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XCMG XCT80 Operation Manual

Truck crane
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Summary of Contents for XCMG XCT80

  • Page 1 Ｘ Ｃ Ｔ８０　Ｔｒｕｃｋ　Ｃ ｒａｎｅ　Ｏｐｅｒａｔｉｏｎ　Ｍａｎｕａｌ Courtesy of CraneMarket.com...
  • Page 2 XCT80 Truck Crane Operation Manual XCT80 Truck Crane Operation Manual Vehicle identification number (VIN) Date of production The product service manual is part of the product, and should always be placed handy for future reference. Please read the product service manual before using the product.

  • Page 3: Table Of Contents

    XCT80 Truck Crane Operation Manual Contents Preface .................................Ⅸ Chapter1 Properly use the product manual ....................1-1 Chapter2 Crane logo ..........................2-1 2-1 Composition and meaning of product models ................2-1 2-2 Product nameplate ........................2-1 2-3 Chassis nameplate ........................2-2 2-4 Crane performance label ......................
  • Page 4 5-1-2 Main characteristics of XCT80 truck crane ................5-1 5-2 Conditions of use ......................... 5-1 5-3 XCT80 truck crane technical parameters and rated lifting weight chart ........5-1 5-4 Crane main structure performance parameters ................5-29 Chapter6 Components and functions of lower crane portion ..............6-1 6-1 General overview .........................
  • Page 5 XCT80 Truck Crane Operation Manual 6-1-8 Electrical system ........................6-1 6-1-9 Auxiliary system ........................6-1 6-2 Main components introduction ....................6-3 6-3 Cab and protective device ......................6-4 6-3-1 The cab interior equipments ....................6-4 6-3-2 Main function introduction of meters, switches and lights in the cab ........ 6-15 6-3-3 Other device ........................
  • Page 6 XCT80 Truck Crane Operation Manual 8-1-3 Upper crane portion control room and rotary bearing system ..........8-1 8-1-4 Upper crane hydraulic system ....................8-1 8-1-5 Upper crane portion electric system ..................8-2 8-2 Main component introduction ..................... 8-3 8-3 Operating cab ..........................8-5 8-3-1 Electric device ........................
  • Page 7 XCT80 Truck Crane Operation Manual 9-3-5 Auxiliary crane arm storage ....................9-15 9-4 Mounting and dismounting of balance weight ................9-16 9-4-1 Operating Precautions ......................9-16 9-4-2 Balance weight combination ....................9-16 9-4-3 Mounting balance weight ....................9-17 9-4-4 Dismounting balance weight ....................9-20 9-5 Mounting and dismounting of arm end single pulley ..............
  • Page 8 XCT80 Truck Crane Operation Manual 10-4-5 Fold and unfold vertical outrigger .................. 10-18 10-4-6 Leveling crane ......................... 10-19 10-5 Throttle operation ........................10-19 10-5-1 Operating precautions ..................... 10-19 10-5-2 Operating method ......................10-20 10-6 Lifting mechanism operation ....................10-21 10-6-1 Operating precautions ..................... 10-21 10-6-2 Main lifting mechanism operation (right handle) ............
  • Page 9 XCT80 Truck Crane Operation Manual 12-2-1 Inspection of steel structure bearing weight ..............12-7 12-2-2 Daily inspection ........................ 12-8 12-2-3 Weekly inspection ......................12-8 12-2-4 Inspection for unusual use ....................12-9 12-2-5 Test requirements ......................12-9 12-3 Wire rope inspection ......................12-10 12-4 Hook inspection ........................
  • Page 10 XCT80 Truck Crane Operation Manual VIII Courtesy of CraneMarket.com...

  • Page 11: Preface

    XCT80 Truck Crane Operation Manual Preface Cordially thanks to the trust and recognition of XCMG brands, and the use of the truck crane produced by XCMG heavy machinery Co., Ltd. The operating service manual is applicable to XCT80 truck crane.
  • Page 12 XCT80 Truck Crane Operation Manual Signs and their meanings: ——The warning word "Danger" indicates the impending dangerous situation. If not avoided, it could result in death or serious injury. ——The warning word "Warning" indicates the potentially hazardous situation. If not avoided, it could result in death or serious injury.

  • Page 13: Chapter1 Properly Use The Product Manual

    XCT80 Truck Crane Operation Manual Chapter 1 Properly use the product manual 1. Product instruction is a component of the product. Please safekeeping it for use in the product life period. 2. When you transfer this crane, product instruction together with the product should be simultaneously transferred to the new customer.
  • Page 14 XCT80 Truck Crane Operation Manual Courtesy of CraneMarket.com...

  • Page 15: Chapter2 Crane Logo

    XCT80 Truck Crane Operation Manual Chapter 2 Crane logo 2-1 Composition and meaning of product models QZ 80K Enterprise custom code Special purpose vehicle use feature code: truck crane Structure feature code: crane lifting truck Product serial number: successively using the number 0, 1, 2 ...

  • Page 16: Chassis Nameplate

    XCT80 Truck Crane Operation Manual 2-3 Chassis nameplate The chassis nameplate is mounted on the right side front of the chassis frame, and VIN code is located on the product nameplate and under the chassis nameplate(see figure 2-1 and 2-2 )

  • Page 17: Crane Performance Label

    XCT80 Truck Crane Operation Manual 2-4 Crane performance label The crane performance label （Performance of being equipped with 3.5t balance weight）is installed on the right side in control room so that it is convenient to observe for the operator (see figure 2-1).
  • Page 18 XCT80 Truck Crane Operation Manual Figure2-3 Warning label positions schematic Crane logo Courtesy of CraneMarket.com...
  • Page 19 XCT80 Truck Crane Operation Manual Table 2-1 Warning label instructions Graphical sign Instruction When operating the slewing, please keep a certain safety distance away f r o m t h e m a c h i n e t o a v o i d t h e extrusion.
  • Page 20 XCT80 Truck Crane Operation Manual Courtesy of CraneMarket.com...

  • Page 21: Chapter3 Basic Safety Instructions

    Chapter 3 Basic safety instructions 3-1 Properly use the crane slewing, luffing or the arm stretching; 4. Drawing away the connected object XCT80 truck crane (the following is using the crane; abbreviated crane) is developed according to 5. Two hooks operation;...
  • Page 22 XCT80 Truck Crane Operation Manual ground, not suspended; 3-1-2 General requirements of the crane safety operation b. Switch on the operation mechanism brake or other safety device; The crane safety operation general- - c. Lift the lifting appliance to the specified requirements as follows: location;...
  • Page 23 XCT80 Truck Crane Operation Manual 10. When the wind speed exceeds the lifting appliance weight and lifting steel wire prescribed maximum work speed, prohibit the rope weight are 100kg, so the actual lifting crane operation. weight of the crane does not exceed 80000- 11.

  • Page 24: Personnel Selection And Qualification

    XCT80 Truck Crane Operation Manual 3-2 Personnel selection and 3-2-2 Crane operator qualification 1. Duties 3-2-1 Assignment personnel One is responsible for the crane safe The assignment personnel shall have the operation according to products specification following responsibilities: and safe working system provided by our a.

  • Page 25: Slingers

    XCT80 Truck Crane Operation Manual for the crane operator is control, operation and the crane adjustment,so that operators and other personnel around the crane are all not in danger. If not achieve this goal, our company is willing to offer you the following important safety...

  • Page 26: Command Personnel

    XCT80 Truck Crane Operation Manual command personnel must transmit signal to the 3-2-4 Command personnel driver and visual or auditory signals are both 1. Duties The command personnel should have the During the crane machine work, if the responsibility of passing signals from slingers responsibilities of commanding the crane to the driver.

  • Page 27: Installation Personnel

    XCT80 Truck Crane Operation Manual 3-2-5 Installation personnel 3-2-6 Maintenance personnel 1. Duties 1. Duties The installation personnel is responsible The maintenance personnel are responsible for mounting the crane machine according to the for maintenance of the crane machine and safety installation plan and product manual, when need use of the crane machine and normal operation.

  • Page 28: Personnel Safety Equipment

    XCT80 Truck Crane Operation Manual 3-3 Personnel safety equipment 1. Choose suitable things according to the work site condition, such as safety helmets, safety gloves, safety glasses, safety belt, safety boots and hearing protection device; 2. Check safety equipment before and after the work, and have maintenance according to the prescribed procedure or replace if necessary;...

  • Page 29: Crane Driving Safety Instructions

    XCT80 Truck Crane Operation Manual 3-5 Crane driving safety instructions 3-5-1 Road traffic rules When the crane is driving on the road, one should obey the national and local road traffic rules. Before the crane is driving on the road, one must ensure that the complete crane quality, axle load and appearance size are in the scope of vehicle license provisions (pecific requirement details see operation...

