2590/2590/2590/2590/2590/2590 ±1%...
  • Page 48 QAY220 All Terrain Crane Operation Manual Table 3-2 Main technical data of QAY220 AT in travel configuration Parameter Allowance Item Unit XZJ5723JQZ220 XZJ5723JQZ220 Overall length 15850 ±1% 3000 Overall width -1%～0 ≥-1%, but not more than 4000 3970 Overall height...
  • Page 49 QAY220 All Terrain Crane Operation Manual Chapter 3 Fig. 3-2 XZJ5726JQZ220 All terrain crane outline in travel configuration Main technical speciations Courtesy of CraneMarket.com...
  • Page 50 QAY220 All Terrain Crane Operation Manual Table 3-3 Main technical data of QAY220 AT in travel configuration Parameter Allowance Item Unit XZJ5726JQZ220 XZJ5726JQZ220 Overall length 15850 ±1% Overall width 3000 -1%～0 ≥-1%, but not more than 4000 Overall height 3970...
  • Page 51 QAY220 All Terrain Crane Operation Manual Table 3-4 Main technical data for lifting operation Item Unit Parameter Allowance Category ±5% Max. total rated lifting capacity ±1% Min. rated working radius ±1% 5087 Turning radius at turntable tail (counterweight) ±5% kN·m 6774/2752 Max.

  • Page 52: Structure And Specifications Of Main Parts

    QAY220 All Terrain Crane Operation Manual Auxiliary winch system 3-2 Structure and specifications of Model: GFT80W3B77-46 planetary reducer main parts Reduction ratio: 76.68 1. Superstructure engine Motor: A2FE160 constant displacement Type: in-line, six-cylinder, supercharging motor intercooler, compliant with Euro II standard.
  • Page 53 QAY220 All Terrain Crane Operation Manual Chapter 3 Courtesy of CraneMarket.com...
  • Page 54 QAY220 All Terrain Crane Operation Manual Chapter 3 3-10 Courtesy of CraneMarket.com...

  • Page 55: Chapter 4 Crane Operation

    QAY220 All Terrain Crane Operation Manual Chapter 4 Crane operation 4-1 Operation of engine Independent engine is equipped for superstructure. Electric controlled engine of TAD720VE made by VOLVO is selected. It is specialized for construction machinery, with features of low noise, compact structure and powerful output torque.

  • Page 56: Starting Engine

    QAY220 All Terrain Crane Operation Manual 4-1-1 Starting engine Turn on the main power switch first, and then insert the starting key into the starting If the engine can’t be started for switch, and turn it clockwise to position Ⅰ to turn 3 attempts, stop starting and check the on power source.

  • Page 57: Preheating Engine

    QAY220 All Terrain Crane Operation Manual 4-1-2 Preheating engine The engine should be preheated under Using the engine after starting without idle speed after starting. Only 60℃ of water preheating will lead to serious wear and temperature is reached, can the engine run. In reduce the working life of engine.

  • Page 58: Notes On Operation

    QAY220 All Terrain Crane Operation Manual 4-1-4 Notes on operation 1 . D u r i n g o p e r a t i o n , o b s e r v e w a t e r temperature gauge, oil pressure gauge and ammeter for correct readings.

  • Page 59: Operation Of Pto

    QAY220 All Terrain Crane Operation Manual 4-2 Operation of PTO 4-2-1 Engaging PTO Start engine, and then press PTO switch to Before engaging PTO, make sure that all engage the PTO. control buttons of chassis are in original state. Air pressure is more than 0.45Mpa.

  • Page 60: Acceleration

    QAY220 All Terrain Crane Operation Manual 4-3 Acceleration 4-3-1 Operating method Independent superstructure engine system is available for supplying power to lifting operation. Acceleration makes engine speed up and down by hydrostatic pressure oil. Depress the accelerator pedal in operator's cab, and the speed will be increased in engine, winch as well as in boom telescoping, boom elevation and slewing operation.

  • Page 61: Operation Of Winches

    QAY220 All Terrain Crane Operation Manual 4-4 Operation of winches 4-4-1 Operation of main winch (right lever) Push the right lever forward, the hook block will lower; pull it backward, the hook block will raise. The raising and lowering speeds are adjusted by the control lever and accelerator. After main winch high-speed switch is pressed, the hoisting speed will increase.

