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Zoomlion ZLJ5550JQZ100A Operator's Manual

Truck crane
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Summary of Contents for Zoomlion ZLJ5550JQZ100A

  • Page 3 ZLJ5550JQZ100A ruck Crane Operator’s Manual Edition 2 August 2022...
  • Page 5 Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science and Technology Co., Ltd.
  • Page 6 Operator’s Manual for Truck Crane Safety Instructions DANGER, WARNING, CAUTION and NOTICE labels are provided in signs and decals, as well as in texts of this manual to show important instructions. In this manual, the labels are followed by the paragraph or item they apply to.
  • Page 7 Operator’s Manual for Truck Crane Contents To Users .............................. I Safety Instructions ..........................II Chapter 1 Description of Crane 1.1 Models and nameplates ....................1-1 1.1.1 Models ........................1-1 1.1.2 Nameplates ......................1-1 1.1.3 Nameplates installation locations ................. 1-2 1.1.4 Vehicle identification number (VIN) and its locations ........... 1-3 1.1.5 Engine model and manufacturer ................
  • Page 8 Operator’s Manual for Truck Crane 2.4.4 Working conditions ..................... 2-11 2.4.5 Points for attention for safe operation ..............2-16 2.5 Hand signals ........................2-19 Chapter 3 Operation – Crane Chassis 3.1 Driver’s cab ........................3-1 3.1.1 Overview ....................... 3-1 3.1.2 Steering wheel assy....................3-3 3.1.3 Instrument assy.....................
  • Page 9 Operator’s Manual for Truck Crane 3.4.3 Parking the vehicle ..................... 3-73 3.4.4 Emergency stop on the roadway ................ 3-73 Chapter 4 Operation – Crane Superstructure 4.1 Operator’s cab ........................4-1 4.1.1 Overall view ......................4-1 4.1.2 Instrument panel ....................4-2 4.1.3 Emergency stop button ..................
  • Page 10 Operator’s Manual for Truck Crane Chapter 5 Equipment 5.1 Safety technical guidelines for installation ................ 5-1 5.2 Jib ............................. 5-2 5.2.1 General ......................... 5-2 5.2.2 Erection ......................... 5-2 5.2.3 Angle settings ....................... 5-9 5.2.4 Removal......................5-10 5.2.5 Reeving in the auxiliary hoist rope ..............5-11 5.2.6 Connection of hoisting limit switch ..............
  • Page 11 Operator’s Manual for Truck Crane Chapter 7 Transportation and Storage 7.1 Transportation ........................7-1 7.2 Storage ..........................7-2 ZTC1000A763 汽车起重机...
  • Page 13 Truck Crane Operator’S Manual Chapter 1 Description of Crane...
  • Page 15 Operator’s Manual for Truck Crane Chapter 1 Description of Crane 1.1 Models and nameplates 1.1.1 Models Model in automobile industry: ZLJ5550JQZ100A Model in engineering industry: ZTC1000A7 Chassis model: ZLJ5606JQZV6 1.1.2 Nameplates For nameplate of crane, refer to Figure 1-1. For nameplate of chassis, refer to Figure 1-2.
  • Page 16 Operator’s Manual for Truck Crane 1.1.3 Nameplates installation locations The nameplate of crane is installed on the left side of operator’s cab. The nameplate of chassis is installed on the right longitudinal beam of chassis frame. For exact locations, please refer to Figure 1-4 and 1-5. Crane nameplate Figure 1-3 Crane nameplate location Chassis nameplate...
  • Page 17 Operator’s Manual for Truck Crane 1.1.4 Vehicle identification number (VIN) and its locations The VIN of ZLJ5550JQZ100A is L5E6H5D4××A××××××, and is stamped in the crane nameplate, chassis nameplate and right longitudinal beam of chassis frame. The exact location is shown in Figure 1-5.
  • Page 18 Operator’s Manual for Truck Crane Engine name plate Figure 1-7 Engine nameplate location Please provide the above information when contacting Zoomlion for service. ZTC1000A763 汽车起重机...
  • Page 19 Operator’s Manual for Truck Crane 1.2 Crane components and product description 1.2.1 Crane components 1.2.1.1 Crane chassis Figure 1-7 Main components of crane chassis Pos. Description Pos. Description Clutch 5th outrigger Exhaust system Rear outrigger box Front axle Spare tire Engine housing Chassis frame assy.
  • Page 20 Operator’s Manual for Truck Crane 1.2.1.2 Complete vehicle Figure 1-8 Main components of complete vehicle Pos. Description Pos. Description Slewing gear Telescopic boom Derricking gear Length indicator Main hook Auxiliary winch Outrigger beam Main winch Auxiliary hook Fixed counterweight Special purpose chassis Operator’s cab The 5 outrigger...
  • Page 21 Operator’s Manual for Truck Crane 1.2.2 Product description 1.2.2.1 Crane chassis The low-mounted full-width sheet steel cab offers a comfortable and Driver’s cab functional working environment. The control elements and displays are ergonomically arranged. Thus a safe and fatigue free working is assured. The cab has the following features: –...
  • Page 22 Operator’s Manual for Truck Crane Propeller shaft Styre series open-type propeller shaft assy. with contrate gear connected 1.2.2.2 Crane superstructure Operator's cab The sheet steel cab offers a comfortable and functional working environment. The cab can be tilted backwards by 20° during operation. The cab has the following features: Adjustable seat with headrest –...
  • Page 23 Operator’s Manual for Truck Crane 1.2.3 Boom system It includes the telescopic boom and jib. Boom includes 1 basic boom and 6 telescopic sections. Boom length: 13.7m - 75m Jib length: 10.4 m, 17.5 m When the fully extended telescopic boom is fitted with jib (3 angles: 0° , 15° and 30° ), the boom length is L=68.9m+10.4m=79.3m or L=68.9m+17.5m=86.4m.
  • Page 24 Operator’s Manual for Truck Crane Jib =17.5m Extension =9.5m Boom =68.9m Boom (fully retracted) =13.7m Figure 1-10 Boom lengths with optional extension Tip boom: optional, 3.0 m Different length combinations of boom and the tip boom can meet your needs. Refer to Figure 1-11. Note: Before you begin a lift operation with the tip boom, assemble it at an angle of 30°...
  • Page 25 Operator’s Manual for Truck Crane 1.3 Technical data 1.3.1 Overall view Unit: Metric mm Figure 1-12 Overall view ZTC1000A763 汽车起重机 1-11...
  • Page 26 Operator’s Manual for Truck Crane 1.3.2 Protection devices Unit: Metric mm Left guard rail (Material: glassfiber reinforced plastics, connection type: bolt) Right guard rail (Material: glassfiber reinforced plastics, connection type: bolt) Front guard rail Rear guard rail (Material: HG16Mn, connection type: (Material: HG785, connection type: welding) bolt) Figure 1-13 Protection devices...
  • Page 27 Operator’s Manual for Truck Crane 1.3.3 Technical data Table 1-1 Technical data Item Value Remarks Max. rated lifting capacity 100000 Max. load moment of basic kN.m 3880 boom Max. load moment of boom (fully kN.m 1592 extended) Max. lifting height of basic boom 15.1 Max.
  • Page 28 Operator’s Manual for Truck Crane Table 1-1 (continued) Item Value Remarks Front / rear overhang angle ° 10/18 Initial speed: 30 Brake distance ≤10 km/h Deadweight in driving 54600 condition Complete vehicle kerb Mass 54405 mass Load of axle 1 and 2 24000 Load of axle 3 and 4 20600...
  • Page 29 Operator’s Manual for Truck Crane Table 1-1 (continued) Item Value Remarks King pin inclination ° angle Wheel Wheel caster angle ° alignment Wheel camber angle ° Model WP12.400E62 6-cylinder in line, Type turbo-charged, inter-cooling Fuel type Light diesel Engine Displacement 11596 Rated power / RPM kW/r/min...
  • Page 30 Gear pump Part-time 3WD for Zoomlion axles; Drive type 10×6 Real-time 3WD for Drive axle Hande axles 5.73 (Zoomlion axles) Speed ratio 5.92 (Hande axles) An air suspension is Number of leaf springs (front/rear) 12/12/10/- installed for Axle 5 Cab capacity...
  • Page 31 Operator’s Manual for Truck Crane 1.3.4 Work parameters 1.3.4.1 Max. support strength per outrigger When the crane is working within the rated lifting capacities, the max. support strength per outrigger is 90 tons. 1.3.4.2 Hook Table 1-2 Hook configurations Number of Hook model (t) Max.
  • Page 32 Operator’s Manual for Truck Crane 1.3.4.4 Standard rope reevings Table 1-4 Standard rope reevings for various boom lengths Boom 13.7-18.3 22.9-27.5 27.5-32.1 32.1-36.7 36.7-41.3 length Reeving Boom length 41.3-45.9 45.9-50.5 55.1-75.0 68.9+9.5 68.9+10.4 Reeving Boom length 68.9+17.5 68.5+9.5+10.4 68.9+9.5+17.5 Reeving (1) If rope reevings are less than the value listed in the above table during lifting, examine the load on single wire rope to make sure that it is no more than the max.
  • Page 33 Operator’s Manual for Truck Crane Table 1-5 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9...
  • Page 34 Operator’s Manual for Truck Crane Table 1-6 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 35 Operator’s Manual for Truck Crane Table 1-7 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3...
  • Page 36 Operator’s Manual for Truck Crane Table 1-8 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5...
  • Page 37 Operator’s Manual for Truck Crane Table 1-9 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3...
  • Page 38 Operator’s Manual for Truck Crane Table 1-10 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 39 Operator’s Manual for Truck Crane Table 1-11 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 40 Operator’s Manual for Truck Crane Table 1-12 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 41 Operator’s Manual for Truck Crane Table 1-13 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 42 Operator’s Manual for Truck Crane Table 1-14 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 43 Operator’s Manual for Truck Crane Table 1-15 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 44 Operator’s Manual for Truck Crane Table 1-16 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 45 Operator’s Manual for Truck Crane Table 1-17 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 46 Operator’s Manual for Truck Crane Table 1-18 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5 50.5...
  • Page 47 Operator’s Manual for Truck Crane Table 1-19 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 48 Operator’s Manual for Truck Crane Table 1-20 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 49 Operator’s Manual for Truck Crane Table 1-21 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 50 Operator’s Manual for Truck Crane Table 1-22 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3 41.3...
  • Page 51 Operator’s Manual for Truck Crane Table 1-23 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 52 Operator’s Manual for Truck Crane Table 1-24 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 53 Operator’s Manual for Truck Crane Table 1-25 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 54 Operator’s Manual for Truck Crane Table 1-26 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1 32.1...
  • Page 55 Operator’s Manual for Truck Crane Table 1-27 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 56 Operator’s Manual for Truck Crane Table 1-28 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 57 Operator’s Manual for Truck Crane Table 1-29 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 58 Operator’s Manual for Truck Crane Table 1-30 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9 22.9...