  • Page 30: Passengers On Driving Crane

    XCT80 Truck Crane Operation Manual 3-5-3 Passengers on driving crane 3-6 Crane operation safety----- instructions During the crane driving, the cab is---- licensed to carry two persons, and prohibit carry Please be careful to choose safe space for the people outside the cab.
  • Page 31 XCT80 Truck Crane Operation Manual 3-11 Courtesy of CraneMarket.com...
  • Page 32 XCT80 Truck Crane Operation Manual 3-12 Courtesy of CraneMarket.com...

  • Page 33: Chapter4 Construction Instructions

    XCT80 Truck Crane Operation Manual Chapter 4 Construction instructions 4-1 Planning To ensure the crane in the best working condition, besides the operator must pass the professional training and obtain the qualification certificate, planning before using the crane is the important premise of safety operation.

  • Page 34: Crane Operation Management

    XCT80 Truck Crane Operation Manual 4-2 Crane operation management 4-2-1 Safe working system understood by including the crane operators. k. Should timely report and record the The crane safe working system should be happened faults and accidents. established, whether for individual work or a l.

  • Page 35: Crane Operation Plan

    XCT80 Truck Crane Operation Manual 4-2-2 Crane operation plan 4-3 Crane settings The operation plan is an important----- The crane settings should mainly consider the prerequisite for safe and reliable operation of the following factors affecting its safety operation: crane. The crane operation plan should ensure a.
  • Page 36 XCT80 Truck Crane Operation Manual Figure 4-1 Fixation of road running hook Parameter provision: 1. To soft and soil backfill ground, safety distance ( D ) must be greater than 2 times the depth ( T ): D＞2×T； 2. To solid ground, safety distance ( D ) must be greater than the depth ( T ): D＞T...
  • Page 37 XCT80 Truck Crane Operation Manual Table 4-1 ground bearing capacity reference Soil texture type kg/cm Backfill soil and inartificial compacted ground 0～1 Natural soil, not be significantly damaged: 1. Sludge, mud-coal and marsh land； 2. Non-sticky and solid soil: Moderate quality sand;...

  • Page 38: Obstacles Around Crane

    XCT80 Truck Crane Operation Manual 4. Put up crane before operation a. During the crane operation, all the tires should be completely off the ground. b. The horizontal outrigger must depend on working conditions in the rated crane weight table to...
  • Page 39 XCT80 Truck Crane Operation Manual Table4-2 the minimum distance between crane and transmission line ＜1 Transmission line voltage V/kV 1～20 35～110 Minimum distance /m Crane is not insulated. The main boom, steel wire rope, hook, lifting rigging or guide wire rope contacting with cable can cause very serious damage.

  • Page 40: Wind Load Influence

    XCT80 Truck Crane Operation Manual casually; e. lifting weight along the horizontal direction as much as possible to reduce high-frequency ray absorption; f. when doing some necessary manual operations, firstly put it on the ground or insulation place; g. use the appropriate detection equipment to test temperatures of the used tools, if the distance tool in the range of 1cm ~ 2cm is measured of 500V voltage, the tool may not be touched by hand;...
  • Page 41 XCT80 Truck Crane Operation Manual 2. Wind pressure height change coefficient K The crane operation is affected by wind speed, the higher away from the ground, the larger the wind speed and also the wind pressure value. Ground pressure times K (Wind pressure height change coefficient), that can get wind pressures at different heights.

  • Page 42: Crane Grounding

    3. Load handling device quality the crane operation The load handling device quality should be XCT80 truck crane can be of 360 rotation as one part of the crane lifting load calculation, operation, and the specific is as shown in Figure and subtract the load handling device quality 5-3 work area division diagram of section 5.3.

  • Page 43: Lifting Weight

    XCT80 Truck Crane Operation Manual 7. Bearing capacity requirements in joint c. Slings should not be dragged along the lifting operation process ground. When the first to fifth related factors meet 3. Hovering lifting weight should meet the the prescribed qualified requirements and are...

  • Page 44: Disaster Treatment And Emergency Measures

    XCT80 Truck Crane Operation Manual d. The crane can not drag heavy objects in b. Close the brake device and the engine and an inclined direction. cut off all power sources; e. When lifting the lifting weight, no c. The operators should immediately evacuate personnel pass through above.

  • Page 45: Accident Disaster

    XCT80 Truck Crane Operation Manual 4-6-2 Accident disaster 1. High altitude drop: Avoid moving as After the accident, carefully check whether all blind as a bat so that no second injury will be the parts, instruments and meters and safety caused.

  • Page 46: Operation Instructions For The Crane In Out-Of-Service Condition

    XCT80 Truck Crane Operation Manual 4-7 Operation instructions for the crane in out-of-service condition The out-of-service condition of the crane means the state in which the crane does not carry out any hoisting operation. The landing outriggers are in fully collapsed state and the...
  • Page 47 XCT80 Truck Crane Operation Manual 4-15 Courtesy of CraneMarket.com...
  • Page 48 XCT80 Truck Crane Operation Manual 4-16 Courtesy of CraneMarket.com...

  • Page 49: Chapter 5 Main Characteristics And Technical Parameters

    The whole machine has low center of XCT80 truck crane adopts the 4-axis gravity, good stability, high travel speed, great chassis, features full head cab, full coverage climbing ability, flexibility, and fast transitions in plate, front-H and rear-H type outriggers, working process.
  • Page 50 XCT80 Truck Crane Operation Manual 3795 2800 3890 Figure 5-1 XCT80 crane traveling state dimension and parameters Main characteristics and technical parameters Courtesy of CraneMarket.com...
  • Page 51 XCT80 Truck Crane Operation Manual Table 5-1 XCT80 crane traveling status and main technical parameters Parameter Type Item Unit Overall length 14770 Overall width 2800 Overall height 3890 Wheelbase between axle 1 1470 and 2 Dimension Wheelbase parameters Wheelbase between axle 2...
  • Page 52 XCT80 Truck Crane Operation Manual Table 5-1 continue XCT80 crane traveling status and main technical parameters Type Item Unit Parameter Suspension type Leaf spring Specification of leaf spring and —— Multiple, 8/8/- number (front/rear) Chassis structure —— Leaf spring type Vertical placement ——...
  • Page 53 Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 2.2t Length 12.4 16.79 21.17 25.56 29.95 Working Elevation...
  • Page 54 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m.。 Outrigger full extension 7.9m, counterweight 2.2t Length 34.34 38.72 43.11 47.5 Working Lifting...
  • Page 55 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m.。 Outrigger full extension 7.9m, counterweight 2.2t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 56 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 3.5t Length 34.34 38.72 43.11 47.5 Working Lifting...
  • Page 57 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 8t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 58 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 8t Length 34.34 38.72 43.11 47.5 Lifting Working...
  • Page 59 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 11.5t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 60 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 11.5t Length 34.34 38.72 43.11 47.5 Working Lifting...
  • Page 61 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 2.2t 12.4 16.79 21.17 25.56 29.95 Length Working...
  • Page 62 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 2.2t Length 34.34 38.72 43.11 47.5 Working Lifting...
  • Page 63 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 3.5t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 64 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 3.5t 34.34 38.72 43.11 47.5 Length Working Lifting...
  • Page 65 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 8t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 66 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 8t Length 34.34 38.72 43.11 47.5 Working Elevation...
  • Page 67 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 11.5t Length 12.4 16.79 21.17 25.56 29.95 Working...
  • Page 68 Continued Table 5-3 Main arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 11.5t Length 34.34 38.72 43.11 47.5 Working Lifting...
  • Page 69 Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 2.2t 10.5 17.5 Boom angle 0° 15° 30° 0°...
  • Page 70 Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 8t 10.5 17.5 0° 15° 30° 0° 15° 30°...
  • Page 71 Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger full extension 7.9m, counterweight 11.5t 10.5 17.5 Boom angle 0° 15° 30° 0°...
  • Page 72 Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m.。 Outrigger half extension 5.6m, counterweight 2.2t 10.5 17.5 Boom angle 0° 15° 30° 0°...
  • Page 73 Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 8t 10.5 17.5 Boom angle 0° 15° 30° 0°...
  • Page 74 Continued Table 5-4 Auxiliary arm lifting performance of XCT80 truck crane Note: unit of weight lifting: t, elevation angle unit: ° Height unit: m, amplitude unit: m. Outrigger half extension 5.6m, counterweight 8t 10.5 17.5 Boom angle 0° 15° 30°...
  • Page 75 XCT80 Truck Crane Operation Manual Description of tables 5-3 and 5-4: 1. The weight listed in the table is the maximum lifting weight that the machine on a flat and firm ground can guarantee. Working over the weight is prohibited strictly;...
  • Page 76 Minimum distance between the auxiliary hook center and center of the main arm pulley the center of the main arm pulley Arm length(m) 47.5+17.5 Lifting height(m) Working range(m) Figure 5-2 XCT80 lifting height plot 5-28 Main characteristics and technical parameters Courtesy of CraneMarket.com...