  • Page 62: Operation Of Auxiliary Winch (Left Lever)

    QAY220 All Terrain Crane Operation Manual 4-4-2 Operation of auxiliary winch (left lever) Push the left lever forward, the hook block will lower; pull it backward, the hook block will raise. The raising and lowering speeds are adjusted by the control lever and accelerator.

  • Page 63: Notes On Operation

    QAY220 All Terrain Crane Operation Manual 4-4-3 Notes on operation 1. Lift up loads in the vertical direction only. Avoid side-loading or dragging loads on the ground. 2. Do not abruptly move the winch control lever. 3. Before operation, confirm that the winch brake is in proper order.

  • Page 64: Boom Telescoping Operation (Left Lever)

    QAY220 All Terrain Crane Operation Manual 4-5 Boom telescoping operation 4- Operating method (left lever) Before operation, press the lower end of the telescoping/auxiliary winch selector switch on instrument panel. Boom telescoping operation can be controlled automatically and manually. The automatic method is recommended.
  • Page 65 QAY220 All Terrain Crane Operation Manual 1. Automatic telescoping mode The automatic telescoping operation can be realized through selecting boom length telescoping code on the display and moving the left control lever to the left or right. Chapter 4 Fig. 4-9 Automatic telescoping mode...
  • Page 66 QAY220 All Terrain Crane Operation Manual 2. Manual telescoping mode When manual telescoping mode is selected, the cylinder pin and boom pin operations should be done slowly and cautiously. The operations can be finished through the selection of the boom length telescoping code with the aid of “cylinder pin/boom pin selector switch”, “cylinder pin/boom...

  • Page 67: Boom Extending And Retracting Procedure

    QAY220 All Terrain Crane Operation Manual 4-5-2 Boom extending and retracting procedure Boom extending procedure: extract the cylinder pin→locate the boom position→insert the cylinder pin→extract boom pin→ extend boom→insert boom pin (locate the pin position in the forward direction ) extract the cylinder pin→locate the boom position→insert the cylinder pin→extract boom pin→...
  • Page 68 QAY220 All Terrain Crane Operation Manual Chapter 4 4-14 Crane operation Courtesy of CraneMarket.com...
  • Page 69 QAY220 All Terrain Crane Operation Manual Chapter 4 Follow the procedure above for retracting T2 and T3. Crane operation 4-15 Courtesy of CraneMarket.com...

  • Page 70: Notes On Operation

    QAY220 All Terrain Crane Operation Manual 4-5-3 Notes on operation 1. The hook block will rise or lower when the boom is telescoped. Compensate for this by simultaneously letting out or taking in the winch rope by operating right lever.

  • Page 71: Boom Elevating Operation

    QAY220 All Terrain Crane Operation Manual 4-6 Boom elevating operation 4-6-1 Operating method (right lever) Move right lever right, boom will be lowered; move it left, boom will be raised. The speed is controlled jointly by the lever and accelerator.

  • Page 72: Relationship Among Boom Angle, Total Rated Load And Working Radius

    QAY220 All Terrain Crane Operation Manual 4-6-2 Relationship among boom angle, total rated load and working radius Except under the working condition of When the boom is lowered, the working basic boom with outriggers extended fully, radius increases and the value of the total rated even no load, the boom should not be lowered load decreases;...

  • Page 73: Slewing Operation

    QAY220 All Terrain Crane Operation Manual 4-7 Slewing operation 4-7-1 Operating method (left lever) Before slewing operation, unlock the turntable lock and press down the slewing brake release switch on instrument panel. Move left lever right, turntable will turn right; move it left, turntable will turn left.

  • Page 74: Notes On Operation

    QAY220 All Terrain Crane Operation Manual 4-7-2 Notes on operation 1. Before slewing operation, make sure that the lateral span of outriggers is within the specified value. 2. Before slewing operation, first operate the turntable lock pin switch to lift up the turntable lock pin to disengage the turntable locking device (at this time, turntable lock pin out indicator comes on), and press down the lower end of slewing brake release switch on left control panel to release brake.

  • Page 75: Operation Of Tilting Operator's Cab

    QAY220 All Terrain Crane Operation Manual 4-8 Operation of tilting operator’s cab 4-8-1 Operating method Press the upper end of the operator’s cab tilting switch on the instrument panel in the operator’s cab, the cab will tilt upward. Press the lower end of the switch, the cab will lower down. The max.