  • Page 59 Operator’s Manual for Truck Crane Table 1-31 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1 32.1...
  • Page 60 Operator’s Manual for Truck Crane Table 1-32 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3 41.3...
  • Page 61 Operator’s Manual for Truck Crane Table 1-33 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5 50.5...
  • Page 62 Operator’s Manual for Truck Crane Table 1-34 Rated capacity chart (with boom only) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3 68.9...
  • Page 63 Operator’s Manual for Truck Crane Table 1-35 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 13.7 18.3 18.3 18.3 18.3...
  • Page 64 Operator’s Manual for Truck Crane Table 1-36 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5...
  • Page 65 Operator’s Manual for Truck Crane Table 1-37 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7...
  • Page 66 Operator’s Manual for Truck Crane Table 1-38 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9...
  • Page 67 Operator’s Manual for Truck Crane Table 1-39 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 40 t full counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 55.1 59.7...
  • Page 68 Operator’s Manual for Truck Crane Table 1-40 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3...
  • Page 69 Operator’s Manual for Truck Crane Table 1-41 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5...
  • Page 70 Operator’s Manual for Truck Crane Table 1-42 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7...
  • Page 71 Operator’s Manual for Truck Crane Table 1-43 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9...
  • Page 72 Operator’s Manual for Truck Crane Table 1-44 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 27 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 59.7 59.7 59.7...
  • Page 73 Operator’s Manual for Truck Crane Table 1-45 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3...
  • Page 74 Operator’s Manual for Truck Crane Table 1-46 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5...
  • Page 75 Operator’s Manual for Truck Crane Table 1-47 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7...
  • Page 76 Operator’s Manual for Truck Crane Table 1-48 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9...
  • Page 77 Operator’s Manual for Truck Crane Table 1-49 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 23 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 55.1 59.7 59.7...
  • Page 78 Operator’s Manual for Truck Crane Table 1-50 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 18.3 18.3 18.3 18.3 18.3 22.9...
  • Page 79 Operator’s Manual for Truck Crane Table 1-51 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5...
  • Page 80 Operator’s Manual for Truck Crane Table 1-52 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7 41.3...
  • Page 81 Operator’s Manual for Truck Crane Table 1-53 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9...
  • Page 82 Operator’s Manual for Truck Crane Table 1-54 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 18 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 59.7 59.7 59.7...
  • Page 83 Operator’s Manual for Truck Crane Table 1-55 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3...
  • Page 84 Operator’s Manual for Truck Crane Table 1-56 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5...
  • Page 85 Operator’s Manual for Truck Crane Table 1-57 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7...
  • Page 86 Operator’s Manual for Truck Crane Table 1-58 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9...
  • Page 87 Operator’s Manual for Truck Crane Table 1-59 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 13 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 55.1 59.7 59.7...
  • Page 88 Operator’s Manual for Truck Crane Table 1-60 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 18.3 18.3 18.3 18.3 18.3 22.9 22.9...
  • Page 89 Operator’s Manual for Truck Crane Table 1-61 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1...
  • Page 90 Operator’s Manual for Truck Crane Table 1-62 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3...
  • Page 91 Operator’s Manual for Truck Crane Table 1-63 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m,2 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5...
  • Page 92 Operator’s Manual for Truck Crane Table 1-64 Rated capacity chart (with tip boom) Unit: ton Outriggers fully extended to 8m, 2 t counterweight, over side or rear working area Tip boom length: 3m; angle: 30° Radius Radius 55.1 55.1 55.1 55.1 59.7 59.7...
  • Page 93 Operator’s Manual for Truck Crane Table 1-65 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9...
  • Page 94 Operator’s Manual for Truck Crane Table 1-66 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1...
  • Page 95 Operator’s Manual for Truck Crane Table 1-67 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3...
  • Page 96 Operator’s Manual for Truck Crane Table 1-68 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5...
  • Page 97 Operator’s Manual for Truck Crane Table 1-69 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 40 t full counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3...
  • Page 98 Operator’s Manual for Truck Crane Table 1-70 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9 22.9...
  • Page 99 Operator’s Manual for Truck Crane Table 1-71 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 100 Operator’s Manual for Truck Crane Table 1-72 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 101 Operator’s Manual for Truck Crane Table 1-73 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 102 Operator’s Manual for Truck Crane Table 1-74 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 27 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 103 Operator’s Manual for Truck Crane Table 1-75 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 104 Operator’s Manual for Truck Crane Table 1-76 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 105 Operator’s Manual for Truck Crane Table 1-77 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 106 Operator’s Manual for Truck Crane Table 1-78 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 107 Operator’s Manual for Truck Crane Table 1-79 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 23 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 108 Operator’s Manual for Truck Crane Table 1-80 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9 22.9...
  • Page 109 Operator’s Manual for Truck Crane Table 1-81 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 110 Operator’s Manual for Truck Crane Table 1-82 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3 41.3...
  • Page 111 Operator’s Manual for Truck Crane Table 1-83 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 112 Operator’s Manual for Truck Crane Table 1-84 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 18 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3 68.9...
  • Page 113 Operator’s Manual for Truck Crane Table 1-85 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 114 Operator’s Manual for Truck Crane Table 1-86 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 115 Operator’s Manual for Truck Crane Table 1-87 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 116 Operator’s Manual for Truck Crane Table 1-88 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 117 Operator’s Manual for Truck Crane Table 1-89 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 13 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 118 Operator’s Manual for Truck Crane Table 1-90 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 2 t counterweight, over side or rear working area Boom length (m) Radius Radius 13.7 18.3 18.3 18.3 18.3 18.3 22.9 22.9 22.9...
  • Page 119 Operator’s Manual for Truck Crane Table 1-91 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 2 t counterweight, over side or rear working area Boom length (m) Radius Radius 27.5 27.5 27.5 27.5 27.5 27.5 32.1 32.1 32.1...
  • Page 120 Operator’s Manual for Truck Crane Table 1-92 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 2 t counterweight, over side or rear working area Boom length (m) Radius Radius 36.7 36.7 36.7 36.7 36.7 36.7 41.3 41.3 41.3...
  • Page 121 Operator’s Manual for Truck Crane Table 1-93 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 2 t counterweight, over side or rear working area Boom length (m) Radius Radius 45.9 45.9 45.9 45.9 45.9 45.9 50.5 50.5 50.5...
  • Page 122 Operator’s Manual for Truck Crane Table 1-94 Rated capacity chart (with boom only) Unit: ton Outriggers intermediately extended to 5.3m, 2 t counterweight, over side or rear working area Boom length (m) Radius Radius 55.1 55.1 55.1 55.1. 59.7 59.7 59.7 64.3 64.3...
  • Page 123 Operator’s Manual for Truck Crane Table 1-95 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 40 t full counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0°...
  • Page 124 Operator’s Manual for Truck Crane Table 1-96 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 27 t counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0° 0°...
  • Page 125 Operator’s Manual for Truck Crane Table 1-97 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 23 t counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0° 0°...
  • Page 126 Operator’s Manual for Truck Crane Table 1-98 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 18 t counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0° 0°...
  • Page 127 Operator’s Manual for Truck Crane Table 1-99 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 13 t counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0° 0°...
  • Page 128 Operator’s Manual for Truck Crane Table 1-100 Rated capacity chart (with jib/extension) Unit: ton Boom + jib/extension (m) Outriggers fully extended, over side or rear working area, 2 t counterweight Boom angle (° ) 68.9+9.5 68.9+10.4 68.9+17.5 68.9+9.5+10.4 68.9+9.5+17.5 0° 0°...
  • Page 129 Operator’s Manual for Truck Crane 1.3.6 Lifting height charts Figure 1-14 Lifting height chart for boom + jib + extension ZTC1000A763 汽车起重机 1-115...
  • Page 130 Operator’s Manual for Truck Crane Figure 1-15 Lifting height chart for boom + tip boom 1-116 ZTC1000A763 汽车起重机...
  • Page 131 Operator’s Manual for Truck Crane (1) The outrigger beams of Outriggers must be extended (to a uniform length on both sides) to the extent stated in the rated capacity chart. All wheels must be raised clear of the ground. (2) When you set up the 5 outrigger, the values in the rated capacity charts are suitable for 360°...
  • Page 132 Operator’s Manual for Truck Crane (7) The Maximum rated lifting capacity for the rooster sheave is 6500 kg. If the rated lifting capacity found out in the rated capacity chart is less than 6500 kg according to the actual working conditions, take the value in the rated capacity chart. For example (OM: boom is fully extended to 75 m, with 38 tons counterweight): The rated lifting capacity is 6500 kg when the working radius of 20 m.
  • Page 133 Operator’s Manual for Truck Crane 1.3.7 Working areas Over front Over side rear working area working area Figure 1-16 Working areas ZTC1000A763 汽车起重机 1-119...
  • Page 134 Operator’s Manual for Truck Crane Appendix: more information Technical data Item Value Remarks Power Change interval of fuel hose Month system Rated work pressure of air Brake reservoir system Response time of system 0.55 Position and backrest angle of Center position, moving Measure the depth °...
  • Page 135 Truck Crane Operator’S Manual Chapter 2 Safety Guidelines...
  • Page 137 Operator’s Manual for Truck Crane Chapter 2 Safety Guidelines 2.1 Safety instructions and safety signs 起 重 2.1.1 Safety instructions 机 说 Be sure to comply with all valid national and regional traffic regulations when driving the 明 crane on roads! No person is allowed to stay in operator’s cab during driving.
  • Page 138 Operator’s Manual for Truck Crane Do not telescope the boom with 警 告 WARNING a suspended load. This decal is only stuck on the 严禁带载伸缩 right pane in the operator’s cab. Do Not Telescope With Suspended Loads Exit This decal is only stuck on the front windshield in the operator’s cab.
  • Page 139 Operator’s Manual for Truck Crane Always lock the door when not in use. This decal is stuck on the lower 起 right corner of left hood. 重 机 说 明 No step This decal is on the roof of left hood.
  • Page 140 Operator’s Manual for Truck Crane 2.2 Planning crane operation In addition to a perfectly working crane and a well-trained crew, crane operation planning is an important principle of safe crane operation. The crane operator must obtain or receive the necessary information in a timely fashion before driving to the work site.
  • Page 141 Operator’s Manual for Truck Crane 2.3 Break-in instructions The purpose of crane break-in is to improve its adaptability to the environment. Proper break-in 起 operation can extend crane service life, increase work reliability and save energy consumption. 重 机 Pay attention to the following items during the break-in period: 说...
  • Page 142 Operator’s Manual for Truck Crane 2.4 General safety technical guidelines 2.4.1 Requirements of the crane operator, rigger and signalman The primary responsibility of crane operator, rigger and signalman is to control, operate, adjust the crane and conduct the operation in a manner that is safe for both themselves and others. Many crane accidents are caused by incorrect crane operation.