  • Page 77: Crane Main Structure Performance Parameters

    Side region Rear region Travelling direction Side region Figure 5-3 XCT80 working range division 5-4 Crane main structure performance parameters 1. Cab The new composite structure of the full width cab features good sealing and anti-corrosion, as well as front and rear shock-proof plastic block. The cab is fully enclosed, with luxurious equipment,...
  • Page 78 XCT80 Truck Crane Operation Manual second axes, and the second circuit acts on the Type： QBL400D1 planetary reducer wheels of third and fourth axes. Speed ratio：59.37 4. Parking brake Model of wire rope：NOTOR HP------- φ20-2160 Deflation brake acts on the rear two axles, playing the role through the spring energy Rope diameter：20mm...
  • Page 79 XCT80 Truck Crane Operation Manual and 11.5t. It can carry 3.5t balance weight (2.2t fixed balance weight, balance weight bracket 1.3t balance weight) in traveling state. 15. Turntable Type: Single vertical plate plus local box- shaped structure, the mechanical locking pins are set.
  • Page 80 XCT80 Truck Crane Operation Manual 5-32 Courtesy of CraneMarket.com...

  • Page 81: Chapter6 Components And Functions Of Lower Crane Portion

    Chapter 6 The components and functions of lower crane portion 6-1 General overview 6-1-6 Hydraulic system XCT80 truck crane lower crane portion is The hydraulic system consists of the mainly composed of nine major components, hydraulic pump, the hydraulic valve, the i n c l u d i n g p o w e r s y s t e m , t r a n s m i s s i o n cylinder and piping components.
  • Page 82 XCT80 Truck Crane Operation Manual Movable outrigger Outrigger plate Frame Figure 6-1 Locations of main components of XCT80 chassis Tyre Engine Figure 6-2 Locations of main components of XCT80 chassis The components and functions of lower crane portion Courtesy of CraneMarket.com...

  • Page 83: Main Components Introduction

    XCT80 Truck Crane Operation Manual 6-2 Main components introduction 1. Cab: The cab is of a full width integral type cab, and elastically connects to frame with four rubber cushions. The driver seat is used with before and after, and backrest angle adjustable hydraulic shock...

  • Page 84: Cab And Protective Device

    XCT80 Truck Crane Operation Manual 6-3 Cab and protective device 6-3-1 The cab interior equipments The cab interior equipments comprise a dashboard, a control switch， an operating mechanism and seats. (Figure 6-3). Figure 6-3 Contour diagram of the cab interior equipments...
  • Page 85 XCT80 Truck Crane Operation Manual 6-3-1-1 Dashboard The instrument panel consists of the combination instrument, switches, and indicator lights, as shown in Figure 6-4. a. Combination instruments Figure 6-4 Combination instruments Name Name Name Speedometer Sign indication region Engine speed gauge...
  • Page 86 XCMG trademarks will be displayed in region 1. 2)Region 2 displays the following contents: the voltage information, the accelerator opening degree, the engine torque, engine running time, and fuel economy.
  • Page 87 XCT80 Truck Crane Operation Manual 1.Lighting settings 1.Instrument display language setting Exit Exit Instrument brightness: 1.Lighting settings 1.Instrument display language setting Decrease for rotating to the left, and increase for rotating to the right Exit Exit Figure 6-6 Instrument backlight settings...
  • Page 88 XCT80 Truck Crane Operation Manual b. Indicator lights assembly Sign instructions are as follows: Figure 6-7 Indicator light assembly Name Name Name Left steering indicator Rear fog lamp indicator Charging indicator light light light Distance light indicator Brake indicator light...
  • Page 89 XCT80 Truck Crane Operation Manual Engine TEST indicator light Water in the oil alarm lights (Weichai engine) Figure 6-8 Indicator lights on operation panel 6-3-1-2 Seats Figure 6-9 Seats in the cab Name Name Name Headrest height lock Damping stiffness...
  • Page 90 XCT80 Truck Crane Operation Manual Two seats are equipped in the cab in the driver's own body weight until you feel the left and right sides, and the manipulation comfortable. Clockwise rotation of the load pieces for the seats are mounted symmetrically.
  • Page 91 XCT80 Truck Crane Operation Manual 6-3-1-3 Cab operation panel Figure 6-10 Cab operation panel Name Name Name Wind direction adjustment Wind speed adjustment Flameout switch switch switch Lighting switch Emergency signal switch Fog lamp switch Warning light switch Air-conditioning switch...
  • Page 92 XCT80 Truck Crane Operation Manual 6-3-1-4 Operation parts in cab Figure 6-11 Operation parts in cab (left view) Name Name Name Combination meter Lighting master switch Steering wheel Exhaust brake, wiper Operation panel assembly Gearbox lever switch Hand brake lever...
  • Page 93 XCT80 Truck Crane Operation Manual Figure 6-12 Operation parts in cab (top view) Name Name Name Clutch pedal Steering wheel Start switch Combination switch Power connector Gearbox lever assembly Hand brake lever Cigarette lighter Accelerator pedal Foot brake pedal 6-13 The components and functions of lower crane portion Courtesy of CraneMarket.com...
  • Page 94 XCT80 Truck Crane Operation Manual Overtaking (upper) Automatic reset PUSH/press—Spray A direction (automatic return) Low beam (middle) B direction High beam (lower) A direction A direction Small lamp Headlight Wiper stalls (sequence for each turning 30°: Headlight and small lamp stalls OFF, intermittent, low-speed, high-speed) (sequence for each turning 30°: OFF, Small lamp)

  • Page 95: Main Function Introduction Of Meters, Switches And Lights In The Cab

    XCT80 Truck Crane Operation Manual 6-3-2 Main function introduction of meters, switches and lights in the cab 1. Start switch (Figure 6-14) When the key is inserted into the start switch, four locations can be selected, (KEY position does not work) as shown in the figure...
  • Page 96 XCT80 Truck Crane Operation Manual is used for the hydraulic system of the vehicle and the lifting operation. Power take-off manipulation methods: a.When using the power take-off switch, When the vehicle is parked in the operating the air pressure should be greater than position, pull the hand brake, make the engine 0.45MPa.
  • Page 97 XCT80 Truck Crane Operation Manual on, indicating that the vehicle cannot be started 7. Engine water temperature gauge (4 in or the power take-off cannot be operated. Figure 6-4) 5. Engine speed hour meter (3 in Figure The engine water temperature gauge 6-4) indicates the temperature of the coolant.
  • Page 98 XCT80 Truck Crane Operation Manual This switch must be used when driving in the fog, then the fog lamp indicator light and front and rear fog lamps go on. When using the differential locking 12. Warning light switch (optional) (7 in...
  • Page 99 XCT80 Truck Crane Operation Manual parking brake, first pull up the locking sleeve In the summer and winter, the water, frost on the lever, and then pull the lever forward, so or thin ice on the rear-view mirror will affect that the lever is in the range of 0°...

  • Page 100: Other Device

    XCT80 Truck Crane Operation Manual A small DC motor is installed in the 27.Reversing indicator light (8 in Figure rearview mirror, when the rearview mirror 6-7) needs to adjust slightly, in accordance with the When the shift lever is in the reverse position, direction shown by arrow on the button, the the reverse indicator light goes on.
  • Page 101 XCT80 Truck Crane Operation Manual 2. Quartering hammer When encountering emergencies, one can use the quartering hammer to break down the vehicle window for life surviving. Figure 6-16 Quartering hammer 3. Fire extinguisher Dry powder fire extinguisher, the operating temperature is -20℃～55℃, the do's and don'ts in details see the fire extinguisher instruction.

  • Page 102: Protective Devices

    Structure: Frame-covering structures; Joints and form: a. rear shield is connected with frame by welding; b. side shield is connected with platen by bolts; Dimensions see XCT80 the protective devices schematic diagram (Figure 6-21) of the lower crane portion. 6-22 The components and functions of lower crane portion Courtesy of CraneMarket.com...
  • Page 103 Right protective device diagram Rear protective device diagram Typical structure of side protective device is frame-covering structure. Material: Q235 Left protective device diagram Connection diagram between side shield and frame Bolt connection Frame side bracket Angle ironbracket 40×40×4 Bolt connection Frame Courtesy of CraneMarket.com...
  • Page 104 XCT80 Truck Crane Operation Manual 6-24 Courtesy of CraneMarket.com...

  • Page 105: Chapter 7 Traveling Status On Highway

    XCT80 Truck Crane Operation Manual Chapter 7 Traveling Status on Highway 7-1 Preparations before traveling 7-1-1 Crane traveling mode on highway Travelling on highway should be ----- consistent with the relevant national road traffic regulations, the maximum weight of the vehicle The 3.5t balance weight for travelling...
  • Page 106 XCT80 Truck Crane Operation Manual situations. If the water level drops to below the lowest limit, you should shot down the engine to continue filling the coolant until the engine works more than 20 minutes and the liquid level is stable between the highest limit and lowest limit.。...
  • Page 107 XCT80 Truck Crane Operation Manual 7. Check tire tank, and to ensure the cleaning agent is sufficient. a. Check the tread depth of tires (including 12. Check the air compression system the spare tire) should not be less than 3.2mm;...