  • Page 76: Operation Of Turntable Locking Device

    QAY220 All Terrain Crane Operation Manual 4-9 Operation of turntable locking device 4-9-1 Operating method Press the upper end of the turntable lock pin switch on the instrument panel in the operator’s cab, the turntable lock pin will extend out. Press the lower end of the switch, the pin will retract in.

  • Page 77: Notes On Operation

    QAY220 All Terrain Crane Operation Manual Name Name Turntable locking device Frame Turntable Slewing ring Turntable unlocked indicator lamp Turntable locked indicator lamp Turntable lock pin switch Instrument panel in operator’s cab 4-9-2 Notes on operation 1. During driving, make sure the turntable and frame are locked by the lock pin.
  • Page 78 QAY220 All Terrain Crane Operation Manual Chapter 4 4-24 Courtesy of CraneMarket.com...

  • Page 79: Chapter 5 Accessories

    5-1-2 Counterweight combination There are six counterweight slabs for QAY220, i.e. slabsⅠ, Ⅱ (2), Ⅲ and Ⅳ (2) as shown in Fig. . Weight of each slab respectively is 12.5 t (Ⅰ), 10 t (Ⅱ) ,9.5 t (Ⅲ) and 11.5 t (Ⅳ).
  • Page 80 QAY220 All Terrain Crane Operation Manual 2. Counterweight combination and assembly sequence Total weight (t) Single weight (t) Combination sequence Ⅰ＋2×Ⅱ＋Ⅲ＋2×Ⅳ 12.5+2×10+9.5+2×11.5 Ⅰ＋2×Ⅱ＋Ⅲ 12.5+2×10+9.5 Ⅰ＋Ⅱ＋Ⅲ 12.5+10+9.5 Ⅰ＋Ⅲ 12.5+9.5 3. Notes on erection • In lifting operation, different counterweight combination can be selected according to the load lifting capacity.

  • Page 81: Counterweight Erection

    QAY220 All Terrain Crane Operation Manual 5-1-3 Counterweight erection 1. Counterweight erection can be performed by using the moveable control box on the turntable with the aid of instrument panel: • Press the lower end of the counterweight working selector switch (see No. 1 in Fig. 5-3) on the instrument panel, and then the counterweight working indicator lamp (No.
  • Page 82 QAY220 All Terrain Crane Operation Manual 2. Using the switches on instrument panel in the operator’s cab to install counterweight: • Press the lower end of counterweight Only after the indicator comes on could working selector switch (No.1 in Fig. 5-3) on the next operation be performed.
  • Page 83 QAY220 All Terrain Crane Operation Manual • Press the upper end of counterweight cylinder up/down switch (No.5 in Fig. 5-3) on instrument panel to retract the counterweight cylinder; • After counterweight is installed stably, press the lower end of counterweight working selector (No.1 in Fig.

  • Page 84: Counterweight Dismantling

    QAY220 All Terrain Crane Operation Manual 5-1-4 Counterweight dismantling 1. Position the boom over rear of the vehicle by slewing the turntable; Whatever way you take, the following has to be confirmed: 2. Press the upper end of turntable lock ●...
  • Page 85 QAY220 All Terrain Crane Operation Manual Chapter 5 Fig. 5-4 Counterweight Accessories Courtesy of CraneMarket.com...

  • Page 86: Transportation Of Counterweight

    QAY220 All Terrain Crane Operation Manual 5-1-5 Transportation of counterweight 1. Transportation for a short distance within job site I t i s n o t n e c e s s a r y t o r e m o v e t h e...