  • Page 143 Operator’s Manual for Truck Crane Be familiar with safety rules, safety signals and symbols. Be qualified with the work in hearing, eyesight and reaction ability. Have the requisite physical to operate the crane safely. Be able to estimate the distance, height and 起...
  • Page 144 Operator’s Manual for Truck Crane 2.4.1.3 General qualifications for signalman The signalman is to transfer signal from the rigger to operator. He can substitute for the rigger to conduct the crane operation, but such work can only be done by one person at any time. Qualifications for signalman: Be qualified with the work in hearing, eyesight and reaction ability.
  • Page 145 Operator’s Manual for Truck Crane 2.4.2.2 Permissible ground pressure of outrigger When the crane is supported on outriggers for a lift operation, the outriggers transmit significant 起 forces to the ground. In certain cases, a single outrigger has to transmit almost the entire 重...
  • Page 146 Operator’s Manual for Truck Crane Note: If there is anything about the load bearing capacity of the ground at the placement site that you do not understand, use a special detecting instrument to do a soil test. Only strong materials may be used for the outrigger pad bases such as properly dimensioned wooden timbers.
  • Page 147 Operator’s Manual for Truck Crane If the crane is positioned at an incline and the boom is turned towards the downslope, 起 then the radius is increased as a result. It is possible that the crane can topple in 重 extreme cases.
  • Page 148 Operator’s Manual for Truck Crane Table 2-2 Wind speed Instantaneous Average wind Beaufort Description wind speed Effect of the wind on the land speed (m/s) (m/s) Calm 0 – 0.2 0 – 0.3 No wind, smoke rises vertically Slight air Wind direction shown by smoke 0.3 –...
  • Page 149 Operator’s Manual for Truck Crane Take the ground wind speed of 14.1 m/s as an example. For the wind pressure and wind speed of different heights, please refer to Table 2-3. 起 Table 2-3 Wind speeds for different heights above ground 重...
  • Page 150 Operator’s Manual for Truck Crane The higher the height above sea level is, the lower the air pressure is, and the less the oxygen content is. The height above sea level is higher than 2000 m, the following crane performance will be affected: –...
  • Page 151 Operator’s Manual for Truck Crane same time, fully retract and correctly stow the boom. Strong electromagnetic fields are likely to be present if the construction site is close to a 起 transmitter. Under this condition, be sure to consult a high frequency specialist or contact 重...
  • Page 152 Operator’s Manual for Truck Crane 2.4.5 Points for attention for safe operation Personnel must stay away from the area below the boom. Do not let personnel on the slewing table while you operate the crane. Do not move personnel on the load or other equipment used to lift.
  • Page 153 Operator’s Manual for Truck Crane The crane, with extended outriggers, must be on the ground with a slope α of less than 0.6° during operation. 起 重 机 说 明 Do not pull load at an angle and do not lift a load that is not in balance.
  • Page 154 Operator’s Manual for Truck Crane m) When the job-site is near live power lines, you must keep a safe distance. Make sure that you comply with the related regulations. Personnel must stay away from the reach of the boom. Stop the crane in an emergency. When the load is off the ground, do not adjust the hoist gear brake.
  • Page 155 Operator’s Manual for Truck Crane 2.5 Hand signals Start 起 重 Hold the right arm stretched vertically 机 upwards. The palm faces forwards. 说 明 Use main winch Tap fist on head, then use regular signal. Use auxiliary winch Tap elbow with one hand, then use regular signal.
  • Page 156 Operator’s Manual for Truck Crane Lower the load With arm extended downward with a 30° angle to the body, forefinger pointing down, move hand in small horizontal circle. Lift the load slowly With forearm vertical, palm of the hand facing upwards, wave hand up repeatedly.
  • Page 157 Operator’s Manual for Truck Crane Rotate slowly Turn left: With right forearm vertical, the palm of the hand facing outwards, move 起 forearm horizontally and repeatedly, 重 机 fingers pointing in the direction of 说 rotation. 明 Turn right: With left forearm vertical, the palm of the hand facing outwards, move forearm horizontally and repeatedly, fingers pointing in the direction of...
  • Page 158 Operator’s Manual for Truck Crane m) Raise boom slowly Forearm extends in front of body with palm facing downwards, another hand moves up and down with thumb pointing upwards. Lower boom slowly Forearm extends in front of body with palm facing upwards, another hand moves up and down with thumb pointing downwards.
  • Page 159 Operator’s Manual for Truck Crane Stop Arm extended, palm down, and move the arm back and forth horizontally. 起 重 机 说 明 Emergency stop Both arms extended, palms down, move arms back and forth horizontally. End a movement Cross your hands in front of your forehead.
  • Page 161 Truck Crane Operator’S Manual Chapter 3 Operation – Crane Chassis...
  • Page 163 Operator’s Manual for Truck Crane Chapter 3 Operation – Crane Chassis 3.1 Driver’s cab 起 重 3.1.1 Overview 机 说 明 – Figure 3-1 Cab exterior Pos. Description Pos. Description Wire rope holder Side turn signal Rotating beacon Corner marker light Handrail Mirror (L) Mirror (R)
  • Page 164 Operator’s Manual for Truck Crane 起 重 机 说 明 – Figure 3-2 Cab interior Pos. Description Pos. Description Instrument console Sleep berth Steering wheel assy. Co-driver’s seat Oil reservoir, clutch Center console (Not applicable to ATM) Air horn switch Center electric control box Foot pedal (L): Clutch Toolbox...
  • Page 165 Operator’s Manual for Truck Crane 3.1.2 Steering wheel assy. See Figure 3-3. 起 重 机 说 明 Figure 3-3 Steering wheel assy. – Pos. Description Pos. Description Ignition starter switch Left-hand steering column switch Steering wheel adjustment handle Electric horn buttons Steering wheel Right-hand steering column switch 3.1.2.1 Steering wheel adjustment handle...
  • Page 166 Operator’s Manual for Truck Crane 3.1.2.2 Left-hand steering column switch See Figure 3-4. 起 重 机 说 明 Figure 3-4 Left-hand steering column switch – Turn signal activation (left / right) Jog steering column switch forwards (in direction 1): activate turn signal (right). Jog steering column switch backwards (in direction 3): activate turn signal (left).
  • Page 167 Operator’s Manual for Truck Crane 3.1.2.3 Right-hand steering column switch See Figure 3-5. 起 重 机 说 明 – Figure 3-5 Right-hand steering column switch Activate the windshield wiper Jog the steering column switch forwards (in direction 1, MIST): activate the windshield wiper and automatically reset.
  • Page 168 Operator’s Manual for Truck Crane 3.1.2.5 Ignition starter switch The 4 positions of the switch (in clockwise sequence) are as follows: 起 LOCK All circuits are OFF. You can plug in or pull out the key. 重 The battery begins to supply electricity and parts of the electrical system begin to 机...
  • Page 169 Operator’s Manual for Truck Crane 3.1.3 Instrument assy. 3.1.3.1 Instruments 起 重 机 说 明 – Figure 3-6 Instrument assy. Pos. Description Pos. Description Engine coolant thermometer Fuel level indicator Engine tachometer Main interface Indicator lights Operational buttons Speedometer 1. Engine coolant thermometer When the ignition starter switch is in ON position, the engine coolant thermometer displays the engine...
  • Page 170 Operator’s Manual for Truck Crane 2. Engine tachometer Displays engine speed (RPM). 起 重 机 说 明 3. Odometer Displays the speed of the crane in kilometers per hour (km/h) – 4. Fuel level indicator Displays the level of remaining fuel in the fuel tank.
  • Page 171 Operator’s Manual for Truck Crane 3.1.3.2 Control lights 起 重 机 说 明 – Figure 3-7 Instrument indications Description Pos. Description Warning light Warning light Air filter clogged (Not used) AMT (Not used) Warning light Control light Water in fuel ASR (Not used) Control light Control light...
  • Page 172 Operator’s Manual for Truck Crane Warning light Air filter clogged (Not used). 起 重 机 说 明 Warning light Water in fuel Illuminates: Indicating that the water level in the fuel coarse filter element’s water collecting cup is too high. Discharge the water from the cup.
  • Page 173 Operator’s Manual for Truck Crane Control light DPF regeneration prohibited Illuminates and remains on in red: 起 Indicating that the DPF regeneration prohibition 重 机 switch is pressed. 说 The DPF regeneration prohibition switch can 明 automatically return to its original position after being pressed and then released.
  • Page 174 Operator’s Manual for Truck Crane Cruise indicator light (Not used) 起 重 机 说 明 10. Warning light Transmission malfunction (Not used) 11. Control light – (Not used) 12. Control light Emergency steering (Not used) 13. Warning light Driver’s seatbelt unfastened Illuminates: The driver’s seatbelt is unfastened.
  • Page 175 Operator’s Manual for Truck Crane 15. Control light Right friction lining worn out One or multiple friction linings at the right side of 起 the axles are worn out. This control light 重 机 illuminates when an open circuit is detected. 说...
  • Page 176 Operator’s Manual for Truck Crane 3.1.3.3 Control lights 起 重 10 11 12 13 14 15 16 机 说 明 30 29 28 27 26 25 24 23 22 21 20 19 Figure 3-8 Display unit – Pos. Description Pos. Description Control light Control light...
  • Page 177 Operator’s Manual for Truck Crane Control light Warning light PTO engaged Power supply undervoltage Control light Warning light 起 ABS malfunction Coolant level low 重 机 Control light Warning light 说 ABS error code displayed Adblue level low 明 Control light VVEB applied Control light Vehicle direction of travel left...
  • Page 178 Operator’s Manual for Truck Crane Control light Rear fog light Illuminates: 起 The rear fog light is ON. 重 机 说 明 Warning light Fuel level low Illuminates: The fuel level is lower than the set value (10%). Warning light –...
  • Page 179 Operator’s Manual for Truck Crane low or the engine oil filter element is dirty. Immediately bring the crane to a standstill 起 and rectify! Otherwise the 重 机 engine will be damaged 说 seriously! 明 Warning light Left door opened Illuminates: The left door is opened.
  • Page 180 Operator’s Manual for Truck Crane Warning light ABS error code displayed Illuminates: 起 Indicates that there is a system 重 failure. 机 说 Switch fault 明 diagnosis switch to read the flash code. Control light VVEB applied Illuminates: The VVEB is working. –...
  • Page 181 Operator’s Manual for Truck Crane Control light Diesel engine preheating system 起 Illuminates: 重 机 The engine is being preheated. 说 Note: 明 The preheating system works automatically and is controlled by the air intake temperature of the engine. Control light Engine after-treatment malfunction –...
  • Page 182 Operator’s Manual for Truck Crane After the engine is successfully started and it will go off immediately. 起 Note: 重 机 A Class C malfunction will 说 become a historic malfunction 明 after three driving cycles. Class B malfunction Can be further divided into Class B1 and B2: Class B1 malfunction: refers to a malfunction which will possibly...