  • Page 108: The Use Of Air Conditioning

    XCT80 Truck Crane Operation Manual 7-1-3 The use of air conditioning The cool-warm air conditioning is adopted, the engine circulating hot water is used for warm air, and cool air is provided by the air conditioning system refrigerant cycle. When warm air is used in winter, the hot water valve on warm air piping must be opened (see...
  • Page 109 XCT80 Truck Crane Operation Manual Cold and warm Wind direction Wind speed Air conditioning switch selection switch adjustment switch regulation switch Figure7-2 ●Ensure to close the hot water valve in the refrigeration, and open it in heating. ●When the water in the engine cooling system needs to be discharged in winter, the water in warm air piping must also be released.

  • Page 110: Operation Of Lower Crane Portion Engine

    XCT80 Truck Crane Operation Manual 7-2 Operation of lower crane portion engine 7-2-1 Check before starting the engine 1. Check hydraulic system stop valve The stop valve is located in the right side of the hydraulic tank, and must be opened before engine start.
  • Page 111 XCT80 Truck Crane Operation Manual Unscrew (Do not open it!) the lid of hole 1 at the operating temperature lower limit to release pressure. Open the lid. The coolant level should at least reach the minimum position. If the oil level is too low, add coolant in accordance with the “Engine Manual”.
  • Page 112 XCT80 Truck Crane Operation Manual Oil filler neck China National Heavy Duty Truck engine oil The Weichai engine oil refueling port is located refueling port is located in left front of the engine. on the rear left side of the engine.

  • Page 113: Start Lower Crane Portion Engine

    XCT80 Truck Crane Operation Manual 7-2-2 Start lower crane portion engine 1. Start ignition switch Check the gearbox in neutral, turn on the ignition switch, insert the key and turn to the "START". Figure 7-6 Start switch When starting the engine or ignition switch, the indicator light is used as the alarm light in system detection.

  • Page 114: Inspection After The Engine Startup

    XCT80 Truck Crane Operation Manual Check the position of the handbrake. It indicates the handbrake is locked when the shift joystick is backward. ●This engine is equipped with flame preheating cold start device, start by start fluid is prohibited. ●Do not step down the throttle pedal;...

  • Page 115: General Operation

    XCT80 Truck Crane Operation Manual 7-3 General operation 7-3-1 Starting and gear shift 1. Starting Release the handbrake handle. The spring brake can only be completely released when air reservoir pressure in the brake system reaches 0.45MPa and after the handbrake indicator light and low pressure warning light goes out.
  • Page 116 XCT80 Truck Crane Operation Manual Figure 7-7 shows the transmission shift position Natural Forward direction Figure 7-7 Transmission shift position diagram ● In gear shift, the clutch must be completely separated and the shift lever should be shifted in place, otherwise it will cause the gear off or tooth impact.

  • Page 117: Trail Operation

    XCT80 Truck Crane Operation Manual 7-3-2 Trail operation a. When the vehicle needs to be moved but its driveline has failure, the towed vehicle speed can not exceed 10 km/h, and the emergency signal switch should be turned on. The steering indicator lights should also be on.

  • Page 118: Steering System

    XCT80 Truck Crane Operation Manual In the case of the clutch pedal to the end, the clutch should be able to completely separate, if the clutch can not be completely separated, the clutch operating system should be checked. The clutch operating system is realized by static pressure oil, so you should first add static pressure oil to the system and eliminate the air in the system.
  • Page 119 XCT80 Truck Crane Operation Manual Steering process:： a. Intermediate position: when the vehicle travels in straight, the steering wheel will not rotate is if no steering force is applied to the steering wheel.。 b. Steering process: When the vehicle needs steering, the driver turns the steering...

  • Page 120: Braking System

    XCT80 Truck Crane Operation Manual 7-3-5 Braking system The brake system consists of the service brake (foot brake), the parking brake (hand brake) and auxiliary brake (engine exhaust brake and engine retarder brake). 1. Service brake The service brake, dual-circuit pneumatic brake, is operated by pedal, with the maximum working pressure of 0.8MPa.

  • Page 121: Driving Cranes In Winter

    XCT80 Truck Crane Operation Manual brake is damaged, the hand brake can be used in place of the service brake to drag the vehicle. Block 3. Auxiliary brake Auxiliary brake is the engine exhaust brake. When the vehicle travels down a long slope in...

  • Page 122: Braking Device

    XCT80 Truck Crane Operation Manual 7-4-2 Braking device Before driving, the condensed water in the air reservoir must be released. 7-4-3 Battery This model adopts a maintenance-free battery. The middle of the battery is equipped with a status indicator light, as shown below: Camel battery Hubei Camel Storage Battery Co., Ltd.
  • Page 123 XCT80 Truck Crane Operation Manual 1. When checking the battery, you should pay attention to following matters: a. The battery should be kept clean and dry. If the terminal is polluted, it should be released and cleaned, and then lubricated with clean, acid-free and acid-resistant grease;...
  • Page 124 XCT80 Truck Crane Operation Manual 7-20 Courtesy of CraneMarket.com...

  • Page 125: Chapter8 Components And Functions Of Upper Crane Portion

    Chapter 8 The components and functions of upper crane portion 8-1 General overview XCT80 truck crane mainly consists of five major components including a lifting device, a safety device, an upper crane portion control room, and slewing bearing system, hydraulic system and electric system.
  • Page 126 XCT80 Truck Crane Operation Manual XCT80 XCT80 Figure 8-1 Components locations diagram a of XCT80 upper crane portion Name Name Name Main boom Safety device Control cab Lifting hook Shield Fixed balance weight Figure 8-2 Components locations diagram b of XCT80 upper crane portion...

  • Page 127: Main Component Introduction

    XCT80 Truck Crane Operation Manual 8-2 Main component introduction 1. Main boom Five-section main suspension boom with U-shaped cross section is designed with special slider and centering device and has high strength steel plate which makes the suspension boom weight light, rigidity good, stretch stably, centering reliably, and be of the powerful lifting capacity;...
  • Page 128 XCT80 Truck Crane Operation Manual box to provide faster and more convenient balance weight hitching. 7. Upper crane portion operating room The new steel control room has good sealing and corrosion protection, providing safety and comfort. The fully enclosed front view window is equipped without vision dead corner and adopts safety glass and a scroll sunshade.

  • Page 129: Operating Cab

    XCT80 Truck Crane Operation Manual 8-3 Operating cab Figure8-3 Layout of operating cab interior Name Name Name Top window wiper Lifting performance table Right operating handle Right electric control box Front window wiper Instruments desk panel Air conditioning and Front air outlet...

  • Page 130: Electric Device

    XCT80 Truck Crane Operation Manual 8-3-1 Electric device The electric device in operating room comprises a dashboard (a rocker switch, an indicator lamp and display ), a combination switch, a start key switch, an air conditioning control switch, control mechanism ( an accelerator pedal, a left handle, a right handle, etc. ), and so on( Figure 8-4 ).

  • Page 131: Instrument Panel

    XCT80 Truck Crane Operation Manual 8-3-2 Instrument panel Figure 8-5 Instrument panel 1. Hour meter 2. Air conditioning control panel 3. Radio 4. Start lock 5. Emergency stop switch button Press the button switch, to shut down the engine. The switch must be reset in time.
  • Page 132 XCT80 Truck Crane Operation Manual 6. Switch – for pilot pressure control Yo u s h o u l d p r e v e n t d a n g e r o u s movements of the crane caused by operator mistakenly touching handles when getting in and out of the control room.
  • Page 133 XCT80 Truck Crane Operation Manual 15. Switch - balance weight selection I n n o r m a l s t a t e , t h e l e f t h a n d l e manipulate the telescopic movement of the crane forward and backward.

  • Page 134: Control Handle

    XCT80 Truck Crane Operation Manual 8-3-3 Control handle Left handle Right handle 左手柄 右手柄 Figure 8-6 Control handle Name Name Name Horn Rotary brake release Free slip and turning Telescopic/auxiliary Pilot pressure Horn hoisting switch Free slip and turning Pilot pressure...

  • Page 135: Electric System Manual

    XCT80 Truck Crane Operation Manual K0+ relay (model: JQ202S-FLO): control 8-3-5 Electric system manual power supply of lower crane portion 1. Before close the main power, place K0 relay (model: JQ202S-FLO): control all the control handles in media and reset all power supply of upper crane portion switches.