  • Page 87: Jib

    QAY220 All Terrain Crane Operation Manual 5-2 Jib 5-2-1 Erecting and stowing Jib Jib consists of a quadrilateral lattice type jib base and a quadrilateral box type jib top. The jib can be operated only after outriggers are extended fully and with Two jib extensions each 8 m are optional.
  • Page 88 QAY220 All Terrain Crane Operation Manual Chapter 5 Fig. 5-6 5-10 Accessories Courtesy of CraneMarket.com...
  • Page 89 QAY220 All Terrain Crane Operation Manual 3) When use 1st jib section of 11.55 m: • Remove No. 4 pin and pin B on jib, and then disconnect the 1st jib section and the 2nd jib section by pulling line. Let the pin holes on the jib align with boom by turning the jib around No.
  • Page 90 QAY220 All Terrain Crane Operation Manual 5) When use the combination of 1st, 2nd jib section and a jib extension of 28 m: Jib extension is between 1st jib section and turning bracket, with its roller towards 2nd jib section, see Fig.
  • Page 91 QAY220 All Terrain Crane Operation Manual 7) When jib with 0° offset angle is to be used, reeve rope directly around the pulley on jib head; when jib with 15° or 30°offset angle is to be used, first set up the pulley holder, and then reeve the rope around the guider on the pulley holder and over jib head pulley successively, see Fig.
  • Page 92 QAY220 All Terrain Crane Operation Manual 30° offset angle Fig. 5-9 8) Connect jib anti-two block: insert the plug on jib into the socket in control box on boom head, and then install the limiter weight. Chapter 5 9) Install anemometer on jib: pull out the cable plug of anemometer on boom head and take the anemometer off, and then install it on its bracket on the jib in the reverse order, after that insert the cable plug into the related socket in jib control box.

  • Page 93: Notes On Operation

    QAY220 All Terrain Crane Operation Manual 5-2-2 Notes on operation 1. Extend the outriggers fully and make the frame level. 2. When erecting the jib, no person is allowed to stand in the direction that jib is to extend. 3. When erecting and stowing the jib, make sure that there are no personnel and obstacles in its swing path.

  • Page 94: Single Top

    QAY220 All Terrain Crane Operation Manual 5-3 Single top (single pulley on boom top) 1. The single top is positioned at the left side of boom and fixed by pins A and B, as Fig. 5-10 (a) shown when the vehicle travels on a road;...

  • Page 95: Auxiliary Winch

    QAY220 All Terrain Crane Operation Manual 5-4 Auxiliary winch When the vehicle travels on a road the auxiliary winch should be removed from the crane, and be transported along with the vehicle. 5-4-1 Installation of auxiliary winch 1. Insert the plate for connecting auxiliary winch system into the connecting ear on turntable tail;...

  • Page 96: Pipeline Connection

    QAY220 All Terrain Crane Operation Manual 5-4-2 Pipeline connection Auxiliary winch hydraulic pipeline is as shown in the figure below. Connect it correctly and make sure there is no leakage. Chapter 5 5-18 Accessories Courtesy of CraneMarket.com...

  • Page 97: Hook Block

    5-5 Hook block 5-5-1 Basic type and structure Four hook blocks are available for QAY220 AT. Select proper hook block according to working condition and the total rated lifting load so as to give full rein to its lifting capacity.
  • Page 98 QAY220 All Terrain Crane Operation Manual Fig. 12 Chapter 5 Fig. 13 5-20 Accessories Courtesy of CraneMarket.com...

  • Page 99: Re-Reeving Winch Rope

    QAY220 All Terrain Crane Operation Manual 5-6 Re-reeving winch rope 5-6-1 Working conditions Extend and set the outriggers. Fully retract the boom and swing it over side or rear. 1. Place the hook block on the ground by lowering the boom.
  • Page 100 QAY220 All Terrain Crane Operation Manual 3. Remove the weight from the winch rope. 4. When reeve the winch rope in the desired number of parts of line, it is not necessary to remove the pouch socket from boom head, only remove the spring pin as shown in Fig. 14 and pull out the rope from the socket, and then spool the rope around boom head and the pulley of hook block.

  • Page 101: Reeving Method

    QAY220 All Terrain Crane Operation Manual 5-6-2 Reeving method 1. When hook block of 160 t with 16 parts of line is used, reeve the rope according to the way shown in Fig. 15a; Fig. 15a 2. When hook block of 160 t with 12 parts of line is used, reeve the rope according to the way shown in Fig.
  • Page 102 QAY220 All Terrain Crane Operation Manual 4. When hook block of 100 t with 10 parts of line is used, reeve the rope according to the way shown in Fig. 15d; Fig. 15d 5. When hook block of 100 t with 9 parts of line is used, reeve the rope according to the way shown in Fig.
  • Page 103 QAY220 All Terrain Crane Operation Manual 7. When hook block of 65 t with 5 parts of line is used, reeve the rope according to the way shown in Fig. 15g; Fig. 15g 8. When hook block of 65 t with 4 parts of line is used, reeve the rope according to the way shown in Fig.
  • Page 104 QAY220 All Terrain Crane Operation Manual 10. When hook block of 30 t with 3 parts of line is used, reeve the rope according to the way shown in Fig. 15j; Fig. 15j 11. When hook block of 30 t with 2 parts of line is used, reeve the rope according to the way shown in Fig.

