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Operator’s Manual for Crawler Crane

Assembly

and

Dismantli

5-26

h) The assembly of central counterweight on the other side of crane is performed in the same

way. See the figure 5-28.

Figure 5-28 Assembly of central counterweight on the other side of the crane

5.2.5 Self-assembly and dismantling of counterweight

5.2.5.1 Components of counterweight self-assembly & dismantling

mechanism

Counterweight self-assembly & dismantling mechanism consists of mounting cylinder, rear

anchoring rods of A-frame, A-frame, derricking pulley block, main boom pivot section, main

boom tilting-back support, counterweight lifting cylinder and so on. It is mainly used to

assemble counterweight plates onto the basic machine, or dismantle counterweight plates from

the basic machine. See the figure 5-29 and the table 5-5.

For reference only.

Operators manual should be consulted and adhered to.

Summary of Contents for ZCC1100

Page 1: ...dustrial Park No 1636 2nd Yuanda Road Economic and Technological Development Zone Changsha Hunan Province China PC 410131 www zoomlion com Zoomlion Heavy Industry Science and Technology Co Ltd CRAWLER...

Page 2: ...For reference only Operators manual should be consulted and adhered to...

Page 3: ...Edition 1 5 2014 ZCC1100H Crawler Crane Operator s Manual For reference only Operators manual should be consulted and adhered to...

Page 4: ...For reference only Operators manual should be consulted and adhered to...

Page 5: ...erty of a different person make sure that the manual stays in the cab of the crane The data data specifications illustrations in this manual is for cranes in production at the time of this manuals pub...

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

Page 7: ...ng specific operation phases 1 4 1 8 Special Hazards 1 4 1 8 1 Electrical power 1 4 1 8 2 Gas dust steam smoke and noise 1 5 1 8 3 Welding or naked flames 1 5 1 8 4 Hydraulic equipment 1 5 Chapter 2 D...

Page 8: ...ator 3 5 3 2 2 The requirement for the crane operator during the whole operation 3 5 3 2 3 Safety instructions for the rigger 3 6 3 2 4 Safety instructions for the signalman 3 7 3 2 5 Safety instructi...

Page 9: ...h gas pipes 3 35 3 7 4 The consequences of a gas pipe s damage 3 35 3 7 5 Measures adopted if a gas pipe is damaged and the gas escapes or a leak is suspected 3 36 3 7 6 Measures adopted in the event...

Page 10: ...moment limiter 4 29 4 4 5 Boom angle indicator 4 31 4 4 6 Derricking limiter 4 32 4 4 7 Lowering limiter 4 33 4 4 8 Hoisting limiter 4 34 4 4 9 Anemometer 4 35 4 4 10 Crane inclinometer 4 35 4 4 11 C...

Page 11: ...configuration 5 37 5 4 1 Main boom S 1 5 37 5 4 2 Main boom with fixed jib SF 1 5 50 5 5 Assembly and dismantling of main boom 5 59 5 5 1 Preparations for assembly 5 59 5 5 2 Assembly of main boom 5...

Page 12: ...For reference only Operators manual should be consulted and adhered to...

Page 13: ...Operator s Manual for Crawler Crane Chapter 1 Safety For reference only Operators manual should be consulted and adhered to...

Page 14: ...For reference only Operators manual should be consulted and adhered to...

Page 15: ...y the manufacturer If technical parameters can not be obtained clearly experienced and qualified engineer should judge the restrictions of using which should be recorded in the archive Do not exceed t...

Page 16: ...entially harmful waste used on this crane includes such items as hydraulic oil fuel coolant filters and batteries etc 6 Use leak proof containers for draining fluids Do not use food or beverage contai...

Page 17: ...connect battery ground cable and power supply before making adjustments on electrical systems g Disconnect battery ground cable switch off the engine and unplug all plugs of controllers before welding...

Page 18: ...rm could be pulled in and amputated 3 Stop the crane before removing any safety devices or guarding devices 4 Limit access to the machine and its surrounding where barrier guards are appropriately ere...

Page 19: ...in a sealed container and marked to ensure safe disposal 1 8 3 Welding or naked flames a Welding flame cutting and grinding work on the crane must only be carried out if this has been expressly author...

Page 20: ...and quality of the hoses must comply with the technical requirements f Only fit replacement components of a type provided by the manufacturer g Always keep hydraulic elements clean h Hydraulic fluid u...

Page 21: ...Operator s Manual for Crawler Crane Chapter 2 Description of Crane For reference only Operators manual should be consulted and adhered to...

Page 22: ...For reference only Operators manual should be consulted and adhered to...

Page 23: ...ZCC1100H Crawler Crane 2 1 Chapter 2 Description of Crane 2 1 Product model 2 1 1 Product name plate and its position Figure 2 1 Position of product name plate Figure 2 2 Product name plate Position...

Page 24: ...Any other type of use or otherwise use which goes beyond its limits specified such as handling of general cargo or grab operation are not classified as intended use The manufacturer shall not be liabl...

Page 25: ...roup of normal winch is M4 2 1 4 3 Service life Classification of the crane is based on a total operating life service life of 20 years under the following conditions a The crane is operated as an ass...

Page 26: ...ne s entire service life is under 10 of the maximum load Load is to be understood in this connection as the sum total of load load handling devices and lifting tackle e g load load hook sling rope Und...

Page 27: ...ain boom Length of fixed jib Remarks S 1 Main boom 42 8 13m 219 10 67m No The load is attached onto main boom S 2 Main boom with fixed jib 101 9 31m 180 5 55m 19 8 6m 59 18m The load is attached onto...

Page 28: ...sts an assembly mode for ZCC1100H crawler crane which is used for crane self assembly and dismantling during crane conversion During crane self assembly and dismantling operation mounting cylinder is...

Page 29: ...ly mode CAUTION Whenever using mounting cylinder on the boom to lift the load be sure to make the crane in assembly mode According to actual requirements there are five working modes and an assembly m...

Page 30: ...slewing table Table 2 3 Description of components on slewing table No Names of the components No Names of the components 1 Rear counterweight 9 Slewing mechanism 2 Counterweight lifting cylinder 10 F...

Page 31: ...re 2 6 Components on undercarriage Table 2 4 Description of components on undercarriage No Names of the components No Names of the components 1 Drive sprocket 8 Vertical support optional 2 Crawler car...

Page 32: ...performance Infinitely variable speed from 0 0 78 mph 0 1 25kmph 2 3 3 Crane superstructure Slewing table Self manufactured and high rigid welded structure of high stiffness structural steel connected...

Page 33: ...l levers Crane winches Both hoisting winches and derricking winch are hydraulically driven by axial piston variable displacement pump and planetary gear with spring loaded multi disc brake Slewing mec...