  • Page 183 Operator’s Manual for Truck Crane remains on for 5 s, then it goes off for 10 s. After that, this indicator light remains on all the 起 time. 重 机 After the engine is successfully 说 started, this indicator light still 明...
  • Page 184 Operator’s Manual for Truck Crane Control light Low pressure 1 Illuminates: 起 重 The pressure of service brake of 机 front axle is lower than the set 说 明 value (0.5 MPa). Control light Transversal differential lock Illuminates: The button “Longitudinal and transversal differential locks”...
  • Page 185 Operator’s Manual for Truck Crane temperature is decreased, so as to avoid engine cylinder damage due to sudden 起 temperature reduction. 重 机 说 明 Warning light Adblue level low Illuminates: The Adblue level is lower than the setting value of 10%. –...
  • Page 186 Operator’s Manual for Truck Crane 3.1.3.4 Main instrument interface 起 重 机 说 明 – Figure 3-9 Main interface Pos. Description Pos. Description Current air pressure Mileage subtotal Axle 5 suspension Indicator Number of counterweight plates Low pressure 2 Indicator Target pressure, Axle 5 Low pressure 1 Interface indication...
  • Page 187 Operator’s Manual for Truck Crane Indicator Mileage subtotal Displays the mileage within the current driving cycle 起 重 Number of counterweight 机 plates 说 Displays the number of detected 明 counterweight plates on the chassis frame. Target air pressure Displays the target air pressure of Axle 5 suspension corresponding to current number of counterweight plates detected...
  • Page 188 Operator’s Manual for Truck Crane Air pressure control mode, Axle 5 suspension The two control modes, i.e. 起 automatic and manual, can be 重 机 switched over using the mode 说 switch（A/M）. 明 Under the automatic mode, when the PTO is not engaged and the parking brake is applied, the 0.5/0.6Mpa switch and the air relief pressure switch are invalid.
  • Page 189 Operator’s Manual for Truck Crane Current air pressure, axle 5 suspension Displays current air pressure of 起 Axle 5 suspension. 重 机 10 Air pressure 2 说 明 Indicates air pressure of the front axle braking system. 11 Air pressure 1 Indicates air pressure of the rear axle braking system.
  • Page 190 Operator’s Manual for Truck Crane 15 GPS prompt box Not used 起 重 机 16 Vehicle speed digital display 说 Displays current vehicle 明 speed. 3.1.3.5 Secondary instrument interface Press function key F2 to enter the superstructure interface. This interface displays the working hours and fuel consumption subtotal etc. of the superstructure.
  • Page 191 Operator’s Manual for Truck Crane Pos. Description Pos. Description 起 重 Superstructure working hours Average driving fuel consumption 机 Accumulated driving fuel 说 Fuel consumption subtotal 明 consumption Accumulated fuel consumption of Fuel consumption total superstructure Average fuel consumption of Engine working hours superstructure Superstructure working hours...
  • Page 192 Operator’s Manual for Truck Crane 3.1.3.6 Level 3 instrument interface Press function key F3 to enter the chassis interface. 起 This interface displays some engine data. As shown in the following figure. 重 机 说 明 – Figure 3-11 3 instrument interface Pos.
  • Page 193 Operator’s Manual for Truck Crane 3.1.3.7 System function setting interface Press F4 in the main interface to enter the system function setting interface as shown in Figure 起 3-12. 重 Select an item by maneuvering F3 and F4. 机 Press F2 to confirm it and enter a sub-interface. 说...
  • Page 194 Operator’s Manual for Truck Crane The fault check interface is as shown in Figure 3-14. Information related to instrument pin definition, GPS information (not applicable), engine 起 malfunctions, ABS trouble code table and instrument CAN bus can be queried in this interface. 重...
  • Page 195 Operator’s Manual for Truck Crane d) Zeroing of mileage subtotal Press F3 and F4 in the system function interface to select the subtotal mileage clearing 起 interface. 重 Press F2 to enter the sub-interface as shown in Figure 3-16. 机 Press F3 and F4 to select the “Fuel subtotal”...
  • Page 196 Operator’s Manual for Truck Crane In the maintenance info interface: Press F3 and F4 to select the item to be queried. Press F2 to confirm the selection and enter the sub-interface of the selected item. 起 重 The maintenance reminder query interface is as shown in Figure 3-18, which provides the 机...
  • Page 197 Operator’s Manual for Truck Crane Press F3 and F4 to go the next or previous page. Press F2 to complete and confirm current maintenance. g） Following operations can be conducted in the parameter setting interface: 起 - Backlight brightness adjustment; 重...
  • Page 198 Operator’s Manual for Truck Crane 3.1.8 Center console 起 重 机 说 明 – Figure 3-24 Center console Pos. Description Pos. Description Reversing, navigation, radio player Cigarette lighter assembly Switch panel, center console Gear lever Control panel, A/C and cab heater Hand brake 3-36 ZTC1000A763 汽车起重机...
  • Page 199 Operator’s Manual for Truck Crane 3.1.8.1 Keyboard 起 重 机 说 明 – Figure 3-24 Keyboard Pos. Description Pos. Description Button Control mode selections witch, axle 5 Engine stop suspension Button Air relief switch Rear fog light Button Longitudinal and transversal differential 0.5Mpa/ 0.6Mpa charging switch locks Button...
  • Page 200 Operator’s Manual for Truck Crane Button Engine stop Press and hold for 2 – 3 seconds: The engine stops running. 起 重 机 说 明 Button Rear fog light Pressed: The rear fog light is ON. Note: The rear fog light can be activated only when the high beam or low beam is activated.
  • Page 201 Operator’s Manual for Truck Crane switch for 3-3.6 s to clear historic faults. Button Highland mode 起 Pressed: 重 机 In order to avoid engine shutdown after 说 the power takeoff is engaged for the 明 superstructure when the vehicle works at the highland, engine idle speed will be automatically increased to the set value of 850 r/min after this button is pressed.
  • Page 202 Operator’s Manual for Truck Crane When the PTO is engaged or during crane traveling, the automatic control mode is invalid. 起 Under the manual mode, when the parking 重 机 brake is applied and PTO is not engaged, 说 the 0.5/0.6Mpa air charging switch and the 明...
  • Page 203 Operator’s Manual for Truck Crane 13 Headlight beam adjusting switch To adjust the angle of the beams sent from the headlights. 起 重 机 说 明 14 Button Engine fault diagnosis It is used for inputting standby switch to decode urgently after the engine automatically locks.
  • Page 204 Operator’s Manual for Truck Crane 3.1.8.2 Reversing display, navigation and radio assy. Please refer to the manual of the media player delivered with the crane. 起 3.1.8.3 Gear shift joystick 重 机 The gear shift joystick is located at the right side of the driver’s seat. It can be used to select 说...
  • Page 205 Operator’s Manual for Truck Crane 3.1.8.5.2 Air pressure control mode When an optional 325/95R24 is installed for Axle 5 起 Auto mode (air pressure control switch is in A position) 重 When the second counterweight plate is detected, and the first one is not, the number of 机...
  • Page 206 Operator’s Manual for Truck Crane In case of a faulty air pressure sensor, an alarm will be given and this auto mode is exited. When the parking brake is applied and the PTO is not engaged, if air pressure of Axle 5 suspension fails to reach target value, an overpressure or underpressure alarm will be given.
  • Page 207 Operator’s Manual for Truck Crane 3.1.9 Crane lighting 3.1.9.1 Front combination signals 起 Take the lights on the left as an example. The lights on right side are the same as the left ones. 重 机 For the details, refer to Figure 3-22. 说...
  • Page 208 Operator’s Manual for Truck Crane 3.1.9.3 Interior illumination The interior illumination is located at 起 the roof of the driver's cab, including 重 small lamp & its button and door lamp 机 & its button. 说 明 Small lamp & its button: The direction of small lamp can be adjusted by pressing its edge.
  • Page 209 Operator’s Manual for Truck Crane 起 重 机 说 明 Inside door switch Door handle Locking switch Electric window switch Figure 3-24 Door of driver’s cab – Open the door from inside Pull the inside door switch upwards and hold the handle to push the door outwards. Lock the door from inside The locking knob is on the lower edge of door window.
  • Page 210 Operator’s Manual for Truck Crane 3.1.11 Seats in driver's cab 3.1.11.1 Seat adjustment 起 This crane is equipped with a suspension 重 机 seat, which can be adjusted to suit any 说 driver height or size before setting off. 明 When you adjust the stiffness of the seat, please set the red pointer within the range between 40 kg to 130 kg.
  • Page 211 Operator’s Manual for Truck Crane 3.1.11.3 Putting on seat belt Fasten and adjust the three-point seat belt to suitable position before setting off. 起 Insert tongue piece into belt lacer to fasten the belt. 重 Press the button to unfasten the belt. 机...
  • Page 212 Operator’s Manual for Truck Crane initial position. 起 重 Set the ignition starter switch to "ACC", when you use the cigarette lighter with the 机 engine in the OFF position. 说 明 – 3-50 ZTC1000A763 汽车起重机...
  • Page 213 Operator’s Manual for Truck Crane 3.2 Before starting up the vehicle 3.2.1 Prerequisites 起 重 If the crane is used for the first time, make sure the crane is in proper working condition 机 (without damage or abnormalities). 说 明 Always use the correct light diesel oil and engine oil.
  • Page 214 Operator’s Manual for Truck Crane The engine will give an alarm. And after the engine has been running for 60 min or when the engine starts next time, the engine output torque will be limited to 60% of max. value till the suitable AdBlue is added. 起...
  • Page 215 Operator’s Manual for Truck Crane wires are tight. Examine the level of the battery electrolyte. Turn the ignition starter switch to the “ON” position and examine the functions of the 起 items that follow: 重 机 – Instruments 说 – Switches and buttons 明...
  • Page 216 Operator’s Manual for Truck Crane Before the crane can be driven on public roads, make sure that the following prerequisites are met: – All loose parts are secured onto the crane. 起 – The operator’s cab is in the driving direction and secured mechanically. 重...
  • Page 217 Operator’s Manual for Truck Crane Left rear combination signals (on chassis frame left rear part) Refer to Figure 3-34. The left rear combination signals are combined in a rectangle plate. 起 重 机 说 明 Figure 3-29 Left rear combination signals –...
  • Page 218 Operator’s Manual for Truck Crane Examine the following illuminations and warning devices before setting off. Interior illumination It is installed on the roof of the driver's cab to supply interior illumination. 起 Sliding beam illumination 重 机 They are installed near the front outrigger boxes to supply illumination for sliding 说...
  • Page 219 Operator’s Manual for Truck Crane CAUTION Turn off the shutoff gate valve on the hot-water pipe of heater at the bottom of driver's cab when you use the air conditioning in summer and turn on the valve 起 in winter. 重...