  • Page 105: Installation Of The Weight

    QAY220 All Terrain Crane Operation Manual 5-6-3 Installation of the weight 1. The mounting position of the over-wind cutout device weight is determined by the position in which the rope socket is attached, the anchor on the boom or that on the hook block.
  • Page 106 QAY220 All Terrain Crane Operation Manual (1) Check the direction of the twining and count the number of twining turns. (2) Lower the hook block to the ground. (If the hook block cannot be hoisted down, lower the boom.) (3) Disconnect the rope socket from the hook block (or boom head).
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  • Page 109: Chapter 6 Crane Electric System

    QAY220 All Terrain Crane Operation Manual Chapter 6 Crane electric system The electric system is supplied by the way of DC 24V, single line with negative ground. With PLC programmable controller as core, the system consists of engine control, safety...

  • Page 110: Electric System Of Operator's Cab

    QAY220 All Terrain Crane Operation Manual 6-3 Electric system of operator’s cab 6-3-1 Devices in operator’s cab Fig. 6-1 Devices in operator’s cab Name Name Name Triple-color warning lamp Working lamp Instrument panel Left lever Right lever Main power switch...

  • Page 111: Instrument Panel

    QAY220 All Terrain Crane Operation Manual 6-3-2 Instrument panel Fig. 6-2 Instrument panel Name Name Name Display Air conditioner control panel Indication instruments Switch assembly Ⅱ Oil pressure gauge Starting switch Chapter 6 Switch assembly Ⅰ and indicator assembly Emergency stop button Crane electric system Courtesy of CraneMarket.com...
  • Page 112 QAY220 All Terrain Crane Operation Manual 1. Indication instruments Fig. 6-3 Indication instruments Name Name Name Ammeter Hour meter Fuel gauge Water temperature gauge Tachometer Oil pressure gauge Chapter 6 Crane electric system Courtesy of CraneMarket.com...
  • Page 113 QAY220 All Terrain Crane Operation Manual 2. Switch assembly Ⅰ and indicator assembly Chapter 6 Fig. 6-4 Crane electric system Courtesy of CraneMarket.com...

  • Page 114: Notes On Operation

    QAY220 All Terrain Crane Operation Manual Name Name Instrument panel illuminator switch Working lamp switch Marker lamp switch Beacon lamp switch Washer switch Windshield wiper switch Roof window wiper switch Charging indicator lamp Low oil pressure indicator lamp Suction filter clogged warning lamp...

  • Page 115: Superstructure Battery

    QAY220 All Terrain Crane Operation Manual 6-4 Superstructure battery If do not use the vehicle for a long time and ambient temperature is very low, it is better to remove the battery and stow it in a warm room. 1. Notes on battery checking •...
  • Page 116 QAY220 All Terrain Crane Operation Manual Chapter 6 Courtesy of CraneMarket.com...

  • Page 117: Chapter 7 Hydraulic System

    QAY220 All Terrain Crane Operation Manual Chapter 7 Hydraulic system 7-1 Check the level of oil in hydraulic tank Check the level of oil in hydraulic tank Use the same brand oil with the one in prior to lifting operation. Add hydraulic oil...

  • Page 118: Hydraulic System Description

    QAY220 All Terrain Crane Operation Manual 7-2 Hydraulic system description The superstructure hydraulic system of QAY220 All Terrain Crane consists of two parts: the first part is open circuit, in which variable displacement double-pump is used for main and auxiliary winch, elevating and telescoping system.

  • Page 119: Main Winch Circuit

    QAY220 All Terrain Crane Operation Manual 7-3 Main winch circuit Max. pump displacement (confluence c o n d i t i o n ) i s 2 8 0 m l / r, v a r i a b l e m o t o r displacement is 200 ml/r.