Page 34: ...0 3350 10 11 R15 5 5440 20 10 6340 17 10 11 10 3600 4 3 1300 6 5 1970 11 6850 22 5 1000 3 3 30 82 5 4 2 8 2 1 9 9 1 3 0 0 0 6 7 0 0 0 16 5 11 2 5000 3400 437 17 2 7 800 3 7 1100 Figure 2 7 Overall dim...

Page 35: ...d 2 With free fall function ft min m min 374 114 On the 6th rope layer Without free fall function ft min m min 425 129 On the 5 th rope layer Single rope speed of derricking winch ft min m min 190 58...

Page 36: ...0 Exhaust emission According to U S EPA Tier 3 Distance between track center crawler contact length crawler width ft m 8 2 17 10 2 7 2 5 5 44 0 8 Crawler carrier retracted 13 9 17 10 2 7 4 2 5 44 0 8...

Page 37: ...erformance of wire rope and winch 2 4 3 1 Hoisting rope reeving Under crane operation with main boom maximum hoisting rope reevings for different boom lengths are shown in the table 2 7 When crane is...

Page 38: ...ope type will be the same with that of hoisting winch 2 2 4 3 3 Parameters of winches The tables 2 9 to 2 12 show the performance parameters of hoisting winch 1 hoisting winch 2 derricking winch and h...

Page 39: ...nch speed with max load ft min m min Permissible length of wire ropes on each layer ft m 1 15 6 7 1 15 6 7 1 147 45 72 22 2 14 3 6 5 14 3 6 5 160 49 79 24 3 13 2 6 13 2 6 173 53 85 26 4 12 3 5 6 12 3...

Page 40: ...awn without considering boom deflection 42 8 13 52 6 16 62 4 19 72 3 22 82 25 91 11 28 101 9 31 111 6 34 121 5 37 131 3 40 141 2 43 150 11 46 160 10 49 170 8 52 180 5 55 190 4 58 200 2 61 210 64 219 1...

Page 41: ...in ft m 2 The boom lifting height curve is drawn without considering boom deflection 40 12 2 60 18 3 80 24 4 100 30 5 120 36 6 140 42 7 160 48 8 180 54 9 20 6 1 200 61 220 67 1 101 9 19 8 31 6 101 9...

Page 42: ...curve is drawn without considering boom deflection 40 12 2 60 18 3 80 24 4 100 30 5 120 36 6 140 42 7 160 48 8 180 54 9 20 6 1 200 61 220 67 1 101 9 19 8 31 6 101 9 39 4 31 12 101 9 59 31 18 180 5 19...

Page 43: ...load is suspended according to the standard ASME ANSI B30 5 The value can not exceed 75 of the overturning lifting capacity when the crane is on firm and flat ground b The value mentioned in the char...

Page 44: ...9 1 40 4 88 8 40 3 88 8 40 3 88 6 40 2 88 4 40 1 88 2 40 0 25 7 6 30 9 1 69 5 31 5 69 2 31 4 69 0 31 3 68 8 31 2 68 8 31 2 68 6 31 1 68 4 31 0 68 1 30 9 67 9 30 8 30 9 1 35 10 7 55 8 25 3 55 6 25 2 55...

Page 45: ...7 70 21 3 80 24 4 17 6 8 0 17 4 7 9 17 2 7 8 17 0 7 7 16 8 7 6 16 5 7 5 16 3 7 4 15 8 7 2 15 7 7 1 15 7 7 1 80 24 4 90 27 4 15 0 6 8 14 8 6 7 14 6 6 6 14 3 6 5 14 1 6 4 13 9 6 3 13 7 6 2 13 2 6 13 0 5...

Page 46: ...range otherwise the crane may topple over or be damaged 3 The value in the chart is the maximum lifting capacity of the crane including the weight of lifting device hook wire rope at the end of the h...

Page 47: ...28 2 61 2 27 7 30 9 1 35 10 7 51 23 1 50 7 23 49 8 22 6 49 4 22 4 48 7 22 1 48 1 21 8 35 10 7 40 12 2 42 1 19 1 41 9 19 41 18 6 40 8 18 5 39 9 18 1 39 2 17 8 40 12 2 50 15 2 30 6 13 9 30 4 13 8 29 8...

Page 48: ...7 22 1 47 8 21 7 35 10 7 40 12 2 41 9 19 41 7 18 9 41 18 6 40 6 18 4 39 9 18 1 39 2 17 8 40 12 2 50 15 2 30 4 13 8 30 2 13 7 29 5 13 4 29 1 13 2 28 4 12 9 28 12 7 50 15 2 60 18 3 22 9 10 4 22 9 10 4 2...

Page 49: ...1 5 18 8 40 8 18 5 40 3 18 3 36 7 18 39 17 7 40 12 2 50 15 2 30 2 13 7 30 13 6 29 3 13 3 29 1 13 2 28 4 12 9 27 8 12 6 50 15 2 60 18 3 22 9 10 4 22 7 10 3 22 1 10 21 8 9 9 20 9 9 5 20 7 9 4 60 18 3 70...

Page 50: ...50 15 2 30 2 13 7 30 13 6 29 3 13 3 29 1 13 2 28 4 12 9 27 8 12 6 50 15 2 60 18 3 22 7 10 3 22 5 10 2 21 8 9 9 21 6 9 8 20 9 9 5 20 5 9 3 60 18 3 70 21 3 17 9 8 1 17 9 8 1 17 0 7 7 17 0 7 7 16 1 7 3 1...

Page 51: ...2 29 8 13 5 29 5 13 4 28 9 13 1 28 7 13 28 12 7 27 3 12 4 50 15 2 60 18 3 22 5 10 2 22 3 10 1 21 6 9 8 21 4 9 7 20 7 9 4 20 3 9 2 60 18 3 70 21 3 17 6 8 17 6 8 17 7 7 16 8 7 6 16 1 7 3 15 7 7 1 70 21...

Page 52: ...21 4 9 7 21 2 9 6 20 5 9 3 20 1 9 1 60 18 3 70 21 3 17 4 7 9 17 4 7 9 16 8 7 6 16 5 7 5 15 9 7 2 15 4 7 70 21 3 80 24 4 13 9 6 3 13 7 6 2 13 5 9 12 8 5 8 12 1 5 5 11 9 5 4 80 24 4 90 27 4 11 2 5 1 11...

Page 53: ...50 15 2 60 18 3 22 1 10 21 8 9 9 21 2 9 6 21 9 5 20 3 9 2 19 8 9 60 18 3 70 21 3 17 2 7 8 17 2 7 8 16 5 7 5 16 3 7 4 15 7 7 1 15 2 6 9 70 21 3 80 24 4 13 7 6 2 13 5 6 1 12 8 5 8 12 8 5 8 11 9 5 4 11 7...