  • Page 136: Safety Device

    XCT80 Truck Crane Operation Manual a. Before the lifting operation, please 8-4 Safety device carefully read “torque limiter manual". 8-4-1 Lifting torque limiter b. Although the crane is equipped with 1. Working principle torque limiter, this device is not as a substitute Lifting torque limiter calculates the crane as the judgment of a crane operator.

  • Page 137: Length And Angle Sensor

    XCT80 Truck Crane Operation Manual 8-4-3 Length and angle sensor The sensor mounted on the lifting boom side is composed of a case, a spiral spring a spring chamber and a length measuring cable. The case interior is provided with a length sensor, an angle sensor and electronic slip ring mechanism.

  • Page 138: Groove Jumping Device (Rope Block)

    XCT80 Truck Crane Operation Manual 8-4-4 Groove jumping device (rope block) The pulley group on lifting boom head and lifting hook pulley group both have rope block. Rope block plays a key role in preventing the steel wire rope slipping off from pulley groove and sliding track. For installation, the steel wire rope should be firstly installed and then the rope block;...

  • Page 139: Safety Control Switch

    XCT80 Truck Crane Operation Manual 8-4-7 Safety control switch 1. Hydraulic proportional system safety control switch (also known as hydraulic pilot switch) The safety device is used to prevent accidental touch of handle lever. When the switch is turned off, the system can only work under control of liquid proportion.

  • Page 140: Hydraulic Unloading Valve

    XCT80 Truck Crane Operation Manual 2. Telescopic and auxiliary hoisting footswitch The safety device is used to prevent the dangers due to the misoperation of telescopic and auxiliary hoisting. If arm streching and auxiliary hoisting movement is needed, you must first step on the footswitch, and then operating the corresponding handles.

  • Page 141: Rotary Table Lock Device

    XCT80 Truck Crane Operation Manual 8-4-10 Rotary table lock device Figure8-12 Rotary table lock device This device is composed of a locking pin and a rotary table, when on 0° position in the operating room (facing the vehicle heading direction), the safety device of upper crane portion structure is fixed through a locking pin.
  • Page 142 XCT80 Truck Crane Operation Manual 8-18 Courtesy of CraneMarket.com...

  • Page 143: Chapter9 Crane Accessory

    XCT80 Truck Crane Operation Manual Chapter 9 Crane accessory 9-1 Crane accessory selection it is equivalent balance weight decrease of approximately 0.6t.。 Some risks exist in process of assembly, d. In installation of the auxiliary winch, installation, operation, disassembly and you should pay attention to the installation transportation of crane.

  • Page 144: Mounting Auxiliary Lifting Mechanism

    XCT80 Truck Crane Operation Manual 9-2-2 Mounting auxiliary lifting mechanism The auxiliary lifting mechanism is mounted on the rear side of main lifting mechanism, which can be transported together with the balance weight when it is not in use. 1. Insert the auxiliary lifting mechanism junction plate into the junction bracket plug on the rotary table end (Figure 9-1).

  • Page 145: Dismounting Auxiliary Lifting Mechanism

    XCT80 Truck Crane Operation Manual 9-2-3 Dismounting auxiliary lifting mechanism 1. Disconnect the quick coupling between the auxiliary hoisting mechanism and main oil line (see Figure 9-2), and cover the protective cap. 2. Remove wire connectors of the auxiliary volume counter (three ring protection).

  • Page 146: Mounting And Dismounting Of Auxiliary Crane Arm

    XCT80 Truck Crane Operation Manual 9-3 Mounting and dismounting of auxiliary crane arm 9-3-1 Operating Precautions a. Confirm the outrigger extends to the working position specified in a rated lifting weight b.Before mount and retract the auxiliary crane arm, should ensure that there is enough operation space on the operating site.

  • Page 147: Component Name Of Auxiliary Crane Arm

    XCT80 Truck Crane Operation Manual 9-3-2 Component name of auxiliary crane arm Figure9-4 Auxiliary crane arm position and its structure schematic Name Name Name Auxiliary arm installation Auxiliary arm Main boom hole(four places) Auxiliary arm installation Main arm installation hole （（four places）...
  • Page 148 XCT80 Truck Crane Operation Manual Figure9-5 Auxiliary crane arm position and its structure schematic Name Name Name Second section auxiliary Rear bracket First section auxiliary arm Middle bracket Front bracket Crane accessory Courtesy of CraneMarket.com...

  • Page 149: Mounting Auxiliary Crane Arm

    XCT80 Truck Crane Operation Manual 9-3-3 Mounting auxiliary crane arm The first installation process: In accordance with the requirements to mount the crane, after the main crane boom fully retracting, it is slewing to the lateral rear side of the completed crane and falling down to the lowest point.
  • Page 150 XCT80 Truck Crane Operation Manual The third installation process: 1.If only one section auxiliary arm is used, the total length of the auxiliary arm is 10.5m: a. Fasten a tow rope at the end of the first section auxiliary arm, remove the connecting pin axle A and clip on the first and second section auxiliary arms (each of 2), and remove the connecting pin axle...
  • Page 151 XCT80 Truck Crane Operation Manual c. When it rotates to the position that the right mounting hole of the main arm is aligned with the left mounting hole auxiliary arm, insert the auxiliary arm mounting pin F and clip (each of upper and lower 2);...
  • Page 152 XCT80 Truck Crane Operation Manual d. Remove the pin axle E and clip on the front bracket, and continue to pull the tow rope, so that the auxiliary arm rotates with the auxiliary arm mounting pin F as rotation axis. When rotating to the position that the auxiliary arm right side mounting hole is aligned with the mounting holes on the left side of the main arm, insert another two auxiliary arm mounting pins F and clip (each one in the upper and lower).
  • Page 153 XCT80 Truck Crane Operation Manual b. Pull the tow rope, so that the auxiliary arm rotates with pin axle E on the front bracket as the rotation axis (as step 2 in 1); c. When it rotates to the position that the right mounting hole of the main arm aligns with the left mounting hole of the auxiliary arm, insert the auxiliary arm mounting pin F and clip (each of two in the upper and lower) (as step 3 in 1);...
  • Page 154 XCT80 Truck Crane Operation Manual Figure 9-13 Support pulley bracket Name Name Name Pin axle I Pulley bracket Pin axle hole K Pin axle hole L Pin axle J The fifth installation process: Support the pulley bracket on the auxiliary boom, take out the wire rope from the auxiliary boom head pulley, and make it pass through the pulley bracket and auxiliary boom head pulley.

  • Page 155: Mounting Angle Adjustment Of Auxiliary Crane Arm

    XCT80 Truck Crane Operation Manual 9-3-4 Mounting angle adjustment of auxiliary crane arm 1. Transformation from 0°to 15°（as shown in figure9-14） Remove the lifting wire rope rigging of the auxiliary winch from the auxiliary hook, tie the auxiliary hook rigging and the auxiliary arm head with the discoloration cotton lifting rope in the spares and confirm it is firm.
  • Page 156 XCT80 Truck Crane Operation Manual 2. Transformation from 0°to 30°（as shown in figure9-15） Remove the lifting wire rope rigging of the auxiliary winch from the auxiliary hook, tie the auxiliary hook rigging and the auxiliary arm head with the discoloration cotton lifting rope in the spares and confirm it is firm.

  • Page 157: Auxiliary Crane Arm Storage

    XCT80 Truck Crane Operation Manual 3. Auxiliary crane arm transformation with 0°mounting angle Dismount the rigging of auxiliary rolling lifting steel wire rope from the auxiliary hook, mount the auxiliary crane arm head ( as mentioned before ), remove idle pin shaft d from auxiliary crane arm, then slowly lift the auxiliary winding so that the included angle is close to 0°...

  • Page 158: Mounting And Dismounting Of Balance Weight

    Any outrigger is required to extend to the position specified in the crane performance table. 9-4-2 Balance weight combination XCT80 truck crane is equipped with the up lifting combined balance weight, and the vertical movement of the balance weight is mainly driven by the balance weight cylinder rod. In different combinations of balance weights, the positioning and fixing of the balance weight can be realized by...

  • Page 159: Mounting Balance Weight

    Combination 4 11.5 XCT80 truck crane balance weight combinations are shown in the above table, "√" represents choosing, no "√" means not choosing. In combination 4, the stacking sequence of the flexible balance weight is A, C, B sequentially from top to bottom. The cylinder is fixed below the fixed balance weight D, the stacking sequence of the rest combinations is the same with combination 4.
  • Page 160 XCT80 Truck Crane Operation Manual 4. Press the " Balance weight working condition selection switch " lower end (Figure9-17 ) on instrument panel, at this time the "Balance weight work condition selection " indicator lamp is brightly on( Figure9-17 ), and the handle can not control slewing;...
  • Page 161 XCT80 Truck Crane Operation Manual 7. Manipulate the "balance weight cylinder lift switch” on the remote control box, so that the balance weight cylinder is fully retracted, the lifting balance weight disengages with the frame. Confirm the plane of the suspension flexible balance weight mates firmly with the fixed balance weight lower surface, and lift the balance weight to the highest position, then the balance lifting limit indicator light goes on (Figure 9-17).。...