  • Page 220 Operator’s Manual for Truck Crane “parking brake closed”, “engine exhaust brake”, “longitudinal differential lock” and “transversal differential lock” etc. Deactivate the PTO control lever. 起 Pressure of control air circuit of clutch should be more than the starting pressure. 重 机...
  • Page 221 Operator’s Manual for Truck Crane 3.3 Driving the crane 3.3.1 Starting and stopping the engine 起 重 3.3.1.1 Starting the engine 机 说 Examine the items that follow: 明 Engine oil for correct level and make sure that it is clean Coolant for correct level Fuel tank for correct level AdBlue tank for correct level.
  • Page 222 Operator’s Manual for Truck Crane (1) In order to make the engine oil flow into each part of engine and raise up 起 重 water temperature to burn the fuel normally, it is necessary to warm up the 机 engine before starting. 说...
  • Page 223 Operator’s Manual for Truck Crane crane. The battery drains in these conditions. If you park the crane on a slope, you must put the chocks before and behind the wheels to avoid accident. 起 To prevent an accident when you park the crane in the dark, you must turn on the hazard 重...
  • Page 224 Operator’s Manual for Truck Crane (1) Only operate the engine exhaust brake with engine running. 起 (2) Sensible use of the retarder with anticipating driving methods reduces 重 机 wear on the service brake and thereby reduces operating cost. 说 (3) On long descending gradients, select a switching stage that leaves further 明...
  • Page 225 Operator’s Manual for Truck Crane 起 If the pointer is near “0”, refill the fuel reserve. Do not drive when the fuel tank is 重 empty, or the fuel system will have to be vented. 机 说 Examining the coolant temperature 明...
  • Page 226 Operator’s Manual for Truck Crane position. Both the high gear and low gear ranges have a neutral position, namely the neutral position between 7 and 8 gears in high gear range and between 2 and 3 gears in low 起 gear range.
  • Page 227 Operator’s Manual for Truck Crane 3.3.5 Clutch operation In the drive system, the clutch is a part directly connected with the engine. Its function is to 起 effectively engage or disengage its driving and driven parts under driver’s operation. 重 3.3.5.1 Points for attention 机...
  • Page 228 Operator’s Manual for Truck Crane 3.3.7 Brake operation The brake system consists of driving brake (service brake), engine exhaust brake and 起 emergency brake (parking brake). The emergency brake can also be selected to park the 重 vehicle in normal condition and on slopes. 机...
  • Page 229 Operator’s Manual for Truck Crane How to activate the engine exhaust brake:  Release the engine control pedal.  Press the VVEB switch on the center console, and the VVEB starts to work and the 起 VVEB indicator light illuminates. 重...
  • Page 230 Operator’s Manual for Truck Crane 3.3.8 PTO operation 3.3.8.1 Engaging PTO 起 See Figure 3-32. 重 机 Open the shutoff gate valve on the hydraulic oil tank to connect the hydraulic oil tank and 说 the oil lines. 明 Start the engine. Examine the barometer to see if the air pressure is between 0.6 and 0.8 MPa after the engine runs stably.
  • Page 231 Operator’s Manual for Truck Crane (1) Depress and release the clutch pedal slowly. 起 (2) If the PTO and the drive device for oil pump need to be repaired or replaced, put 重 a warning board on the ignition starter switch. Otherwise, risk of danger may 机...
  • Page 232 Operator’s Manual for Truck Crane CAUTION The engine exhaust brake system will be invalid if you remove the propeller shaft or the 起 重 half shaft. 机 3.3.11 Finishing driving operations 说 明 Stopping Brake the crane until it comes to a standstill. The selected drive range can remain switched on.
  • Page 233 Operator’s Manual for Truck Crane – Read the error codes by the warning light “Engine error code displayed”.  Press and release the “Engine fault diagnosis” button. The error codes will be flashed out in the warning light “Engine error code displayed”. Refer to the Blink code list for 起...
  • Page 234 Operator’s Manual for Truck Crane 3.4 Points for attention 3.4.1 Road driving 起 Do not skip a gear when you move through the gear cycle. 重 机 Stop the vehicle if there are unusual conditions with the items in the below list: 说...
  • Page 235 Operator’s Manual for Truck Crane Do not let the vehicle move forward after the engine is OFF. 3.4.2 Crane movements in off-road conditions 起 重 When the axles are in the mud (no traction) or on rough terrain, follow these steps: 机...
  • Page 237 Truck Crane Operator’S Manual Chapter 4 Operation-Crane Superstructure...
  • Page 239 Operator’s Manual for Truck Crane Chapter 4 Operation – Crane Superstructure 4.1 Operator’s cab 4.1.1 Overall view – Figure 4-1 Cab interior Pos. Description Pos. Description Pos. Description Rated capacity char A/C control panel Auxiliary switch panel (Not used) Superstructure switch Right joystick Load moment limiter panel...
  • Page 240 Operator’s Manual for Truck Crane 4.1.2 Instrument panel For the instrument panel, refer to Figure 4-2. – Figure 4-2 Instrument panel Pos. Description Pos. Description Bypass switch CAN bus control panel 4.1.2.1 Bypass switch During one of the following cases, the bypass switch can be turned to cancel the limitation on crane movements into a dangerous direction: - Overloading;...
  • Page 241 Operator’s Manual for Truck Crane 4.1.2.1 CAN bus control panel – Figure 4-3 Switch panel Pos. Description Pos. Description Button Button Engine stop Deadman Button Button Counterweight remote control Button Button Increase engine RPM Oil cooler Button Button (Not used) decrease engine RPM Central lubricating system ZTC1000A763 汽车起重机...
  • Page 242 Operator’s Manual for Truck Crane Pos. Description Pos. Description Button Button Pre-selection of normal speed / Manual telescoping intermediate speed / low speed Inching mode switch Button (Not used) Cylinder pin operation Confluence switch Button (Not used) Operator’s cab tilting downwards Button Button Boom pin operation...
  • Page 243 Operator’s Manual for Truck Crane Button PTO Pressed once: The middle light illuminates. Engage the PTO. Superstructure engine RPM is increased to 900 r/min. Pressed twice: The middle light turns red. Disengage the PTO. Engine RPM is decreased to idle speed. Engage the PTO before you begin a lift operation.
  • Page 244 Operator’s Manual for Truck Crane Button Deadman Pressed: The middle control light illuminates. Operate the functions of the joysticks. It has the same function as the deadman switches on the left and right joysticks. Press either the deadman button or deadman switch to operate the joysticks.
  • Page 245 Operator’s Manual for Truck Crane Button Central lubricating system (Not used) Button Pre-selection of normal speed / intermediate speed / low speed (1) Crane movements “Slew” and “Hoist” have 3 speeds which depend on the position of switch. (2) Crane movements “Telescope” have 2 stages at low speed: –...
  • Page 246 Operator’s Manual for Truck Crane 11 Button Confluence (Not used) 12 Button Boom pin operation Manual telescoping mode: activate the switch till the right light illuminates to conduct boom pin retracting operation; activate the switch till the left light illuminates to conduct boom pin extending operation;...
  • Page 247 Operator’s Manual for Truck Crane 15 Button Automatic telescoping Pressed: The middle light illuminates. The boom can perform manual telescoping. 16 Button Cylinder pin operation Manual telescoping mode: activate the switch till the left light illuminates to conduct boom pin retracting operation; activate the switch till the right light illuminates to conduct boom pin extending operation.
  • Page 248 Operator’s Manual for Truck Crane 4.1.3 Emergency stop button Press down this switch to shut down all superstructure movements, so as to avoid injuries and property loss. Figure 4-4 Emergency stop button 4.1.4 Rocker switches and lights – Figure 4-5 Rocker switches and lights Pos.
  • Page 249 Operator’s Manual for Truck Crane Power indicator light When the superstructure power switch is turned on, this indicator light illuminates Superstructure power switch When the cab heater is working, this indicator light illuminates. Control light Superstructure power source Illuminates: The button “superstructure power source”...
  • Page 250 Operator’s Manual for Truck Crane Roof window wiper/cleaner switch When this switch is pressed to Position I, the roof window wiper starts working; when this switch is pressed in Position II, the roof window wiper and cleaner start working simultaneously. Position II is automatically reset.
  • Page 251 Operator’s Manual for Truck Crane 4.1.5 Control boxes 4.1.5.1 Left control box As for left control box, please refer to Figure 4-6. Accelerator locking button Electric horn button Left joystick Operating illustration Figure 4-6 Left control box – As for left joystick and its operating illustration, please refer to Figure 4-7. Electric Accelerator horn...
  • Page 252 Operator’s Manual for Truck Crane 4.1.5.2 Right control box As for right control box, please refer to Figure 4-8. Free swing Superstructure start and Right joystick Operating illustration button stop switch Figure 4-8 Right control box As for right joystick and its operating illustration, please refer to Figure 4-9. Free swing button –...
  • Page 253 Operator’s Manual for Truck Crane Left joystick has an accelerator locking button. First depress the accelerator pedal to any speed, and press this button once to lock the current accelerator, and then press this button twice to unlock the accelerator. Right joystick has a free swing button.
  • Page 254 Operator’s Manual for Truck Crane 4.1.7 Operator's seat Refer to Figure 4-11. Figure 4-11 Operator’s seat Pos. Description Pos. Description Hand lever, upper horizontal seat Hand lever, lower horizontal seat – adjustment adjustment Hand lever, seat cushion (rear Hand lever, backrest angle section) angle adjustment adjustment Hand lever, seat cushion (front...
  • Page 255 Operator’s Manual for Truck Crane When you adjust the backrest angle, pull the hand lever upwards to suit the operator. After the adjustment is done, release the hand lever to lock the seat. 4.1.8 Engine control pedal You can depress the engine control pedal to increase the engine RPM, thus to accelerate the slewing, derricking up, telescoping and hoisting movements.
  • Page 256 Operator’s Manual for Truck Crane 4.2 Computer system 4.2.1 General The load moment limiter is a computer system for controlling and monitoring mobile cranes. In addition to controlling the boom telescoping via computer programs, it is also of self-diagnosis function. The load moment limiter calculates data from the pressure sensors, length sensor, angle sensor and other monitoring devices to judge whether the crane is in safe working conditions, and displays the basic parameters, such as boom length, boom angle, working radius, rated...
  • Page 257 Operator’s Manual for Truck Crane – Figure 4-12 Main screen Pos. Description Pos. Description Pos. Description Actual load (ACT) Operating mode Reeving factor Rated load (MAX) code Jib length Counterweight Load ratio Outrigger setting Current boom section 5th outrigger status status telescoping combination Text prompt scroll...
  • Page 258 Operator’s Manual for Truck Crane The monitor illustrations in this chapter are only examples. The numerical values in the individual icons and tables do not necessarily match exactly to the crane. 4.2.2 Interface description 4.2.2.1 Switching on the computer system and performing self-test After the computer system is switched on, the load moment limiter performs a self-test to examine whether the three PLC controllers and their respective mentor nodes are on line.