Page 54: ...5 20 7 9 4 20 1 9 1 19 6 8 9 60 18 3 70 21 3 17 7 7 17 7 7 16 3 7 4 16 1 7 3 15 4 7 15 6 8 70 21 3 80 24 4 13 5 6 1 13 2 6 12 6 5 7 12 6 5 7 11 9 5 4 11 5 5 2 80 24 4 90 27 4 10 8 4 9 10 8 4 9 10 1 4...

Page 55: ...5 1 2 3 4 4 2 4 4 2 120 36 6 130 39 6 4 0 1 8 4 0 1 8 3 3 1 5 3 1 1 4 130 39 6 140 42 7 3 1 1 4 3 1 1 4 2 4 1 1 2 2 1 140 42 7 150 45 7 2 2 1 2 2 1 150 45 7 CAUTION 1 The values in bold are the lifti...

Page 56: ...unterweight and 22050lbs 10t central counterweight in 360 range 5 The value in the chart is the maximum lifting capacity of the crane including the weight of lifting device hook wire rope at the end o...

Page 57: ...17 6 8 25 7 6 30 9 1 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 30 9 1 35 10 7 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 35 10 7 40 12 2 17 6 8 17 6 8 17 6 8 1...

Page 58: ...4 2 9 4 1 8 8 4 8 6 3 9 100 30 5 110 33 5 8 8 4 8 4 3 8 8 2 3 7 8 2 3 7 7 7 3 5 7 5 3 4 7 1 3 2 6 9 3 1 110 33 5 120 36 6 7 1 3 2 6 8 3 1 6 6 3 6 4 2 9 6 2 2 8 6 2 7 5 7 2 6 5 5 2 5 120 36 6 130 39 6...

Page 59: ...ounterweight and 22050lbs 10t central counterweight in 360 range 5 The sign in the chart indicates lifting capacity radius 6 The value in the chart is the maximum lifting capacity of the crane includi...

Page 60: ...15 2 60 18 3 17 6 8 17 6 8 17 6 8 16 3 7 4 12 8 5 8 60 18 3 70 21 3 17 6 8 17 6 8 17 6 8 14 8 6 7 12 3 5 6 8 4 3 8 70 21 3 80 24 4 16 8 7 6 17 0 7 7 17 4 7 9 13 7 6 2 11 9 5 4 7 7 3 5 80 24 4 90 27 4...

Page 61: ...12 8 5 8 60 18 3 70 21 3 17 6 8 17 6 8 17 6 8 14 8 6 7 12 6 5 7 8 4 3 8 70 21 3 80 24 4 16 8 7 6 16 8 7 6 16 8 7 6 13 2 6 12 1 5 5 8 4 3 8 80 24 4 90 27 4 14 1 6 4 14 6 6 6 14 6 6 6 12 3 5 6 11 7 5 3...

Page 62: ...17 6 8 17 6 8 15 4 7 12 6 5 7 8 4 3 8 70 21 3 80 24 4 16 5 7 5 16 5 7 5 17 2 7 8 14 1 6 4 12 3 5 6 7 7 3 5 80 24 4 90 27 4 14 1 6 4 14 3 6 5 14 3 6 5 13 2 6 11 9 5 4 7 5 3 4 90 27 4 100 30 5 11 9 5 4...

Page 63: ...12 8 5 8 70 21 3 80 24 4 16 5 7 5 16 8 7 6 16 8 7 6 15 0 6 8 12 6 5 7 7 9 3 6 80 24 4 90 27 4 13 7 6 2 13 9 6 3 14 1 6 4 13 7 6 2 12 1 5 5 7 5 3 4 90 27 4 100 30 5 11 5 5 2 11 7 5 3 12 1 5 5 12 6 5 7...

Page 64: ...8 12 6 5 7 8 4 3 8 80 24 4 90 27 4 13 2 6 13 9 6 3 13 9 6 3 13 9 6 3 12 1 5 5 7 7 3 5 90 27 4 100 30 5 11 2 5 1 11 5 5 2 11 9 5 4 12 3 5 6 11 2 5 1 7 3 3 3 100 30 5 110 33 5 9 7 4 4 9 9 4 5 10 1 4 6 1...

Page 65: ...8 80 24 4 90 27 4 13 2 6 13 7 6 2 13 9 6 3 14 3 6 5 12 6 5 7 7 7 3 5 90 27 4 100 30 5 11 2 5 1 11 5 5 2 11 5 5 2 12 1 5 5 11 2 5 1 7 5 3 4 100 30 5 110 33 5 9 5 4 3 9 5 4 3 9 9 4 5 10 1 4 6 10 1 4 6...

Page 66: ...5 9 13 2 6 13 5 6 1 14 3 6 5 12 3 5 6 8 2 3 7 90 27 4 100 30 5 10 8 4 9 11 0 5 11 2 5 1 11 9 5 4 11 2 5 1 7 7 3 5 100 30 5 110 33 5 9 0 4 1 9 3 4 2 9 5 4 3 9 9 4 5 9 7 4 4 7 3 3 3 110 33 5 120 36 6 7...

Page 67: ...2 6 5 7 13 2 6 13 2 6 13 5 6 1 12 6 5 7 8 2 3 7 90 27 4 100 30 5 10 6 4 8 11 0 5 11 0 5 11 7 5 3 11 2 5 1 7 5 3 4 100 30 5 110 33 5 8 8 4 9 3 4 2 9 3 4 2 9 7 4 4 9 5 4 3 7 3 3 3 110 33 5 120 36 6 7 3...

Page 68: ...1 6 6 3 6 6 3 130 39 6 140 42 7 4 9 2 2 5 1 2 3 5 3 2 4 5 7 2 6 5 5 2 5 6 2 2 8 140 42 7 150 45 7 4 2 1 9 4 2 1 9 4 4 2 4 9 2 2 4 6 2 1 5 1 2 3 150 45 7 160 48 8 3 3 1 5 3 3 1 5 3 7 1 7 4 0 1 8 3 7 1...

Page 69: ...The value in the chart is the lifting capacity when the crane is working with 61740 Lbs 28t rear counterweight and 22050lbs 10t central counterweight in 360 range 5 The value in the chart is the maxi...

Page 70: ...15 2 60 18 3 17 6 8 17 6 8 17 6 8 16 3 7 4 12 8 5 8 60 18 3 70 21 3 16 1 7 3 16 1 7 3 16 3 7 4 14 8 6 7 12 3 5 6 8 4 3 8 70 21 3 80 24 4 15 2 6 9 15 4 7 17 6 7 3 13 7 6 2 11 9 5 4 7 7 3 5 80 24 4 90...

Page 71: ...3 7 4 12 8 5 8 60 18 3 70 21 3 16 1 7 3 16 1 7 3 17 6 7 3 14 8 6 7 12 6 5 7 8 4 3 8 70 21 3 80 24 4 15 2 6 9 15 2 6 9 15 4 7 13 2 6 12 1 5 5 8 4 3 8 80 24 4 90 27 4 12 6 5 7 13 5 9 13 2 6 12 3 5 6 11...