  • Page 162: Dismounting Balance Weight

    XCT80 Truck Crane Operation Manual 9-4-4 Dismounting balance weight 1.Operate crane slewing so that the main crane boom head is located on the right rear side of the crane; 2. Press the lower end of the "balance weight cylinder lift switch" on the dashboard, so that the balance cylinder is fully extended, and place the balance weight on the bracket;...

  • Page 163: Mounting Arm End Single Pulley

    XCT80 Truck Crane Operation Manual 9-5-2 Mounting arm end single pulley When driving, the arm end single pulley is arranged on the left side of main crane boom and fixed using pins A and B, as shown in the Figure9-20.
  • Page 164 XCT80 Truck Crane Operation Manual Rotate shaft as rotation axis of pin shaft B Pin shaft C Figure 9-21 9-22 Crane accessory Courtesy of CraneMarket.com...

  • Page 165: Storing Arm End Single Pulley

    XCT80 Truck Crane Operation Manual c. Mounting auxiliary crane hook Figure 9-22 Arm end single pulley installation finish (figure 9-22) 9-5-3 Storing arm end single pulley After the use of arm end single pulley working condition, one should timely retract the auxiliary crane arm back to the left side of main crane boom (as the main crane boom head for the front orientation), and the retracting method follows the opposite order as in 9.5.2.

  • Page 166: Hook And Steel Wire Rope

    9-6 Hook and steel wire rope 9-6-1 Hook selection XCT80 truck crane is equipped with 3 hooks, which are main hook (80t hook), middle hook (40t hook) and auxiliary hook (7t hook) respectively, with the maximum ratio for main hook, middle hook and auxiliary hook of 12, 6 and 1 respectively.

  • Page 167: Steel Wire Rope Magnification Conversion

    XCT80 Truck Crane Operation Manual Figure 9-25 Auxiliary hook 9-6-3 Steel wire rope magnification conversion 1. Operating condition Mount the outrigger well, and the crane arm is fully retracted and rotates to the lateral or rear area: a. After falling down the arm, the hook is fallen down to the ground.
  • Page 168 XCT80 Truck Crane Operation Manual c. Unload heavy punch from steel wire rope (Figure9-27). Dismantle the coupling bolts, and remove the heavy hammer Figure 9-27 Unload heavy punch 9-26 Crane accessory Courtesy of CraneMarket.com...
  • Page 169 XCT80 Truck Crane Operation Manual d. Dismount sling（Figure 9-28）. Pin axle Spring axle Bag type noose Steel wire rope Figure 9-28 Unload Sling e. Transform steel wire rope magnification While falling the hook, one should pull the steel wire rope outside (Figure9-29), and the Crossing and winding method of steel wire rope see 9.6.4.
  • Page 170 XCT80 Truck Crane Operation Manual 9-6-4 Crossing and winding method of steel wire rope According to the different requirements of the load, select the appropriate steel wire rope magnification in accordance with the rated crane weight table. Choosing much smaller...
  • Page 171 XCT80 Truck Crane Operation Manual 3. When lift weight with a eight------- magnification, cross and wind steel wire rope according to the method as shown in Figure9- 30c. Figure9-30c：Eight-magnification crossing and winding schematic 4. When lift weight with a six--------...
  • Page 172 XCT80 Truck Crane Operation Manual 6. When lift weight with a four-------- magnification, cross and wind steel wire rope according to the method as shown in Figure9- 30f. Figure9-30f：Four-magnification crossing and winding schematic 7. When lift weight with a three--------...

  • Page 173: Crossing And Winding Of Steer Wire Rope Precautions

    XCT80 Truck Crane Operation Manual 9-6-5 Crossing and winding of steer wire rope precautions 1. The over winding stop device heavy punch installation position varies in accordance with odd or even number of magnification（see heavy punch installation position in Figure9-31）...
  • Page 174 XCT80 Truck Crane Operation Manual 6. The crane uses imported anti-rotation high-quality steel wire rope, so in general no rotation would happen. In case steel wire ropes are twisted together, please correct that as the following steps(Figure9-32). n rate Twisted coil number Xn (rate ) Figure 9-32 a.
  • Page 175 XCT80 Truck Crane Operation Manual 9. On each working day, one should observe all visible parts of any steel wire rope as far as possible to find the general damage and deformation. Special attention should be paid on the steel wire rope connection parts onto crane.
  • Page 176 XCT80 Truck Crane Operation Manual 9-34 Courtesy of CraneMarket.com...

  • Page 177: Chapter10 Crane Operation

    XCT80 Truck Crane Operation Manual Chapter 10 Crane operation 10-1 Crane operation preparations 9. Before the crane operation, the power switch should be turned off in operating room of Two conditions of the safe use of the lower crane portion.

  • Page 178: Air Conditioning Equipment Use

    XCT80 Truck Crane Operation Manual 10-1-3 Air conditioning equipment use The control room air conditioning control device is located in the left side of the instrument panel. Please select the appropriate temperature range depending on the operating environment temperature. Figure10-1 Air conditioning panel...
  • Page 179 XCT80 Truck Crane Operation Manual The display panel consists of a LCD display and 10 keys, which is used for setting room temperature and wind direction in operating room to when using cooling and warming air conditioning，see figure10-1. 1. Display panel and symbol instructions...
  • Page 180 XCT80 Truck Crane Operation Manual d. Defrosting key: On the crane inner temperature display state, press this key to display a setting Press this key, and the system enters into temperature, at this time press the key each defrosting mode.

  • Page 181: Operating Cab Seat Adjustment

    XCT80 Truck Crane Operation Manual 10-1-4 Operating cab seat adjustment Figure10-2 Operating cab seat Name Name Name Headrest height lock Damping stiffness Seat height adjustment switch adjustment knob switch Backrest angle adjustment Upper seat portion back Armrest box uplift switch...
  • Page 182 XCT80 Truck Crane Operation Manual increase, and vice versa. 3)Height adjustment: upward pull the height adjustment switch in the front of the seat, you can release seat height locking, and lower seat height by its own weight. Release the switch to lock the position. Pull up the switch, which the body leaves the seat at the same time, the seat can automatically rise.

  • Page 183: Check The Winch Steel Wire Rope Position

    XCT80 Truck Crane Operation Manual 10-1-5 Check the winch steel wire rope position 1. Slowly rotate the winch winding reel to at least release a ring of steel wire rope. At the same time check the released steel wire rope.
  • Page 184 XCT80 Truck Crane Operation Manual 1. Check crane torque limiter After the test program is running, check if: a. Display error messages b. The early stage alarming and the closing alarm lamps light c. Continuous alarm sound If none of the above circumstances occur, the lifting torque limiter is normal.

  • Page 185: Engine Operation

    XCT80 Truck Crane Operation Manual 10-2 Engine operation The engine operation method please refers to the content 7.2. In addition to 7.2 of the described engine operation, the following several situations can also start the engine. 1. Press "weight selection switch" down in operating room, then use the engine start button in remote control box to start the engine.

  • Page 186: Power Take-Off Operation

    XCT80 Truck Crane Operation Manual 3. Press the counter weight selection switch in operating room, and then use the engine flameout button on remote control box to shut it down. Engine flameout button Counter weight selection switch Figure10-6 Engine flame out button 10-3 Power take-off operation Power switch is located in the chassis cab.When the crane needs to open outrigger and does the...
  • Page 187 XCT80 Truck Crane Operation Manual Figure 10-7 Cab manipulation parts Name Name Name Combination instrument Lighting master switch Steering wheel Exhaust brake, wiper Control panel assembly Gearbox lever switch Hand brake lever Electric rearview mirrors Foot brake pedal Foot accelerator pedal...
  • Page 188 XCT80 Truck Crane Operation Manual Cab operating panel and rocker switches are shown below: Figure 10-8 Cab operating panel Name Name Name Wind direction adjustment Wind speed adjustment Flameout switch switch switch Lighting switch Emergency switch Fog lamp switch Warning light switch...

  • Page 189: Outrigger System Operation

    XCT80 Truck Crane Operation Manual 10-4 Outrigger system operation 10-4-1 Operating precautions 1. Ensure that there is enough space for completely unfolding the crane outrigger Automobile crane in work should be placed in a much widen place, prevent the outrigger touching the barrier when outrigger unfolding or moving, and after the outrigger fully unfolding, will the upper crane operations do so as to be able to successfully complete the heavy lifting work.