  • Page 259 Operator’s Manual for Truck Crane For the “OM selection” screen, refer to Figure 4-14. Figure 4-14 OM selection If a connection error is found during the test, the corresponding controller cannot pass the test and the monitor shows the following screen (Refer to Figure 4-15). Troubleshooting: –...
  • Page 260 Operator’s Manual for Truck Crane For the “Self-test failed” screen, refer to Figure 4-15. – Figure 4-15 Self-test failed 4.2.2.2 Main screen – configuration program After the OM is selected, it switches automatically to the Main screen – configuration program (Refer to Figure 4-16).
  • Page 261 Operator’s Manual for Truck Crane Pos. Description Pos. Description Pos. Description Alarm icons Scrolling alarm texts Operating mode code Engine and functional Load ratio Suspending load status switches Instrument and Functional keys pressure indications Figure 4-16 Main screen – configuration program The functions of the individual monitor operating elements are program-dependent, and can be different in any running program.
  • Page 262 Operator’s Manual for Truck Crane Hydraulic oil level too low Central passage pressure too high. The operator should rectify the fault according to system reminding or actual condition. Fault reminding for the buzzer is located in: F5: Fault query – F5: Movement parameter query –...
  • Page 263 Operator’s Manual for Truck Crane System setting: including date and time, display brightness, Chinese and English display as well as metric and English systems setting function. OM setting: set OMs. Maintenance: check the date and interval of maintenance. Query function: including IO port, AD value and calculated values of load moment limiter. Debugging tool: benchmark debugging before delivery and convention debugging, only limit to the professional personnel.
  • Page 264 Operator’s Manual for Truck Crane Figure 4-19 Boom status Pos. Description Pos. Description Pos. Description Maximum lifting – Actual load weight Current wind speed capacity Jib length Jib angle Boom length Lifting height Boom angle Working radius Figure 4-19 displays boom length, boom angle, lifting height and chassis frame levelness, etc.
  • Page 265 Operator’s Manual for Truck Crane Pos. Description Pos. Description Pos. Description Operating mode code Reeving factor Counterweight Outrigger fully/half Telescopic boom 5th outrigger extended extended section code As for the instruments and the pressure indications, refer to Figure 4-21. (Pressing key F8 can switch between these two interfaces.) –...
  • Page 266 Operator’s Manual for Truck Crane Coolant temperature As for the load percentage, refer to Figure 4-22. Figure 4-22 Load percentage display The figure above displays the load weight including digit display, graph display and wind speed scale. Figure 4-23 Speeds and function switches –...
  • Page 267 Operator’s Manual for Truck Crane Figure 4-24 Speed display As for the boom telescoping combination, refer to Figure 4-25. The combination indicates the current boom telescoping one. Figure 4-25 Boom telescoping combination display As for the top indicators, refer to Figure 4-26. Figure 4-26 Top indicators Pos.
  • Page 268 Operator’s Manual for Truck Crane Figure 4-27 OM selection interface – Horizontal inclination angle of the chassis frame should be adjusted to be within 0.3 degree (green) before crane operations. After a lifing operation is started, the level gauge is only used for safety reminding, and the levelness should not be ajusted at will.
  • Page 269 Operator’s Manual for Truck Crane Figure 4-28 Main OM selection interface – Press to scroll down items in the main page. Press to enter next page of items. When all paramters of a certain operting modes are selected, press to save current operating mode.
  • Page 270 Operator’s Manual for Truck Crane Press in the operting mode interface to select a reeving factor, as shown in Figure 4-29. Figure 4-29 Hook reeving selection interface Press to switch over between number change at the first and second digits. Press to increase or decrease reeving factor number.
  • Page 271 Operator’s Manual for Truck Crane Press in the OM interface or the main interface to enter the telescopic boom confirm interface, as shown in Figure 4-30. Figure 4-30 Boom telescopic status confirm interface Current telescopic boom section status is displayed. If the displayed status conforms to the actual status, press to confirm the stausand enter telescopic boom control interface.
  • Page 272 Operator’s Manual for Truck Crane Figure 4-32 Telescopic boom section edit interface Press in the OM selection interface or the main interface to enter into the telescoping combination selection interface. Refer to Figure 4-30. – Figure 4-30 Telescoping combination selection interface Press to switch over between table pages;...
  • Page 273 Operator’s Manual for Truck Crane Press to select target boom section combination, the nubmerselected will be displayed in the lower left part of the screen. Press to save current combination. After the target combination is set, press “Auto start” to enable automatic boomsection telescoping.
  • Page 274 Operator’s Manual for Truck Crane 4.2.2.4.1 Automatic telescoping The automatic telescoping has 3 steps in total. Figure 4-35 Automatic telescoping Refer to Figure 4-35. Make sure that the following prerequisites are met: The valid operating mode has been set. The hoisting limit switch and lowering limit switch are not activated. Switch “pre-selection of derrick / telescope”...
  • Page 275 Operator’s Manual for Truck Crane accidents! Top display area displays the following parameters: Boom length Boom angle Working radius Wind speed. Main display area displays: Control light icons Current boom status Target boom status Information about boom pin, cylinder pin and other related information. –...
  • Page 276 Operator’s Manual for Truck Crane Pos. Description Pos. Description Left cylinder pin opened Boom unpinned Left cylinder pin closed Right cylinder pin opened Boom pinned Right cylinder pin closed Start automatic telescoping When “Auto start” and the return icon turn green, it indicates that the prerequisites for automatic telescoping have been fulfilled.
  • Page 277 Operator’s Manual for Truck Crane Figure 4-39 Enter password – Figure 4-40 Current boom status modification How to modify the current boom status (Refer to Figure 4-38): Press function keys F1 and F2 to select the corresponding telescopic section which needs to be modified.
  • Page 278 Operator’s Manual for Truck Crane 4.2.2.4.2 Manual telescoping Because the manual telescoping is complex, it is recommended to initiate manual telescoping only when the automatic telescoping is invalid. The manual telescoping has 6 steps in total. The valid operating mode has been set. For details, please refer to the instructions in “Automatic telescoping”.
  • Page 279 Operator’s Manual for Truck Crane Figure 4-41 Boom status during manual telescoping Pos. Description Pos. Description – Control light icons Actual load Boom code Telescoping control value Current status Cylinder length 1 Target status Current cylinder length Target telescopic section Cylinder length 2 Pressure display Telescope speed...
  • Page 280 Operator’s Manual for Truck Crane Observe the following instructions when carrying out manual telescoping operation. Unlock the telescoping cylinder Telescope in the boom and hold the pressure Press the switch till the left light Control light Control light illuminates. lights up Hold the switch lights up Move the joystick...
  • Page 281 Operator’s Manual for Truck Crane Pin the telescopic section The difference between cylinder length 2 (Pos. 12 in Fig.4-39) and Control light current cylinder length distinguishes. A loud sound (Pos. 11 in Fig..4-39) is Move the right sounds like a 300 mm.
  • Page 282 Operator’s Manual for Truck Crane (1) During manual telescoping, slowly telescope the boom with a large boom angle (slow gear is recommended) if the boom section is unpinned. Icon "Boom pin operational” must be lighting up during boom telescoped-in process. Accelerate telescoping operation after the telescoping cylinder retracts for a certain length.
  • Page 283 Operator’s Manual for Truck Crane highlighted section is telescopic section 1. So, the telescopic section 1 is to carry out telescoping movements. CAUTION In the automatic telescoping operation, the telescoping cylinder will drive the boom to retract automatically if the telescopic section is unpinned (the control light "Boom unpinned”...
  • Page 284 Operator’s Manual for Truck Crane Special precautions for use of load moment limiter: 1. The load moment limiter can be used to prevent crane tip-over, boom rupture or injuries due to crane overloading in construction sites. However, it shall not be solely depended upon by the operator.
  • Page 285 Operator’s Manual for Truck Crane 4.3 Starting up the crane 4.3.1 Checks before starting up Make sure that the following prerequisites are met before starting up: Examining the engine oil level The crane has been leveled. Pull out the dipstick and clean it. Re-insert it into oil and pull out again.
  • Page 286 Operator’s Manual for Truck Crane Deaerate the fuel system before adding fuel. If the fuel tank has been run dry, always deaerate the whole fuel system. Do not run the fuel tank dry! Examining the coolant level Do a check of the coolant to make sure that the engine coolant is at the correct level. Add more if below the cold engine level.
  • Page 287 Operator’s Manual for Truck Crane 4.4 Safety devices 4.4.1 Levelness gauge A levelness gauge is installed near the outrigger operation mechanism at each side of the chassis frame. Its screen displays vividly the overall levelness of the chassis frame, with information displayed in symmetry in the two screens at the two sides.
  • Page 288 Operator’s Manual for Truck Crane Maintain the chassis frame’s inclination angle to be lower than 0.3, otherwise there is an increased risk of accident! Adjust crane levelness after the counterweight is changed. DANGER It is strictly prohibited to adjust levelness of the crane during operations. 4.4.2 Hoisting limit switch The hoisting limit switches on the boom, jib and rooster sheave are intended to prevent the hook block from colliding with the rope pulley.
  • Page 289 Operator’s Manual for Truck Crane Activate the bypass key switch to bypass the switch-off during commissioning and maintenance. Do not use the bypass key switch when you do usual crane operations. The connection and installation of hoisting limit switches on the jib, tip boom and rooster sheave are as follows: When the jib is used: Remove a plug at the tail of box jib section.
  • Page 290 Operator’s Manual for Truck Crane Cable of hoisting limit switch of auxiliary winch Figure 4-51 Installation of hoisting limit switch on the rooster sheave 4.4.3 Lowering limit switch In order to prevent the wire rope from being spooled up automatically after being reeled off completely, the lowering limit switches installed on the winches will automatically switch off the movements “Reel winches off”...
  • Page 291 Operator’s Manual for Truck Crane 4.4.4 Hydraulic safety devices 4.4.4.1 Relief valves in hydraulic system The relief valves in the hydraulic system can prevent the pressure in the circuit from rising too high, thus avoid the hydraulic pump and hydraulic motor from being damaged and the hydraulic system from being overloaded.
  • Page 292 Operator’s Manual for Truck Crane 4.4.4.6 System pressure monitoring The maximum pressures are as follows: Superstructure control valve 1: Superstructure control valve 2: Pilot pressure: 2.8 MPa -3.2MPa Relief valve of raising left and right Main relief valve: 34 MPa ± 0.5 MPa counterweight cylinders: Relief valve of reel main winch off: 20 MPa ±...
  • Page 293 Operator’s Manual for Truck Crane Table 4-1 Movements allowed or blocked under overloading, overwinding and overlowering conditions Auxiliary Main winch Derrick Slew Telescope winch Operation down down down left right Overloading × √ × √ √ × √ √ √ √...