Page 72: ...3 17 6 8 17 6 8 17 6 8 15 4 7 12 6 5 7 8 4 3 8 70 21 3 80 24 4 15 6 8 15 6 8 15 9 7 2 14 1 6 4 12 3 5 6 7 7 3 5 80 24 4 90 27 4 12 6 5 7 12 8 5 8 13 5 9 13 2 6 11 9 5 4 7 5 3 4 90 27 4 100 30 5 10 4 4...

Page 73: ...4 15 9 7 2 12 8 5 8 70 21 3 80 24 4 15 6 8 15 2 6 9 15 4 7 0 15 0 6 8 12 6 5 7 7 9 3 6 80 24 4 90 27 4 12 1 5 5 12 3 5 6 12 8 5 8 12 3 5 6 12 1 5 5 7 5 3 4 90 27 4 100 30 5 9 9 4 5 10 1 4 6 10 8 4 9...

Page 74: ...15 0 6 8 12 6 5 7 8 4 3 8 80 24 4 90 27 4 11 7 5 3 12 3 5 6 12 6 5 7 12 6 5 7 12 1 5 5 7 7 3 5 90 27 4 100 30 5 9 7 4 4 9 9 4 5 10 6 4 8 11 5 9 9 4 5 7 3 3 3 100 30 5 110 33 5 8 1 3 7 8 4 3 8 8 8 4 9...

Page 75: ...8 4 3 8 80 24 4 90 27 4 11 7 5 3 12 1 5 5 12 6 5 7 13 0 5 9 11 2 5 1 7 7 3 5 90 27 4 100 30 5 9 7 4 4 9 9 4 5 10 1 4 6 10 8 4 9 9 9 4 5 7 5 3 4 100 30 5 110 33 5 7 9 3 6 7 9 3 6 8 6 3 9 8 8 4 8 8 4 6...

Page 76: ...90 27 4 11 5 5 2 11 7 5 3 11 9 5 4 13 5 9 11 5 8 2 3 7 90 27 4 100 30 5 9 3 4 2 9 5 4 3 9 7 4 4 10 6 4 8 9 9 4 5 7 7 3 5 100 30 5 110 33 5 7 5 3 4 7 7 3 5 8 2 3 7 8 6 3 9 8 4 3 8 7 3 3 3 110 33 5 120...

Page 77: ...8 80 24 4 90 27 4 11 5 11 7 5 3 11 7 5 3 12 1 5 5 11 2 5 1 8 2 3 7 90 27 4 100 30 5 9 4 1 9 5 4 3 9 5 4 3 10 4 4 7 9 9 4 5 7 5 3 4 100 30 5 110 33 5 7 3 3 3 7 7 3 5 7 7 3 5 8 4 3 8 8 2 3 7 7 3 3 3 110...

Page 78: ...120 36 6 130 39 6 4 4 2 4 6 2 1 4 8 2 2 5 5 2 5 130 39 6 140 42 7 3 3 1 5 3 5 1 6 4 1 8 4 4 2 140 42 7 150 45 7 2 6 1 2 2 6 1 2 3 1 1 4 3 5 1 6 150 45 7 160 48 8 1 8 0 8 1 8 0 8 2 4 1 1 2 6 1 2 160 4...

Page 79: ...6 Lifting capacity in assembly mode Use the mounting cylinder on the boom to lift a load during crane self assembly and dismantling operation The lifting capacity chart is shown in the table 2 18 Tabl...

Page 80: ...For reference only Operators manual should be consulted and adhered to...

Page 81: ...Operator s Manual for Crawler Crane Chapter 3 Safety Guidelines For reference only Operators manual should be consulted and adhered to...

Page 82: ...For reference only Operators manual should be consulted and adhered to...

Page 83: ...rial dimensions and weight of load s to be lifted h Required lifting height and slewing radius i Load bearing capacity of soil or surface to be operated upon j Height and width of thoroughfares leadin...

Page 84: ...ossible consequences resulting from improper use of the crane a Improper use of crane may cause the following consequences 1 The life of the operator and other related personnel will be threatened 2 T...

Page 85: ...irement from the manufacturer 8 Make sure maintain and service the equipment in specified time period 9 Allow relevant personnel from the manufacturer to approach the equipment to supervise its perfor...

Page 86: ...ould be followed a Keep the cab clean Clean the pedal and ashtray and put the drinks in the designated place b Don t put the magazines or other items on the control panel c Don t put the tools in the...

Page 87: ...accept signal which violates operation regulations Stop the crane immediately if somebody is found climbing the crane d Operator who is in low spirits or poor health is not allowed to operate the cran...

Page 88: ...crane 6 Sudden brake of load during free fall process is forbidden and the brake process should be under control otherwise the boom may be destroyed or the crane may topple over 3 2 3 Safety instructi...

Page 89: ...ght and clearance correctly e Be trained in professional hand signals for crane operation and familiar to use them f Use standard hand signals for crane operation If necessary use a radio device to se...

Page 90: ...t At this time stop the crane safely and leave it at once d The temperature of objects affected by high frequency radiation depends on their size Cranes undercarriage and coverings for example are hot...

Page 91: ...ect manager and the safety engineer 3 2 7 Safety signs The positions on the crane that may pose danger or potential danger are labeled with safety signs The arrangement of safety signs on one side of...

Page 92: ...2 Arrangement of safety signs on the other side of the crane near the operator s cab Table 3 1 Description of safety signs near the ladder and operator s cab Figure 3 1 Figure 3 2 Safety signs Descri...

Page 93: ...escription 2 Moving parts can crush and cut Do not operate when the engine is running 3 Moving parts can crush and cut Keep hands clear Do not operate with the door opened 4 3 Standard hand signal for...

Page 94: ...erator s cab Figure 3 1 Figure 3 2 Safety signs Description 6 4 Open flame prohibited 7 1 Do not stand under the jib during assembling and disassembling process 8 2 No standing under the boom 9 16 5 1...

Page 95: ...3 13 Table 3 1 Description of safety signs near the ladder and operator s cab Figure 3 1 Figure 3 2 Safety signs Description 11 10 Risk of falling 12 14 6 8 Keep off folding brackets additional suppo...

Page 96: ...3 and the description of safety signs is shown in the table 3 2 Figure 3 3 Arrangement of safety signs on the slewing table Table 3 2 Description of safety signs on the slewing table No Safety signs D...

Page 97: ...gns is shown in the table 3 3 Figure 3 4 Arrangement of safety signs in the front of slewing table Table 3 3 Description of safety signs in the front of slewing table No Safety signs Description 1 Ris...

Page 98: ...g table Table 3 4 Description of safety signs at the rear side of slewing table NO Safety signs Instructions 1 Keep clear of swinging area to prevent serious body injury 2 Be careful in the working ra...

Page 99: ...not stand under a suspended load b No one should be in danger zone of the machine c Do not reach into moving drives or parts of the machine d Access to the top of the upper carriage is only permitted...