  • Page 120: Auxiliary Winch Circuit

    QAY220 All Terrain Crane Operation Manual 7-4 Auxiliary winch circuit Max. pump displacement is 280 ml/r, constant motor displacement is 160 ml/r. The winch brake for winch circuit is Do not adjust the pressure valve on the constant-closed type. The brake fluid is supplied motor.

  • Page 121: Slewing Circuit

    QAY220 All Terrain Crane Operation Manual 7-5 Slewing circuit Max. pump displacement is 56 ml/r, constant motor displacement is 45 ml/r. The opening of slewing brake is controlled by a solenoid valve. If the solenoid valve is not energized, the brake is closed; if the solenoid valve is energized, the brake is opened by the action of pressure oil.

  • Page 122: Elevating Circuit

    QAY220 All Terrain Crane Operation Manual 7-6 Elevating circuit Max. pump displacement (confluence condition) is 280 ml/r. The max. system setting pressure is 10 Do not adjust the pressure valve on the MPa during boom lowering. Boom lowering balance valve. It is no necessary to depress accelerator during boom lowering, because depends on deadweight.

  • Page 123: Auxiliary Circuit

    QAY220 All Terrain Crane Operation Manual 7-8 Auxiliary circuit PLC program, it may infinitely regulate the speed of single operation or simultaneous Pressure of auxiliary circuit is supplied by operation of four executive mechanisms, no two gear pumps with displacement of 38 ml/ interference.

  • Page 124: Hydraulic Oil Tank

    QAY220 All Terrain Crane Operation Manual 7-11 Hydraulic oil tank 7-12 Specifications The main function of hydraulic oil tank Main circuit working pressure: 32Mpa (refer to nominal value in “Hydraulic is storing oil and radiating heat. It also has the function of separating air and deposit from oil.

  • Page 125: Hydraulic Oil Description

    QAY220 All Terrain Crane Operation Manual 7-13 Hydraulic oil description The suitable temperature for hydraulic system working is about 60℃. When the temperature is more than 80℃, the volume efficiency of power parts (gear pump) and the sealing performance in hydraulic system will lower sharply, especially under idle engine.
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  • Page 127: Chapter 8 Safety Devices

    QAY220 All Terrain Crane Operation Manual Chapter 8 Safety devices 8-1 Load moment indicator (LMI) 8-1-1 Working principle 8-1-2 Safety function LMI consists of a CPU, a display, a length When an overload occurs, the load moment / angle sensor, a pressure sensor, a height limiter will automatically cut the crane motions limiter and connecting cable.

  • Page 128: Notes

    QAY220 All Terrain Crane Operation Manual 8-1-5 Notes: 1. Please read LMI Operation Manual carefully before lifting operation, and observe the instructions in it. 2. Although the load moment limiter is equipped, it does not free the operator from his responsibility with regard to operating safety.

  • Page 129: Lowering Limiter (Counter)

    QAY220 All Terrain Crane Operation Manual 8-2 Lowering limiter (counter) When lifting a load below the crane level, the winch rope may be unwound excessively. When only 3～5 turns of rope left on the winch drum while winch rope is letting out, lowering limiter automatically activates to stop hook lowering, at the same time, the buzzer sounds.

  • Page 130: Safety Switch Of Electric Proportional System

    QAY220 All Terrain Crane Operation Manual 8-3 Safety switch of electric proportional system It is equipped to avoid touching control lever by mistakes to cause dangerous crane movement as access and egress operator’s cab. Before operation only the switch is turned on, the pressure in the system may be built up.

  • Page 131: Electronic Level Gauge

    QAY220 All Terrain Crane Operation Manual 8-4 Electronic level gauge When horizontal and vertical indicator lamps go out, the middle indicator in the level gauge remains light, it means that the crane has been leveled. Otherwise, it is not leveled. Level it until it is level.

  • Page 132: Hydraulic Safety Valve

    QAY220 All Terrain Crane Operation Manual 8-5 Hydraulic safety valve It is used to prevent overloading. It can cut operations that will increase the load moment (boom extending, boom lowering and hoist up) and only reserve those operations that will decrease the load moment (boom retracting, boom raising and hoist down).