  • Page 190: Outrigger Operation Composition

    XCT80 Truck Crane Operation Manual A Through-flow state B OFF state Figure 10-9 Cut-off ball valve state diagram 10-4-2 Outrigger operation composition 1. Outrigger structure as shown in figure 10-10. Figure10-10 Outrigger structure sketch Name Name Name Foot plate Outrigger vertical cylinder Movable outrigger gradeⅠ...
  • Page 191 XCT80 Truck Crane Operation Manual 2. Constitute of front outrigger manipulation Figure 10-11 Front outrigger structure diagram Name Name Name Outrigger vertical cylinder Stabilizer plate Outrigger positioning pin Outrigger swing cylinder Frame In Figure 10-11, when outriggers stretch out, the outrigger positioning pins (3 in Figure 10- 11) must be pulled out, and when the outriggers retract, the outrigger positioning pins must be placed in the position shown in Figure 10-11.
  • Page 192 XCT80 Truck Crane Operation Manual 3. Outrigger operation Figure 10-12 Right outrigger operation box panel Name Name Name Engine ignition switch Outrigger light switch Blank panel Left rear outrigger vertical Left front outrigger vertical Empty panel cylinder switch cylinder switch...
  • Page 193 XCT80 Truck Crane Operation Manual Gradienter Left outrigger operation box panel Figure 10-13 Left outrigger operation box The outrigger operation box is around the third and fourth axis, each one on the right and left side. The right outrigger operation panel is shown in Figure 10-12, 1 is engine ignition switch; 2 is outrigger light switch, which is used for lighting of outriggers during night work.

  • Page 194: Fold And Unfold Foot Plate

    XCT80 Truck Crane Operation Manual 10-4-3 Fold and unfold foot plate Before extending out outrigger, the foot plate should be pulled out from the driving state (A in Figure10-14 ). Firstly, pull out the locating pin (B in Figure10-14), pull the foot plate out (C in Figure10-14 ), and then insert the fixed pin been pulled out into the inside pin hole (D in Figure10-14)

  • Page 195: Throttle Operation

    XCT80 Truck Crane Operation Manual 10-4-6 Leveling crane If the crane has not yet been supported level after stretching the vertical cylinder, its leveling can be realized in accordance with the following steps: 1. Making the level bubble in the middle position by separately adjusting the stretching of each 第...

  • Page 196: Operating Method

    XCT80 Truck Crane Operation Manual 10-5-2 Operating method Engine throttle operation is performed by electronic pedal output signals to realize the engine acceleration and deceleration (see Figure 10-15). Stamping on the throttle pedal in upper crane portion control room can improve the rotation speed of the engine, so that the action speeds of the slewing, the crane boom luffing, the crane boom stretching and each mechanism lifting is increased;...

  • Page 197: Lifting Mechanism Operation

    XCT80 Truck Crane Operation Manual 10-6 Lifting mechanism operation 10-6-1 Operating precautions a. Make the weight lifting or falling smoothly, not sharply pull the operating of the lifting mechanism b. Before doing the crane operation, one should check the brake to confirm its normal and then perform lifting.

  • Page 198: Auxiliary Lifting Mechanism Operation (Left Control Handle)

    XCT80 Truck Crane Operation Manual 10-6-3 Auxiliary lifting mechanism operation (left control handle) Press the telescopic and auxiliary winch switch S17 to the ON position, or press the right handle telescopic and auxiliary winch button (the function of the button is telescopic in bouncing state), while stepping on the telescopic and auxiliary winch footswitch in the cab by foot.

  • Page 199: Free Trackslip Operation

    XCT80 Truck Crane Operation Manual 10-6-4 Free trackslip operation In order to prevent the side load when lifting the weight, while doing the lifting operation, hold on press the free trackslip button on handle to open the free trackslip function, the crane boom free trackslip is aligned at the center of gravity of the weight, and then release the free trackslip button after the weight leaving the ground, as shown in figure(10-18).

  • Page 200: Operating Method

    XCT80 Truck Crane Operation Manual 10-7-2 Operating method Press the telescopic auxiliary winch switch S17 to the OFF position and maintain the telescopic and auxiliary winch switch button on the right handle is in the bouncing up state, while stepping on the telescopic and auxiliary winch footswitch in cab.

  • Page 201: Main Crane Boom Luffing Operation

    XCT80 Truck Crane Operation Manual Main crane arm stretching operation(left handle) Second section cylinder work selection switch Figure10-19 Main crane boom stretching operation 10-8 Main crane boom luffing operation 10-8-1 Operating precautions a. The vertical load lifting is only allowed, not allowed to drag the load without leaving the ground to avoid the side load.

  • Page 202: Main Crane Boom Luffing Operation (Right Control Handle)

    XCT80 Truck Crane Operation Manual 10-8-2 Main crane boom luffing operation ( right control handle ) Pull the right control handle rightward, the boom falls; pull the right control handle leftward, the boom lifts ( see Figure10-20); Luffing boom lifting speed is controlled by the control handle and the throttle; the boom falling speed is controlled by the control handle, the engine is idle, and nothing to do with the throttle size.

  • Page 203: Slewing Operation

    XCT80 Truck Crane Operation Manual 10-8-3 Relations between main crane boom elevation angle and total crane weight and working radius When doing the auxiliary boom installation and magnification transformation operation needed to lower the crane boom, one should extend outriggers, retract the crane boom retracted to a fully retraction state, fall the crane boom down, after finishing the required installation, lift the crane boom...

  • Page 204: Slewing Operation (Left Control Handle)

    XCT80 Truck Crane Operation Manual 10-9-2 Slewing operation (left control handle) Before slewing operation, you should first lift the turntable mechanical lock, and press theslewing brake release switch on the control panel or press the the slewing brake release button on the left handle (Figure 10-21b).

  • Page 205: Combined Action Instructions

    XCT80 Truck Crane Operation Manual Free trackslip button Horn button Slewing brake release button Liquid ratio safety control Front part of Turntable the turntable mechanical lock Left handle Figure10-21b Slewing operation 10-10 Combined action instructions In lifting operations, certain principles should be followed for different combinations of actions.
  • Page 206 XCT80 Truck Crane Operation Manual 10-30 Courtesy of CraneMarket.com...

  • Page 207: Chapter11 Oil And Grease

    XCT80 Truck Crane Operation Manual Chapter 11 Oil and Grease 11-1 Fuel and engine oil a. Type, amount and time for engine oil filling of engine is shown in “Users’ manual for engine”. For the machine leaving factory, the oil filling type is CH – 4, and quantity of about 30-33 liters，for type CF-4 quantity of about 20 liters...

  • Page 208: Gear Oil

    XCT80 Truck Crane Operation Manual Check the oil quantity: oil quantity check should be carried out when the crane is in driving preparation condition. The liquid temperature and level meter can not only display oil level scale, but also shows the temperature of hydraulic oil. When checking the oil, be sure to keep oil level liquid level above gauge central line, hydraulic oil should be added if it is lower than the minimum oil level line.
  • Page 209 XCT80 Truck Crane Operation Manual b. Lifting mechanism Main winch and auxiliary winch: idling for 10 to 15 minutes before refueling, screw down the oil drain cock, and discharge completely all the used oil. Screw up the oil drain cock, screw off oil scale plug, and add lubricating oil until there is oil overflow at oil scale hole.

  • Page 210: Grease

    XCT80 Truck Crane Operation Manual 11-4 Grease a. Lubricating position Figure 11-4 XCT80 truck crane lubricating position schematic diagram 11-4 Oil and Grease Courtesy of CraneMarket.com...
  • Page 211 XCT80 Truck Crane Operation Manual b. Lubricating position table Table 11-1 Lubricating position table Interval Name Means Every week of Lithium base grease Main hook beam Oil by oil gun before use ZL45-2 Lifting hook upper transverse Every week of...
  • Page 212 XCT80 Truck Crane Operation Manual Table11-2 Components requiring lubrication of the lower crane portion Interval Name Means Clutch separation fork shaft 100hours 2# Lithium base grease Oil by oil gun Clutch separation bearings 100hours 2# Lithium base grease Oil by oil gun...

  • Page 213: Domestic And Foreign Grease Comparison

    XCT80 Truck Crane Operation Manual 11-5 Domestic and foreign grease comparison Table 11-3 Domestic and foreign grease comparison Bearing, slide block, slewing Winching speed bearing, wire rope, boom Classification Hydraulic system reducer, slewing hinged point, luffing hinged reducer point Heavy duty industrial...

  • Page 214: Coolant

    XCT80 Truck Crane Operation Manual 11-6 Coolant The vehicle requires the use of special antifreeze as the engine coolant. You should replace with different antifreeze models according to the lowest temperature of the environment. The use of purified water, tap water or sea water as coolant is never allowed even if the ambient temperature is above 0℃.
  • Page 215 XCT80 Truck Crane Operation Manual 11-9 Courtesy of CraneMarket.com...
  • Page 216 XCT80 Truck Crane Operation Manual 11-10 Courtesy of CraneMarket.com...