Page 100: ...may only be carried out by qualified technicians with specialized knowledge and experience of hydraulics b Before staring repair work depressurize all pressure hoses and the system sections that are...

Page 101: ...65 149 First aid for burns Immediately run cold water over the burn and to cool it down Cover the burn with an anti bacterial bandage and seek medical attention immediately 3 2 11 Risk of chemical bu...

Page 102: ...engine immediately b If possible use the radio to call for help c Turn ignition key to the 0 position and leave the operator s cab d Evaluate the situation only if there is absolutely no risk to your...

Page 103: ...the vicinity of the equipment h Do not use starting auxiliary device containing ether due to the risk of explosion i Do not carry any combustible liquids on the equipment except for the tanks provide...

Page 104: ...losed rooms thoroughly before entering them Follow these safety instructions and preventive measures a Make sure there is adequate ventilation before operating the machine in an enclosed area b Do not...

Page 105: ...ental protection regulations relating to the disposal of fuels and lubricants applicable in the particular country d When draining fuels and lubricants use only containers that are big enough do not l...

Page 106: ...e load 4 The manufacturer s identification must be forged or die stamped on a low stress and non wearing area of the hook d Safe operation 1 Do not side load hooks 2 Force on the safety latch can caus...

Page 107: ...th identification tags The Information required to be on the identification tags is as follows 1 Manufacturer s name or trademark 2 Diameter or size of sling 3 Material of sling 4 Rated load for the t...

Page 108: ...basket hitch can have the loads balanced to prevent slippage e Slings must be securely attached to their loads f Slings must be padded or protected from the sharp edges of their loads g Suspended loa...

Page 109: ...t a straight vertical pull to prevent swinging of the load In all crane lifts the center of gravity must remain below the hook and below the point of attachment for any rigging A center of gravity abo...

Page 110: ...e crane operation is working on firm ground with the capacity to support your loads 3 4 1 Slopes and trenches The crane can not be too close to slopes or trenches A safety distance must always be kept...

Page 111: ...1 1 Mud peat marshy soil 0 2 Non cohesive sufficiently compactly layered soil 2 1 Fine to medium grained sand 1 5 2 2 From coarse grained sand to gravel 2 3 Cohesive soil 3 1 Loamy Fertile 0 3 2 Soft...

Page 112: ...e as it can and the range should be small as possible as it can d The crane can only travel with a load in low speed The smaller change of the speed the better e Avoid swinging the load all the time i...

Page 113: ...to slip sideways and move into an impermissible side incline position There is a danger of accidents 4 The slewing table must be aligned to the crawler carriers and must be secured to prevent it from...

Page 114: ...own the crane 3 Is not a substitute for judgment of the crane operator 3 5 2 Lightning Strikes Inside the enclosed cab the equipment operator is well protected against the direct effects of lightning...

Page 115: ...on the rotary connection between the upper and lower carriages 3 6 Electrical safety 3 6 1 Safety regulations for auxiliary power supply 220V AC If the auxiliary power is supplied by power 220V AC the...

Page 116: ...companies factories transport companies 3 Building authorities c Only use the latest and effective plans d If there are any deviations or extensions to a project initiate new inquiries e If in doubt l...

Page 117: ...etc Existing markings and information signs must not be covered rearranged or removed 3 7 4 The consequences of a gas pipe s damage The escaping gas a Forms an inflammable gas air mixture around the a...

Page 118: ...ing the door bell or call them by telephone as this may trigger an explosion If the odor of gas is present in the building especially around the area where the gas pipe is known to enter the house do...

Page 119: ...ngerously high voltage b If an underground cable is sheared burn out at the fault location with strong electrical arcing may occur c If a high voltage power cable becomes damaged a hazardous resistanc...

Page 120: ...trol no longer functions use the radio or call 1 To everyone in the vicinity not to come any closer to or touch the machine the hoisting rope or load tell them to keep at least 33ft 10 m away 2 To arr...

Page 121: ...heck if the values shown on the instruments are correct after starting up the engine h Check if the control mechanisms are working normally i Check the brake and the clutch Test the braking performanc...

Page 122: ...rating the crane d Lifting device slings and fixed pulley block must be set in accordance with specified safe operation requirements e Make sure that the total weights of lifting device wire rope and...

Page 123: ...ent should not be greater than 1 100 The complete vehicle should be level and the supporting ground should not be sunken during operating If the ground is soft a steel plate should be placed under the...

Page 124: ...6 3 Wind can be felt on the face the leaves rustle wind sock moves slightly 3 Gentle breeze 3 4 5 3 Leaves and thin twigs move Wind extends a small breeze flag 4 Moderate breeze 5 5 7 8 Swirls up dus...

Page 125: ...r safe operation The instructions for safe operation during crane operation are shown in the table 3 11 Table 3 11 Instructions for safe operation S N Instructions Examples 1 No person is allowed to s...

Page 126: ...d should be less than 50cm The longer the boom the slower the travelling speed Meanwhile the distance from the load to the ground should be as low as possible 7 If the crane is operated in the vicinit...

Page 127: ...nded in the air the operator is not allowed to leave the cab 11 Operation should be carried out stably and gently Never operate control lever jerkily and carry out switch over operation abruptly 12 Wh...

Page 128: ...equences Stop the crane operation if one of the conditions in the table 3 12 occurs Table 3 12 Conditions to stop and inspect the crane S N Conditions to stop the crane 1 The crane is overloaded or th...

Page 129: ...rake and safety equipment fail or the wire rope is damaged etc 6 No one is permitted to ride on the load hook slings or load 7 Leave an ample space for stopping the crane otherwise persons nearby may...

Page 130: ...e commencing the work and the following important requirements for this type of operation must be observed 1 The load is not casually attached to the crane It must be calculated carefully so that the...

Page 131: ...e weight and dimensions of load to be lifted in advance l Crane operation can be carried out within minimum working radius No obstacles hinder necessary movements The ground at the job site is able to...

Page 132: ...fting capacity tables must not be exceeded Driving or slewing too fast with a load or setting up and loading on an uneven surface and swinging of suspended load should be avoided e Diagonal pulling sl...

Page 133: ...ce n Examine if the pressure sensor angle indicators and tension force sensor are in function o The crane may topple over backwards if a load is suddenly freed since the tension created in the boom ca...

Page 134: ...it if necessary e Clean such components as movable parts and exposed part of the piston rod of cylinder f Check if bolts and nuts are fitted tightly Any defects found should be eliminated at once It i...

Page 135: ...s Tap fist on the safety helmet then give further hand signals Bend the left hand and hold it upward tap the underside of the elbow with the right hand then give further hand signals Illustration Ser...

Page 136: ...ded downwards with a 30 angle to the body palm of the hand facing downwards wave hand down repeatedly Illustration Ser No 9 10 Signal Rotate slowly Indicate load lowering position Description Turn lef...