  • Page 294 Operator’s Manual for Truck Crane Anemometer Figure 4-53 Anemometer The crane can topple over! – If the crane is operated at wind speeds which are larger than the maximum permissible value, then it can topple over! 4.4.7 Emergency stop button You can find the emergency stop button on the switch panel in the operator’s cab.
  • Page 295 Operator’s Manual for Truck Crane 4.5 Crane operation 4.5.1 Preparations for crane operation Make sure that following checks are performed before operation: Assess the load condition prior to lifting it. Examine the crane position, ground condition and surface bearing condition. Examine wire ropes (including wire rope end, winding drum and pulleys).
  • Page 296 Operator’s Manual for Truck Crane 4.5.2 Outrigger Both sides of the vehicle chassis frame have the items below: – Accelerator control switch – Outrigger control levers – Levelness gauge. You can operate the control levers to extend or retract the outriggers simultaneously or independently.
  • Page 297 Operator’s Manual for Truck Crane 4.5.2.1 Outrigger control levers As for the outrigger control levels, please refer to Figure 4-55. – Figure 4-55 Outrigger control levers Outrigger control levers are shown in Figure 4-55. Operating illustrations and points for attention are printed in the outrigger label. Control lever 1: extend or retract the horizontal or vertical cylinder Move lever 1 upwards: retract the horizontal / vertical cylinder.
  • Page 298 Operator’s Manual for Truck Crane Move levers 3, 4, 5 and 6 together with lever 1 to initiate corresponding movements. Move levers 3, 4, 5 and 6 upwards and move lever 1 upwards or downwards: extend / retract the horizontal cylinders. Move levers 3, 4, 5 and 6 downwards and move lever 1 upwards or downwards: extend / retract the vertical cylinders.
  • Page 299 Operator’s Manual for Truck Crane Figure 4-57 Extend horizontal cylinder The mid-position marks “ ” on outrigger beams must completely exposed and the pins must be secured if the crane is working with outriggers intermediately extended. Otherwise, the crane may topple. Do the following steps as follows: Stand on the left (or right) side of the crane.
  • Page 300 Operator’s Manual for Truck Crane Levelness of chassis frame is achieved when there is only the indicator light at very center that illuminates, indicating an inclination angle of 0 degree. Right side of the chassis frame -0.5 Indicator light at -0.4 the very center -0.3...
  • Page 301 Operator’s Manual for Truck Crane Release the control lever and put it in neutral position when the crane is leveled. When the crane is operating over the front area with the same lifting performance as that of over side and rear area, the 5 outrigger should be used.
  • Page 302 Operator’s Manual for Truck Crane ) Retract the 5 outrigger. ) Retract all the other outriggers. Remove the pin of the outrigger beam. Refer to Figure 4-61. Figure 4-61 Outrigger beam removal Retract the 5 outrigger (Refer to Figure 4-62): Move lever 2 downwards.
  • Page 303 Operator’s Manual for Truck Crane Figure 4-63 Retract vertical cylinder Retract the outrigger beams: Stand on the left (or right) side of the crane. Move levers 3, 4, 5 and 6 upwards. Move lever 1 upwards to retract outrigger beams completely. Refer to Figure 4-64.
  • Page 304 Operator’s Manual for Truck Crane 4.5.2.4 Install and remove the outrigger pads The outrigger pad is shown in Figure 4-66. Vertical cylinder Outrigger pad Socket pin Figure 4-66 Outrigger pad Installation Before you extend the outriggers, remove the socket pin from the outrigger pads and pull out the outrigger floats.
  • Page 305 Operator’s Manual for Truck Crane Do not operate the outrigger control levers in a lift operation. 4.5.3 Derricking Turn the switch "Pre-selection of telescope / derricking” to the right position. Refer to Figure 4-67. Figure 4-67 Switch “Pre-selection of telescope / derricking” The right joystick controls the derricking gear.
  • Page 306 Operator’s Manual for Truck Crane Note: Do not apply the engine control pedal when the travel distance of control lever is short. Do not change the derricking speed rapidly. The speed of derricking down movement is not dependent upon the travel distance of engine control pedal.
  • Page 307 Operator’s Manual for Truck Crane 4.5.4 Lifting / lowering 4.5.4.1 Preparations Read Lifting capacity tables and Lifting height chart in Chapter 1 before lifting / lowering operation. Lifting capacity table (Refer to Figure 4-70) How to look up lifting capacity in the Lifting capacity table: Look up the boom length according to the lifting height and working radius in lifting height chart.
  • Page 308 Operator’s Manual for Truck Crane Lifting capacities are changed with working radius. Working radius without load Working radius with load Figure 4-71 Working radius change R A T E D L IF T IN G C A P A C IT Y T A B L E –...
  • Page 309 Operator’s Manual for Truck Crane 4.5.4.2 Spooling up / reeling off main winch The right joystick controls the main winch. – Neutral position: stop spooling up / reeling off main winch. – Move the joystick forwards (direction ①). Result: Main winch is reeled off. –...
  • Page 310 Operator’s Manual for Truck Crane 4.5.4.3 Spooling up / reeling off auxiliary winch The left joystick controls the auxiliary winch. – Neutral position: stop spooling up / reeling off auxiliary winch. – Move the joystick forwards (direction ①). Result: Auxiliary winch is reeled off. –...
  • Page 311 Operator’s Manual for Truck Crane After you complete the movement, move the joystick to the neutral position slowly to stop the movements. The speed of the main winch / auxiliary winch movement is changed by: – Joystick – how far you move the joystick forwards or backwards –...
  • Page 312 Operator’s Manual for Truck Crane 4.5.5 Slewing 4.5.5.1 Operation The left joystick controls the slewing gear. – Neutral position: stop the slewing movements. – Move the joystick leftwards (direction ④). Result: Slew to the left. – Move the joystick rightwards (direction ③). Result: Slew to the right.
  • Page 313 Operator’s Manual for Truck Crane 4.5.5.2 Slewing lockout device The slewing lockout device attaches on the front of the slewing table. Make sure that the superstructure is unpinned before initiating the slewing movement. Insert and secure the pin after finishing this operation. Refer to Figure 4-78. Slewing lockout device Retaining seat Figure 4-78 Slewing lockout device...
  • Page 314 Operator’s Manual for Truck Crane 4.5.6 Simultaneous crane movements The crane can do two operations at the same time. This increases the quantity of work that the crane can do and greatly improves the work efficiency. However, because the simultaneous crane movements are toward two different directions, the operator should take maximum care to avoid accident.
  • Page 315 Operator’s Manual for Truck Crane Set the switch “Pre-selection of normal speed / low speed / extremely low speed” to the neutral or right position to make relevant movements get slower. Reel off auxiliary winch Derrick down Derrick up Right joystick Spool up auxiliary winch Left joystick...
  • Page 316 Operator’s Manual for Truck Crane telescoping operation. Slew + Main winch You can slew to the left or right and move the main hook up or down at the same time. To do this, move the left joystick left or right and push or pull the right joystick. Refer to Figure 4-82.
  • Page 317 Operator’s Manual for Truck Crane Figure 4-83 Slew + Telescope It is strongly recommended to select the automatic telescoping mode and deactivate the confluence switch for telescoping operation. Slew + Derrick You can slew to the left or right and derrick the boom up / down at the same time. To do this, move the left and right joystick to the left or right.
  • Page 318 Operator’s Manual for Truck Crane The more the joystick is deflected upward or downward, the faster the winch movements become and the slower the slewing movements. Set the switch “Pre-selection of normal speed / low speed / extremely low speed” to the neutral or right position make relevant movements get slower.
  • Page 319 Operator’s Manual for Truck Crane Reel off main winch + Derrick down Reel off main winch + Derrick up Spool up main winch + Derrick down Spool up main winch + Derrick up Operating illustration, right Figure 4-86 Main winch + Derrick Main winch + Telescope You can telescope the boom in / out and move the main hook up or down at the same time.
  • Page 320 Operator’s Manual for Truck Crane Reel off main winch + Reel off main winch + Telescope in Telescope out Spool up main winch + Telescope out Spool up main winch + Telescope in Operating illustration, right Figure 4-87 Main winch + Telescope Carry out simultaneous crane movements without taking a load or with a suspended load.
  • Page 321 Operator’s Manual for Truck Crane for an even reeving number. Change rope reevings (d). CAUTION (1) You must change the location of the hoisting limit switch weight if you have a different number of wire rope reevings. Refer to Figure 4-89. Odd reeving number Even reeving number Figure 4-89 Location of hoisting limit switch weight...
  • Page 323 Truck Crane Operator’S Manual Chapter 5 Equipment...
  • Page 325 Operator’s Manual for Truck Crane Chapter 5 Equipment 5.1 Safety technical guidelines for installation Reeve the hoist rope between the rope pulley on the boom head and hook pulley in accordance with the corresponding reevings specified in lifting capacity tables. Assemble the counterweight plates according to lifting capacity tables.
  • Page 326 Operator’s Manual for Truck Crane 5.2 Jib 5.2.1 General The jib is one of the important components of truck crane. With the jib assembled, the load can be lifted to a higher height and the working radius can be enlarged via angle changed. The crane has a 2-section jib.
  • Page 327 Operator’s Manual for Truck Crane Figure 5-1 Jib assembly Adjust the tongue plate at left side of the boom head, and make it maintain a clearance of 1-2mm with the bearing block. Refer to Figure 5-2. Tongue plate Figure 5-2 Tongue plate position ZTC1000A763 汽车起重机...
  • Page 328 Operator’s Manual for Truck Crane Remove the pin I. Extend the intermediate bracket and install the removed pin I. See Figure 5-3. Figure 5-3 Extend the intermediate bracket Remove the pins I and II. See Figure 5-4. Pin I Figure 5-4 Pins I and II removal ZTC1000A763 汽车起重机...
  • Page 329 Operator’s Manual for Truck Crane Remove the pin III. See Figure 5-5. Pin III Figure 5-5 Pin III removal Move the front of the jib away from the boom (jib pivots at pin IV). See Figure 5-6. Pin IV Figure 5-6 Move the front of the jib away from the boom ZTC1000A763 汽车起重机...
  • Page 330 Operator’s Manual for Truck Crane Align the end of the jib with the pin holes on the right side of the boom head. Install the pin V and the retaining clip. See Figure 5-7. Pin V Figure 5-7 Pin V installation Remove the pin IV.
  • Page 331 Operator’s Manual for Truck Crane Move the jib (pivots at pin IV) to the front of the boom. See Figure 5-9. Pin V Figure 5-9 Jib rotation Align the end of the jib with pin holes on the left side of boom head. Install the pin VI and the retaining clip.
  • Page 332 Operator’s Manual for Truck Crane If the jib section II is to be used, remove the pin VII and the retaining clip β connecting jib section I to section II. See Figure 5-11. Retaining clip β Pin VII Figure 5-11 Pin VII removal Rotate jib section 2 around pin VIII to the jib section 1 right ahead.