  • Page 217: Chapter 12 Crane Inspection And Maintenance

    XCT80 Truck Crane Operation Manual Chapter 12 Crane inspection and maintenance 12-1 Overview The crane has been tested and checked according to relevant standards prior to delivery, but deviation may occur in the use process due to the main reasons that wear, corrosion and environmental changes, external force damages and changes in use conditions.
  • Page 218 XCT80 Truck Crane Operation Manual Inspection items Operating lever and switch: 1. Operating status. Driving device Slewing Power take-off device: 1. For looseness and oil leakage. 2. For abnormal noise and heating. Brake： 1. The braking performance. 2. Deformation and wear of connecting rod.
  • Page 219 XCT80 Truck Crane Operation Manual Inspection items Boom telescopic cylinder: 1. Action state (with or without pulsation and noise). 2. Action sequence is normal or not. 3. For oil leakage phenomenon. 4. The function of balancing valve. 5. Pipe joint is loose or not.
  • Page 220 XCT80 Truck Crane Operation Manual Inspection items Drum: 1. Crack. 2. Wire rope disorder. Auxiliary arm: 1. Crack, bending and damage. 2. Connecting pin and pin sets lubrication state. Hook and pulley: 1. The hook rotary situation. 2. Deformation. 3. Beam swing is normal or not.
  • Page 221 XCT80 Truck Crane Operation Manual Inspection items Overflow valve: 1. Setting pressure. Control valve: 1. Action situation. 2. Oil leakage. 3. Bolt is loose or not. Main valve: Hydraulic system 1. Action situation. 2. Oil leakage. 3. Brake oil quantity.
  • Page 222 XCT80 Truck Crane Operation Manual Inspection items Pressure gauge: 1. Pointer movement is translation or not. 2. The connection is loose or not. Operating handle and pedal: 1. The function. 2. Clearance. Crane operating mechanism Working light: 1. On or not.

  • Page 223: Inspection Of Steel Structure Bearing Weight

    XCT80 Truck Crane Operation Manual Inspection items Main oil cylinder: 1. Action situation. 2. Oil leakage. Outrigger mechanism 3. Brake oil quantity. 4. Hose for aging, distortion and damage. Auxiliary parts: 1. Damage and loss. Pipe line: 1. The connection positions have loose.

  • Page 224: Daily Inspection

    XCT80 Truck Crane Operation Manual operated; 12-2-2 Daily inspection 12. For safety and fireproof consideration, In every shift or the beginning of each check whether the crane is in a clean and tidy working day, daily inspection is carried out to...

  • Page 225: Inspection For Unusual Use

    XCT80 Truck Crane Operation Manual boom for excess wear trace, welding crack, bolts 12-2-4 Inspection for unusual use and other fasteners for loose phenomenon. If hoisting machinery is stopped not using for 4. Check hook and other lifting for damage, more than one month but no more than one year, abnormal action or wear.

  • Page 226: Wire Rope Inspection

    XCT80 Truck Crane Operation Manual If crane is stopped not working up to 3 months or 12-3 Wire rope inspection above, the wire rope should be checked first before use. 1. Daily visual inspection 4. Test position Every working day all the visible parts of...
  • Page 227 XCT80 Truck Crane Operation Manual d. Wire rope section in balance pulley; e. Any section with wear due to external factors; f. Wire rope internal part with corrosion and fatigue, such as wire rope internal lubrication state, corrosion degree, wear signs and broken wire due to the extrusion or wear etc.;...
  • Page 228 XCT80 Truck Crane Operation Manual cumulative effect, specific rejection standard see the provisions of article 3.5 in GB/T5972-2009 "crane wire rope care, maintenance, installation, test and scrap”. 6. Replacement requirements and steps The new replaced wire rope should be of the same type and specification with the original...
  • Page 229 XCT80 Truck Crane Operation Manual Take replacement of master winch wire rope as an example, firstly place the crane on solid and flat ground, completely retract the boom, and then replace according to the following steps: Steps Precautions Tools Lower the main arm to the...
  • Page 230 XCT80 Truck Crane Operation Manual Steps Precautions Tools Carry out hook decline operation, and pull out wire rope from the drum Wire rope should be pulled out at Protective the same time by hand. gloves Remove the wire rope from the...
  • Page 231 XCT80 Truck Crane Operation Manual Steps Precautions Tools Wind the wire rope 1.Be careful not to wind disorderly wire rope on drum. 2 . Wi r e r o p e e n d s h o u l d b e...
  • Page 232 For wire rope used lubricating oil (grease) model, see chapter 11 of the “XCT80 truck crane operation manual". Shorter service life of wire rope results from the lack of maintenance, especially the crane is used in corrosive environment, as well as the various reasons relating to operation, for example, the use in special situations where wire rope lubricant is strictly prohibited.

  • Page 233: Hook Inspection

    XCT80 Truck Crane Operation Manual 12-4 Hook inspection 1. Use inspection Hook should be regularly checked by professional. Through the inspection, the problem can be found as early as possible, thus can avoid the accidents, the problem should be handled in time after discovery.

  • Page 234: Drum, Pulley And Brake Inspection

    XCT80 Truck Crane Operation Manual 2. Scrap The pulley should be scrapped when one of H o o k s h o u l d b e s c r a p p e d w h e n t h e...
  • Page 235 XCT80 Truck Crane Operation Manual 12-19 Courtesy of CraneMarket.com...
  • Page 236 XCT80 Truck Crane Operation Manual 12-20 Courtesy of CraneMarket.com...

  • Page 237: Chapter 13 Crane Transportation And Storage

    XCT80 Truck Crane Operation Manual Chapter 13 Crane Transportation and Storage Different means of transportation should be selected for XCT80 truck crane according to the actual situation. The center of gravity of the vehicle is 1204mm away from the rotation center (the front direction), with a height of 1950mm.
  • Page 238 XCT80 Truck Crane Operation Manual Figure 13-1 XCT80 truck crane loading diagram 13-2 Crane Transportation and Storage Courtesy of CraneMarket.com...

  • Page 239: Lorry Shipping Parts

    0.25 13-2-1 Balance weight transportation XCT80 truck crane is fully equipped with balance weight of 11.5t, and3.5t for traveling state, its combination is: 2.2t fixed +1.3t movable, for long-distance driving 1.3t of balance weight is required to be fixed firmly on the balance mounting bracket on the frame. In addition, 8t of balance weight should be transported by truck.

  • Page 240: Crane Storage

    XCT80 Truck Crane Operation Manual 13-3 Crane storage The following measures should be taken if the crane is stopped not using in a longer period: a. Lock the doors and windows of the operating room and the cab, ensure all the joysticks and switches are in the neutral or off position, and cut off the power;...
  • Page 241 XCT80 Truck Crane Operation Manual 13-5 Courtesy of CraneMarket.com...
  • Page 242 XCT80 Truck Crane Operation Manual 13-6 Courtesy of CraneMarket.com...

  • Page 243: Terms

    XCT80 Truck Crane Operation Manual Chapter 14 Appendix 14-1 Terms 1. Lifting weight Q It is the mass of lifting heavy objects by the crane in rated lifting weight. Rated lifting weight is the maximum allowable lifting weight for heavy crane safety operations. The weight includes the wire rope from the spreader, slings, and arm head to the hook.
  • Page 244 XCT80 Truck Crane Operation Manual 图14-1 14-2 Appendix Courtesy of CraneMarket.com...

  • Page 245: Lifting Commanding Gestures Diagram

    XCT80 Truck Crane Operation Manual 14-2 Lifting commanding gestures diagram The personnel must be familiar with standard lifting operation command signal and gesture, which should be kept consistent between members. The recommended standard gestures are as follows: 14-2-1 Universal gesture signal 1.
  • Page 246 XCT80 Truck Crane Operation Manual 5 "Hook down" Arm stretches toward in the front, with angle of about 30 degrees, with the fingers naturally separated, and rotates around the wrist. 6 "Hook horizontal movement" Arm stretches straight laterally upward, with fingers kept together and palms facing down, waves to the shoulder level position toward the load movement direction.

  • Page 247: Special Gesture Signal

    XCT80 Truck Crane Operation Manual 9. "Emergency stop" 10. "End of working" Place the two forearms on the chest, with Fingers of both hands outstretched across in fingers outstretched and palms down, and at the front of the forehead. same time wave to both sides in the level.
  • Page 248 XCT80 Truck Crane Operation Manual 3 “Rotating arm” Stretch the arm horizontally straight, pointing the direction of arm turning, with thumb extended and other fingers fist, and rotate around the wrist. 5. “Retracting arm" 4. "Extending arm" Both hands were fist, with fist upward, and Both hands were fist, with fist upward, and...
  • Page 249 XCT80 Truck Crane Operation Manual 14-7 Courtesy of CraneMarket.com...
  • Page 250 Courtesy of CraneMarket.com...

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