Page 137: ...fingers closed wave forearm down Bend the left arm Move the thumb up and down pointing upwards Place the right arm above it Illustration Ser No 14 15 16 Signal Lower boom slowly Stop Emergency stop De...

Page 138: ...an which can be conducted by hand signal or interphone Vigilance is needed no matter which method is used to avoid misunderstanding CAUTION 1 We recommend using the hand signals illustrated above Howe...

Page 139: ...Operator s Manual for Crawler Crane Chapter 4 Crane Operation For reference only Operators manual should be consulted and adhered to...

Page 140: ...For reference only Operators manual should be consulted and adhered to...

Page 141: ...d control instruments in the operator s cab is shown in the figure 4 1 For detailed information please see table 4 1 Table 4 1 Description of operating and control instruments No Names of instruments...

Page 142: ...please see Maintenance Manual 10 Right travel gear pedal Control the movements of right travel gear 11 Left travel gear pedal Control the movements of left travel gear 12 Free fall brake pedal Contro...

Page 143: ...100 moment percent 110 never spool up hoisting winch and raise or lower the main boom At this time press this switch to release the limited movements 3 Engine shutdown switch Press this switch to shu...

Page 144: ...winch Turn the switch clockwise and keep it there at this time When the icon shows on the load moment limiter the hoisting winch can be spooled up CAUTION 1 After the engine is shut down release the i...

Page 145: ...Swing free running Correspond to the right button on the top of control lever Protect the boom against damage by reducing the side force acting on the boom 4 Slew to right Move left control lever to...

Page 146: ...mbol Remarks 1 Horn Correspond to the left button on the top of control lever It is used to control the horn 2 Reel off H1 Push right control lever forwards reel off H1 3 High speed Correspond to the...

Page 147: ...eft control panel crane with free fall function No Names of the switches Remarks 1 Free fall master switch Turn on this switch before any free fall operation of hoisting winch 2 H1 free fall switch In...

Page 148: ...panel No Names of the switches Remarks 1 Ignition key switch Insert the key into the ignition key switch and rotate it clockwise to 1 st position then the power is turned on Continue to rotate the ke...

Page 149: ...when it is cold Moreover delay start of the engine is normal 4 1 6 Control panel on the roof of operator s cab C RGE E ME N O T S P Y 1 3 2 Figure 4 7 Position of control panel on the roof of operato...

Page 150: ...l working floodlights on the slewing table including lighting of monitoring system 5 Derricking ratchet pawl switch If derricking mechanism does not work for a long time turn on derricking ratchet paw...

Page 151: ...urn on this switch to make the oil cooling fan work when there is a need to cool the hydraulic oil 11 Winch low speed switch All winch movements will slow down after the switch is turned on 12 Travel...

Page 152: ...load boom length boom angle and moment percent When abnormal conditions occur the corresponding warning icons will flash 2 LCD screen of electrical system Show the working status of crawler crane in r...

Page 153: ...0 0 X 0 0 Angle X 0 0 Y 0 0 X 3 Res 0 0 Max 0 6 Gradient Y 0 0 X 0 0 Voltage 0 V Pressure Watch H1 H3 Derricking Control 0 0 MPa 0 0 MPa 0 0 MPa 0 0 MPa Slewing Return Oil H2 Pump 0 0 MPa 0 0 MPa 0 0...

Page 154: ...pulled out this icon will flash 5 Icon Oil pipeline clog When oil pipeline is clogged this icon will flash 6 Icon Lower limit switch on H3 winch When there are only three windings of wire rope left on...

Page 155: ...screen of engine information will be described in detail in the table 4 10 Table 4 10 Description of engine information screen No Engine information Remarks 1 Engine speed and working time Show curre...

Page 156: ...icon will flash after the free fall master switch No 1 in figure 4 5 is turned on 2 H1 free fall warning The icon will flash after H1 free fall switch No 2 in figure 4 5 is turned on 3 H2 free fall w...

Page 157: ...No Pressure monitoring Remarks 1 H1 pressure Show the oil pipeline pressure of H1 winch 2 H3 pressure Show the oil pipeline pressure of H3 winch 3 Derricking pressure Show the oil pipeline pressure o...

Page 158: ...een In this screen all the input output points of PLC can be checked 3 Key Parameter adjustment Press this key to enter Parameter adjustment screen then you can adjust relevant parameters of main moti...

Page 159: ...a Vertical adjustment of headrest The height of headrest is adjusted manually with proper strength Figure 4 16 Adjustment of headrest b Adjustment of armrest The height of armrest can be adjusted by t...

Page 160: ...eight There are two levers to adjust the seat height The left lever adjusts the height of the front part of the seat and the right lever adjusts the height of the rear part of the seat Pull the left l...

Page 161: ...of the crane Before starting up the crane the operator must ensure that the following conditions are fulfilled 1 The crane is horizontally aligned 2 The gear of the slewing ring must be clean and grea...

Page 162: ...tion then the power supply is turned on See the figure 4 21 Figure 4 21 Turn on power supply 4 3 3 1 Checking main screen of electrical system After the power supply is turned on press the power switc...

Page 163: ...ne is only fitted with main boom The maximum out of service wind speed should not exceed 15m s when the crane is fitted with main boom and fixed jib If wind speed reaches or exceeds these values the e...

Page 164: ...of the cab Refer to figure 4 23 R OFF OFF MIDDLE HIGH LOW VENT ON COOL VENTILATE WARM COOL WARM Figure 4 23 Air conditioning control 4 3 5 Horn Press horn switch before starting the work to check if...

Page 165: ...are normal See the figure 4 26 Speed 100 0 rpm 500 1000 1500 2000 2500 3000 0 0 hour 0 120 210 0 5 10 0 1 2 1 WaterTEMP Oil Pressure Fule Lever 0 0 0Bar 0 0 X Figure 4 26 Check of engine parameters I...

Page 166: ...oke discharging After the engine starts release ignition key switch at once to let it return to initial position and check the parameters of the engine at the same time 3 When ambient temperature is l...

Page 167: ...stem is switched off and the diesel engine shuts down b All crane movements stop immediately P S T O Y C N E G R E M E Y E P STO M N E E G R C Figure 4 27 Position of emergency stop button DANGER The...

Page 168: ...e Set battery master switch in OFF position during long time work breaks so as to prevent the electricity of battery from discharging excessively G2 G1 Figure 4 28 Position of battery box G2 G1 Figure...

Page 169: ...in a position to carry out this job with the help of lifting capacity chart DANGER The load moment limiter must be adjusted before using the crane to the current set up condition in accordance with th...

Page 170: ...ning and the buzzer sounds continuously 2 Press Setup switch No 2 in the figure 4 2 on the operating console the icon will appear on the load moment limiter if rated load is lifted At this time rotate...