  • Page 333 Operator’s Manual for Truck Crane Pin IX Figure 5-13 Pin IX installation m) Reeve the wire rope from the auxiliary winch through the end of the jib. Install the auxiliary hook and the hoisting limit switch. Do not stand under the jib during the slewing operation! The jib and other components –...
  • Page 334 Operator’s Manual for Truck Crane 30° Figure 5-14 Angle positions 5.2.4 Removal After you complete the jib operation, dismantle the jib in reverse order of the assemble steps. Do not excessively spool up the auxiliary winch when you disassemble the jib. 5-10 ZTC1000A763 汽车起重机...
  • Page 335 Operator’s Manual for Truck Crane After the assembly and disassembly of jib, adjust the limit bolt on the left side of boom head (viewed from travelling direction) till the clearance between the end surface of limit bolt and the bearing block at the boom head is equal or more than 5 mm in order to prevent from damaging the limit bolt during boom telescoping.
  • Page 336 Operator’s Manual for Truck Crane Cable of jib section 1 Adapter cable Figure 5-16 Cable harness connection of jib section 1 For an operating mode with the jib section 2 installed (Refer to Figure 5-17): Properly connect the cable harness of jib section I according to the above-mentioned methods.
  • Page 337 Operator’s Manual for Truck Crane 5.3 Tip boom 5.3.1 General The tip boom is one of the important components of truck cranes. With the tip boom assembled, the load can be lifted to a higher height and the working radius can be enlarged. The one-section tip boom (optional) connects to the boom by pins.
  • Page 338 Operator’s Manual for Truck Crane Move the boom to the side or rear of the crane and position it to the minimum angle. Make sure there is 20 m slewing range to the slewing center. Align the end of the adapter with the pin holes on the end of triangle frame. Install the pins and the retaining clips.
  • Page 339 Operator’s Manual for Truck Crane DANGER Danger of fatal injuries due to falling components! Do not stand under the boom or tip boom during assembly. The tip boom or other components can fall down due to assembly error. 5.3.3 Angle settings The tip boom can be installed at one of the two angles of 0...
  • Page 340 Operator’s Manual for Truck Crane Change the angle of tip boom from 0° to 30° (Refer to Figure 5-14.): Reel off the auxiliary hoist rope for 2 m to 3 m by moving the joystick. Derrick boom down to the minimum angle until the tip boom comes into contact with the ground or is properly supported.
  • Page 341 Operator’s Manual for Truck Crane Figure 5-21 Reeving in the hoist rope for tip boom CAUTION It is recommended to use the hoist rope on the main winch for the tip boom. When you use the hoist rope on the auxiliary winch, make sure that the rope is long enough. ZTC1000A763 汽车起重机...
  • Page 342 Operator’s Manual for Truck Crane 5.3.6 Electrical connection For electrical connection of tip boom, please refer to Figure 5-22. Figure 5-22 Electrical connection of tip boom (1) Protect the plugs and sockets used for electrical connection with black protective shell against contamination and dust. (2) Before you disassemble the tip boom, disconnect the cable harness of the hoisting limiting switch for the tip boom and the cable harness of the tip boom.
  • Page 343 Operator’s Manual for Truck Crane 5.4 Rooster sheave The components of the rooster sheave are as follows: Bracket  Sheave spindle  Sheave  Pins.  When it is not necessary to use the rooster sheave, make sure that it is attached to the side of the top boom section.
  • Page 344 Operator’s Manual for Truck Crane 5.4.2 Removal When it is not necessary to use the rooster sheave, make sure that it is attached to the side of the boom. Disassemble it in the reverse order of the assemble procedure. 5.4.3 Connection of hoisting limit switch Under the rooster sheave working condition: Remove the hoisting limit switch on the jib.
  • Page 345 Operator’s Manual for Truck Crane 5.5 Extension 5.5.1 Overview An extension is an important mechanical structure of the crane and it can be used to lift a load to a higher position and in a wider working radius compared to that of when only the boom is used.
  • Page 346 Operator’s Manual for Truck Crane Pins Removable support Figure 5-26 Removing the movable support b）Install the removable support onto the fixing bracket, as shown in Figure 5-27. Figure 5-27 Installation of the removable support 5-22 ZTC1000A763 汽车起重机...
  • Page 347 Operator’s Manual for Truck Crane 5.5.3 Removal 5.5.3.1 Removal for transportation on a truck After a lifting operation is completed using the extension, remove the extension using a hoisting device and place it onto a truck for transportation. 5.5.3.2 Removal for installation onto the boom After a lifting operation is completed using the extension, remove the extension using a hoisting device and installed it onto the right side of the boom.
  • Page 348 Operator’s Manual for Truck Crane 5.5.5 Reeving in the extension and jib Reeving in the extension and jib is as shown in Figure 5-29. The wire rope is drawn from the longitudinal direction along the boom directly from the main winch or auxiliary winch, and is winded through the wire rope holder, pulley at end of the jib and pulley at the head of the jib respectively (note: for a two-section jib, the wire rope should be winded through another pulley at head of the box-type section jib).
  • Page 349 Operator’s Manual for Truck Crane of the boom. Cable of Cable of the auxiliary winch extension hoisting limit switch Figure 5-30 Cable connection in the extension When the extension is used together with the jib, connect the hoisting limit switch in following steps: Remove the cable plug at end of the lattice section of the jib and connect it to the socket at front end of the extension;...
  • Page 350 Operator’s Manual for Truck Crane 5.6 Counterweight 5.6.1 Counterweight and counterweight handler Composition of the counterweight assembly is as shown in Figure 5-32: – One fixed counterweight plate (2 t) – One auxiliary counterweight plate (11 t) – One upper movable counterweight plate (4 t) –...
  • Page 351 Operator’s Manual for Truck Crane Fixed counterweight Auxiliary counterweight Upper movable counterweight Middle movable counterweight Lower movable counterweight side counterweight Figure 5-32 Counterweight assembly Components of the counterweight handler are as follows: – Counterweight lifting cylinders (left and right) – Two hydraulic locks and other auxiliary elements.
  • Page 352 Operator’s Manual for Truck Crane Risk of accident from toppling of the crane! Attach counterweight in accordance with the information in the lifting capacity tables. If a different counterweight than the one list in the lifting capacity table is used, the crane topple over.
  • Page 353 Operator’s Manual for Truck Crane Table 5-2 Function of buttons in the remote transmitter Pos. Description Function description Remark Button All movements stop when the Stop button is pressed Button All movements stop when the Stop button is pressed The leftward and rightward Button The slewing platform rotates slewing are interlocked,...
  • Page 354 Operator’s Manual for Truck Crane After settling the counterweight plates, press the pre-selection switch of counterweight lifting and air conditioner. Plug in the counterweight remote control box’s plug into the socket in the middle section of the slewing platform. Hereby the remote control box becomes operational. Connect the remote control box and then slew the slewing platform clockwise, until the counterweight lifting cylinder sits into the side position of the mounting groove of the lifting drum.
  • Page 355 Operator’s Manual for Truck Crane different counterweight combinations and driving status: Table 5-3 highest traveling speed and maximum gradeability corresponding to different counterweight combinations Speed limit Gradeability limit Driving Counterweight Highest Max. Gear Gear status combinations speed gradeability position position (km/h) Status 1 Status 2...
  • Page 357 Truck Crane Operator’S Manual Chapter 6 Additional Equipment...
  • Page 359 Operator’s Manual for Truck Crane Chapter 6 Additional Equipment 6.1 Air conditioning in driver's cab 6.1.1 Operating methods The control panel is on the center console in the driver’s cab. Figure 6-1 Control panel, A/C and cab heater 6.1.1.1 Symbol identification Table 6-1 Symbol identification Symbol Description...
  • Page 360 Operator’s Manual for Truck Crane 6.1.1.2 Buttons Temperature adjustment button Pressed: Increase / decrease the temperature. Fan speed button Pressed: Increase / decrease the fan speed. OFF button Pressed: Turn off the air conditioning system. AUTO button Pressed: Activate the auto operating mode. Pressed again, or the A/C or front window air supply button is pressed:...
  • Page 361 Operator’s Manual for Truck Crane WARNING Do not use the cab heater during driving if engine coolant temperature is below 70º C. (1) Make sure that the A/C is in the OFF mode when the engine is OFF or at idle speed for a long time.
  • Page 362 Operator’s Manual for Truck Crane 6.2 Air conditioning in operator's cab In order to provide a comfortable environment, the operator’s cab is equipped with air conditioning and cab heater. Adjust the room temperature via the control panel. The control panel is behind the auxiliary control switch panel in the operator’s cab. There are three rotary switches on it.
  • Page 363 Operator’s Manual for Truck Crane When the air conditioning is used, do not turn the CAB COOLER POWER SWITCH to position “SNOWFLAKE” while the A/C FAN SPEED SWITCH is at “LOW” position. Otherwise, the evaporator may get frost to impair the cooling effect. (1) Do not disassemble an A/C system without consent from the A/C manufacturer.
  • Page 364 Operator’s Manual for Truck Crane (1) Evaporator – air outlet in the cab (2) Condenser – the device is used for the exchange of the hot air outside the driver’s cab. In some vehicles, it is mounted between water tank and fan (without the condenser fan motor).
  • Page 365 Operator’s Manual for Truck Crane 6.2.2.3 Operating instructions Turn the CAB HEATER POWER SWITCH to position “SUN”. Result: FAN POWER CONTROL LIGHT on the auxiliary control switch panel is ON. The cab heater starts to work. Clockwise turn the A/C FAN SPEED SWITCH. Result: The warm air blows out.
  • Page 366 Operator’s Manual for Truck Crane 6.2.2.4 Troubleshooting for common failures Table 6-7 Troubleshooting for common failures Problems Causes Remedy The A/C FAN SPEED SWITCH Turn on the A/C FAN SPEED No warm air blows out. on the air conditioning control SWITCH on the air conditioning panel is not turned on.
  • Page 367 Operator’s Manual for Truck Crane Problems Causes Remedy When the relay of solenoid valve is The control panel is damaged. Replace control panel. electrified, it cannot output signals. When the motor relay is The relay or control panel is electrified, it cannot Replace control panel.
  • Page 369 Truck Crane Operator’S Manual Chapter 7 Transportation and Storage...
  • Page 371 Operator’s Manual for Truck Crane Chapter 7 Transportation and Storage 7.1 Transportation 起 重 This crane can drive on road, and it can also be transported by other carriers for a long 机 说 distance. During transportation, chock the wheels and secure the crane safe with wire ropes. 明...
  • Page 372 Operator’s Manual for Truck Crane 7.2 Storage To store the crane for a long time: Lock the doors and the windows, and switch off control instruments. Clean contaminants off from the crane. Fully retract all the cylinder pistons (except vertical cylinders). Fully extend the vertical cylinders to lift the tires away from the ground.