  • Page 133: Low Oil Pressure Warning Lamp

    QAY220 All Terrain Crane Operation Manual 8-7 Low oil pressure warning lamp When the oil pressure in engine system is too low, the lamp comes on. At this time, stop operation. (Please refer to the engine operation manual for the pressure value).
  • Page 134 QAY220 All Terrain Crane Operation Manual Chapter 8 Courtesy of CraneMarket.com...
  • Page 135 QAY220 All Terrain Crane Operation Manual Chapter 9 General cautions in operation Chapter 9 Cautions in operating the crane are summarized here. Before starting to operate your crane, carefully read and thoroughly understand them for safe operation. Illustrations Cautions Remarks...
  • Page 136 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Check the hydraulic oil level with the crane in the travel configuration, to make sure that the specified quantity is in the tank. Check all the members for defects and abnormalities.
  • Page 137 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Move the control levers and switches without load to check for correct crane functions. If any crane operation is faulty, repair immediately. Perform the specified preoperational checks of the controller (Refer to LMI operation manual.)
  • Page 138 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 If a load must be lifted with two or more cranes, carry out the lifting operation with straight wire ropes, synchronous movements of cranes and the load on each crane must not exceed its rated load capacity.
  • Page 139 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Pay attention to the hydraulic oil temperature, and stop operation when the temperature rises above 80℃. Note that the amount of oil in the cylinders, tanks, etc. changes when the temperature changes.
  • Page 140 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Extend the outriggers to the specified position, and lock them with the lock pins. Do not abruptly move the winch control lever. During hoisting, lift the load off the ground...
  • Page 141 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Do not lower the hook block in the free- fall mode with a load suspended. Do not move the winch brake abruptly. When lowering the hook block, leave at least three turns of the winch rope on the winch drum.
  • Page 142 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Perform the operation of cylinder pin and boom pin out or in slowly. Do not abruptly move the elevating control lever, especially under load. Before swinging the boom, make sure that area in the swing path is clear off personnel and obstructions.
  • Page 143 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 While the free sliding switch is in FREE, take care to prevent the boom from drifting under tilt, wind pressure, or inertia. Do not abruptly move the swing control lever.
  • Page 144 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Do not lower the boom immediately after changing the offset to15° or 30° . B e f o r e c h a n g i n g t h e j i b o ff s e t o r extending, secure sufficient clearance above the ground by raising the boom.
  • Page 145 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Swing crane slowly about 10° to make the counterweight cylinder slide into the counterweight lifting hole. Before lifting counterweight make sure that the turntable cylinder lock pin is inserted in the lifting hole on frame positioning plate.
  • Page 146 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Clean or replace the air filter element regularly. Filter or replace the hydraulic oil regularly to keep it clean. R e p l a c e t h e g e a r o i l a n d o t h e r lubricants regularly.
  • Page 147 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 Replace the filter element regularly. Check the oil levels of the hydraulic oil, gear oil, and other lubricating oils for correct quantity, and refill as necessary. Keep all parts properly adjusted.
  • Page 148 QAY220 All Terrain Crane Operation Manual Illustrations Cautions Remarks Chapter 9 if intend to drive the crane with 72 t of weight, hook block, auxiliary winch and its rope & slings, as well as all counterweight must be removed. During travelling, the superstructure...
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  • Page 151: Chapter 10 Periodic Inspections

    QAY220 All Terrain Crane Operation Manual Chapter 10 Periodic inspections 9. Check all control systems with no load on 10-1 General Chapter 10 the crane for proper function; The crane should be kept in such a condition 10. Check all audible warning devices for as will assure the full performance of each crane normal operation;...

  • Page 152: Weekly Inspections

    QAY220 All Terrain Crane Operation Manual 10-3 Weekly inspections 10-4 Irregular inspections In general, the following should be checked If the crane has not used for more than a weekly: month but less than a year, it should be checked 1.