Page 171: ...cent less than 100 When crane is not lifting the rated load please see section 4 4 4 1 CAUTION 1 Once the limited movements are bypassed by bypass switch their speeds will be reduced to 15 of original...

Page 172: ...ches the maximum value within the minimum radius the crane movement raise main boom will be cut off automatically the icon will appear on the load moment limiter the tricolor light will send out yello...

Page 173: ...ccordance with the following methods 1 Turn bypass switch in the electrical control box of slewing table clockwise until the icon appears on the load moment limiter At this time the limited movement r...

Page 174: ...ck boom down are switched off CAUTION Bypass those limited movements in accordance with the following methods 1 Turn bypass switch in the electrical control box of slewing table clockwise until the ic...

Page 175: ...aced on the ground When the out of service wind speed for Main boom with fixed jib configuration exceeds 15m s the entire boom should be placed on the ground The operator should constantly observe the...

Page 176: ...ed of crane movement decrease 2 When pressing the hoisting bypass switch the speed of crane movement is kept the same 2 There are only three windings of wire rope left on the hoisting winch take H1 wi...

Page 177: ...ounds continuously Press Setup switch the icons and will appear on the load moment limiter if the load moment percent is less than 100 At this time all movements are bypassed However the tricolor ligh...

Page 178: ...decreases 2 When Setup switch is pressed the speed of crane movement is not reduced 7 Main boom angle 80 The buzzer sounds intermittently 8 Main boom angle max main boom angle refer to table 4 15 for...

Page 179: ...ler is electrified again the bypass of cutoff is invalid Press bypass switch the bypass of cutoff is valid for 30mins If the switch is pressed again or the engine stops or the controller is electrifie...

Page 180: ...ing operation 3 Make a sound before operation to warn the persons in the vicinity of the crane 4 5 2 Inspection during operation a If the crane has been working for a long time or the ambient temperat...

Page 181: ...60 60 60 60 60 Figure 4 36 Valid area of control lever when operating a single movement To carry out a simultaneous movement with one control lever the operator must move control lever within 30 60 a...

Page 182: ...e 4 38 Components of travel gear 4 5 5 2 Operation of travel gear The traveling movements are controlled by left and right travel gear pedals No 10 11 in the figure 4 1 The movements left crawler forw...

Page 183: ...g Differential steering to right Depress left travel gear pedal forwards heavily while depressing right travel gear pedal forwards slightly to make the speed of left crawler faster than that of right...

Page 184: ...rn the travel gear pedal to neutral zero position the traveling brake will be activated automatically 3 When the crane is traveling with a load for a long distance ensure that the boom is located stra...

Page 185: ...le maximum gradient and the operator does not know about the ground condition 3 The crane can travel with suspended load providing that the following precautions are taken The ground surface must be f...

Page 186: ...the crane to lift the load Only after the hoisting rope is undone can the load be lifted 3 Under any conditions there must be at least three windings of wire rope left on the winding drum 4 When a lo...

Page 187: ...ompletely release the free fall switch of corresponding winch and turn the free fall master switch to OFF position DANGER 1 If free fall operation is not finished i e the winding drum does not stop ro...

Page 188: ...djust boom angle so as to change the working radius We can use A frame and boom frame to carry out derricking movement During derricking the derricking crown block is located at the top of A frame whi...

Page 189: ...hile main boom angle can vary from 0 to 82 5 under any other working condition And derricking winch is used to control main boom 2 Main boom with fixed jib configuration The fixed jib can be mounted i...

Page 190: ...he crane 2 When the crane is lifting a load the operator should not derrick boom towards dangerous directions Otherwise the crane may topple over 3 Before derricking mechanism is operated first derric...

Page 191: ...o left slew to left CAUTION 1 Before carry out slewing movement an acoustic signal should be given out 2 Operating with high slewing speed will cause an increased risk of accidents Before initiating a...

Page 192: ...ich is used to check if the slewing fixing pin is pulled out If the fixing pin is not pulled out the electrical system will automatically cut off the slewing motions Sometimes it is difficult to pull...

Page 193: ...Crane Crane Operation 4 53 Figure 4 46 Detecting device for slewing fixing pin Bypass switch Detecting switch for slewing fixing pin Slewing fixing pin Support For reference only Operators manual shou...

Page 194: ...ing free running button is shown in the following figure Figure 4 47 Operation of swing free running CAUTION 1 When carrying out the movement Swing free running operate control lever to lift the hook...

Page 195: ...e superstructure may still slew because it is not a positioning lock 9 Activating slewing brake switch to stop slewing operation abruptly should be avoided since it may cause damage to the superstruct...

Page 196: ...peration Function 1 Counterweight lifting undercarriage auxiliary device selector switch Push it up Counterweight lifting is selected Push it down Undercarriage auxiliary device such as crawler carrie...

Page 197: ...over the boom to the pulley head proceed with great caution when walking on the boom 2 There is a great danger of causing a serious accident if the crane function is not operated properly and the per...

Page 198: ...the service life of wire rope will be shortened 1 2 3 Rope reeving 10 Rope reeving 9 Rope reeving 8 Rope reeving 7 Rope reeving 6 1 Deflection pulley on main boom head 2 Rope pulley on main boom head...

Page 199: ...Rope reeving 6 Rope reeving 5 Rope reeving 4 Rope reeving 3 Figure 4 51 Reeving 55USt 50t load hook Rope reeving 4 Rope reeving 3 Rope reeving 2 Figure 4 52 Reeving 33USt 30t load hook For reference...

Page 200: ...oad hook on main boom is reeved in according to the Figure 4 50 Figure 4 52 Figure 4 54 Hoisting rope guidance for tip boom When rope reeving is 2 and the tip boom is fitted on the main boom head the...

Page 201: ...hown in the figure 4 56 Figure 4 56 Rope reeving for fixed jib 4 6 2 Derricking rope reeving The reeving of derricking rope is shown in the Figure 4 57 Figure 4 58 A A Figure 4 57 Reeving of derrickin...

Page 202: ...1 2 3 4 9 10 are the derricking upper pulleys while rope pulleys 5 6 7 8 11 are the derricking lower pulleys Figure 4 58 Reeving of derricking rope between derricking pulley blocks Derricking travelin...

Page 203: ...x wire rope with a rope clamp 4 CAUTION 1 Incorrect fixation of rope end point can diminish the performance of rope and damage the rope 2 Fix rope end point in accordance with the method mentioned in...

Page 204: ...4 60 Fixation of rope clamp Wrong Right Rope length T is six times as much as rope diameter and it should be no less than 150mm Rope length S is three times as much as rope diameter or it is 75mm For...

Page 205: ...Operator s Manual for Crawler Crane Chapter 5 Assembly and Dismantling For reference only Operators manual should be consulted and adhered to...

Page 206: ...For reference only Operators manual should be consulted and adhered to...