  • Page 153: Checklist

    QAY220 All Terrain Crane Operation Manual 10-6 Checklist Be sure to perform the preoperational inspections of • Outriggers; • Crane mechanisms: boom swinging, elevation and telescoping and rope winding; Chapter 10 • Brake systems; • Electrical system; • Safety devices.
  • Page 154 QAY220 All Terrain Crane Operation Manual Inspection item Brake: 1. Braking performance. 2. Lubrication. Rotary Joint: Chapter 10 Electrical conductivity between carbon brush and slip ring. Speed reducer and swing bearing: Slewing system 1. Oil level and contamination. 2. Cracks, deformations and oil leakage of gearbox.
  • Page 155 QAY220 All Terrain Crane Operation Manual Inspection item 5. Loose piping joints. Speed reducer: 1. Tightness of mounting bolts. 2. Noise. Chapter 10 3. Crack, deformation and leakage of gearbox. 4. Wear of bearings. 5. Lubrication. 6. Leakage. Brakes: 1. Wear of brake disc and lining.
  • Page 156 QAY220 All Terrain Crane Operation Manual Inspection item 6. If the rope socket and wedge in place. 7. Connection of the rope and rope socket. Winch system 8. Wear and cracks of rope socket boss and pin. 9. Reeve through correct sheaves.
  • Page 157 QAY220 All Terrain Crane Operation Manual Inspection item Over-wind cutout device (Height Limiter): 1. Operation. 2. Damage of wire rope for weight. 3. Installation. Chapter 10 4. Operation of solenoid valve. Operator’s Cab: 1. Tightness of nuts and bolts. 2. Function of window and door locks.
  • Page 158 QAY220 All Terrain Crane Operation Manual Inspection item 5. Loose piping and loose connections, and deteriorated hose. 6. Leakage. Control valve: 1. Operating conditions. Chapter 10 2. Tightness of piping joints. 3. Tightness of mounting bolts. 4. Leakage. Outrigger Level gauge: system 1.
  • Page 159 QAY220 All Terrain Crane Operation Manual Inspection item Accessories: (pin, clip, connecting bolt, nut, etc.) Others Damage or missing. Re-tightening of slewing ring mounting bolts: if looseness of slewing ring mounting bolts is found during monthly periodic inspection, the Chapter 10 bolts should be re-tightened in service station.
  • Page 160 QAY220 All Terrain Crane Operation Manual Chapter 10 10-10 Courtesy of CraneMarket.com...

  • Page 161: Chapter 11 Transporting And Loading Crane

    QAY220 All Terrain Crane Operation Manual Chapter 11 Transporting and loading crane Different method of transporting crane should be selected according to the actual situation; the gravity center of the whole vehicle is 2367 mm away from the slewing center, 2123...

  • Page 162: Notes On Sea Transportation

    QAY220 All Terrain Crane Operation Manual 11-3 Notes on sea transportation 1. The roll-on-roll-off ship is recommended on the crane transportation, which will save a lot of time and money. The crane could travel to the specified position on the roll-on-roll-off ship.
  • Page 163 QAY220 All Terrain Crane Operation Manual Table 11-1 Dimension and weight of parts transported along with the machine Parts Dimension (L×W×H) (mm) Weight (t) Counterweight slab A 3164×2054×910 12.5×1 Counterweight slab B 3164×2054×263 10×1 Counterweight Counterweight slab C 3164×2054×264 10×1...
  • Page 164 QAY220 All Terrain Crane Operation Manual Chapter 11 11-4 Courtesy of CraneMarket.com...

  • Page 165: Chapter 12 Hand Signs

    QAY220 All Terrain Crane Operation Manual Chapter 12 Hand signs All screw must be familiar with crane signals, such as standard hand signs, and coordinate with each other. The recommended hand signals are as follows: 12-1 General signs 1. Ready (Attention) 2.
  • Page 166 QAY220 All Terrain Crane Operation Manual 5. Hoist down With arm extended downward 30° against the body, fingers extended, move hand in small horizontal circles. 6. Hook block moves this way With forearm vertical, palms facing outwards; forearms move slowly towards the direction of load Chapter 12 movement.

  • Page 167: Dedicated Signs

    QAY220 All Terrain Crane Operation Manual 9. Emergency stop! 10. Dog everything Both arms bent in front of chest, Clasp hands in front of forehead. fingers extended, palm down, outstretch arm horizontally. Chapter 12 12-2 Dedicated signs 1. Raise boom 2.
  • Page 168 QAY220 All Terrain Crane Operation Manual 3. Swing boom Arm extended points to the slewing direction of boom. With fingers closed, thumb pointing upward, move hand by taking wrist as an axis. 4. Extend boom 5. Retract boom Chapter 12...
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