Page 207: ...sting rope strictly in accordance with the reeving plans h Each dismantled parts should not only satisfy the requirement of load bearing capacity under operating conditions but also meet the art techn...

Page 208: ...ting points and surrounding buildings k Influence of communal facilities on crane operation including the overhead high low voltage lines and underground gas pipes l Movement restrictions due to surro...

Page 209: ...load hook according to the following items a Check load hook for distortions e g at the hook jaw b Check all bolts and screws and ensure all cotter pins are complete and open c Check that the rotary...

Page 210: ...hed in accordance with the load capacity chart and operator s manual e All pinned connections have been secured f The hoisting rope has been correctly placed in the rope pulleys and it is prevented fr...

Page 211: ...be familiar with operating procedure and safety regulations and clear about their areas of responsibility before operation c Check the basic machine thoroughly before operation d Switch the system int...

Page 212: ...spindle between A frame rear anchoring rods and slewing table Continue spooling up derricking winch to erect A frame to required position Mount A frame well Figure 5 3 Unloading the basic machine DANG...

Page 213: ...cylinders until they are vertical to the ground and mount support plates Start the engine establish electrical connection between auxiliary remote control box and the junction box on the rear right s...

Page 214: ...rriage control levers which are located in the front of undercarriage central section can control four support cylinders and two horizontal cylinders For detailed operation please see the operating bo...

Page 215: ...ting board as shown in the figure 5 7 EXT cylinder RET Telescopic Cylinder Of Left Track Frame Control Right NO 2 NO 1 Outriggers NO 4 NO 3 Left cylinder NO 1 cylinder NO 2 Right cylinder NO 3 cylinde...

Page 216: ...support 3 Mounting cylinder 2 Main boom pivot section 4 Support cylinder After basic machine is unloaded from the low loader via support cylinders A frame must be erected to required position for the...

Page 217: ...sm is installed remove the pin spindle which is used to connect inner pipe and outer pipe of main boom tilting back support loose the mounting cylinder from main boom pivot section and establish hydra...

Page 218: ...irst check whether there is an object hindering the operation and then adopt the auxiliary device mentioned in step d to move the crawler carrier d Extend left horizontal cylinder part 1 in the figure...

Page 219: ...d for assembly of crawler carrier No Names of the parts No Names of the parts 1 Horizontal cylinder 3 Retaining plate on the crawler carrier 2 Pin spindle Figure 5 12 Working position of horizontal cy...

Page 220: ...linder and main boom pivot section If necessary use right horizontal cylinder to assemble crawler carrier c Adjust the height of support cylinder to allow left and right crawler carriers to contact th...

Page 221: ...sembled See the figure 5 15 Figure 5 15 Dismantling of folding brackets a Retract support cylinders put support plates on the attachment points at the side of folding brackets disconnect hydraulic con...

Page 222: ...ing rods pin spindles and so on Refer to figure 5 17 figure 5 18 and table 5 3 Table 5 3 Crawler carrier extending retracting mechanism No Names of the components No Names of the components 1 Pin spin...

Page 223: ...re 5 18 Enlarged view of crawler carrier extending retracting mechanism WARNING Inspect the hose of traveling motor before extending and retracting crawler carrier and ensure the hose is not damaged d...

Page 224: ...status of adjusting block is shown in the figure 5 19 and the relevant parts are listed in the table 5 4 1 1 2 Figure 5 19 Removal of adjusting block Table 5 4 Positioning bolt of adjusting block No N...

Page 225: ...status of adjusting block is shown in the figure 5 20 Figure 5 20 Locking of adjusting block a Screw out reverse bolt for enough distance via socket wrench b Screw two forward bolts by turns to push a...

Page 226: ...extended completely Put a retaining plate on each pair of folding bracket to limit swiveling of folding bracket c Pull out the positioning pins of horizontal anchoring rods so that the anchoring rods...

Page 227: ...d right crawler carriers are retracted completely and the horizontal anchoring rods are mounted take out the retaining plate on the folding bracket and then put it on the hook of the crawler carrier e...

Page 228: ...is fitted with the boom and counterweight never extend and retract the crawler carriers Otherwise the crane may overturn 2 Prohibit lifting the load before the crawler carrier is extended fully 5 2 4...

Page 229: ...ounting cylinder See the figure 5 23 4500 14 9 Figure 5 23 Unloading of central counterweight b Raise main boom pivot section to make central counterweight move backwards and then adjust the height of...

Page 230: ...ht is in contact with the undercarriage central section completely e After the central counterweight is assembled keep the connection between the mounting cylinder and central counterweight See the fi...

Page 231: ...or Crawler Crane Assembly and Dismantling 5 25 Figure 5 26 Attachment of central counterweight on the undercarriage central section Figure 5 27 Pulling down the main boom pivot section For reference o...

Page 232: ...of counterweight self assembly dismantling mechanism Counterweight self assembly dismantling mechanism consists of mounting cylinder rear anchoring rods of A frame A frame derricking pulley block main...

Page 233: ...lates on the counterweight base plate via mounting cylinder Move basic machine until the counterweight lifting device at the tail of slewing table is aligned with the counterweight base plate Connect...

Page 234: ...ght 4500 14 9 Figure 5 30 Unloading of rear counterweight 5 2 5 3 Stacking of rear counterweight Stack counterweight plates on the counterweight base plate via mounting cylinder See the figure 5 31 Fi...

Page 235: ...of counterweight are aligned with each other See the figure 5 32 Figure 5 32 Moving basic machine b Travel basic machine backwards until the counterweight lifting cylinder is positioned above the moun...

Page 236: ...ion 4 5 8 in Chapter 4 e Put the lever control mechanism for pin spindle in pull out position f Carefully and sensitively lift the counterweight until the mounting holes in the front of counterweight...

Page 237: ...Crawler Crane Assembly and Dismantling 5 31 Figure 5 34 Lifting of rear counterweight DANGER 1 The counterweight plates must be arranged neatly in a pile otherwise accidents will occur For reference...

Page 238: ...s only used for the assembly and dismantling of counterweight It can not be used to lift other objects Otherwise the accident may occur 6 The dismantling of counterweight is carried out in reverse ord...

Page 239: ...der and then align the attachment point of mounting cylinder with the pin hole at position B on the pivot section Lower main boom pivot section to a proper position so that the operator can fix the cy...

Page 240: ...boom length Fixed jib length Remarks S 1 Main boom 42 8 13m 219 10 67m No The load is attached onto main boom S 2 Main boom with fixed jib 101 9 31m 180 5 55m 19 8 6m 59 18m The load is attached onto...

Page 241: ...mponents of boom frame Code Names of the components Length Weight G10 Tip boom on main boom head 337 lb 0 14t G11 Main boom pivot section 21 4 6 5m 2761 lb 1 25t G12 Main boom head 21 4 6 5m 2661 lb 1...

Page 242: ...tion that have not been stipulated in the operator s manual or installation drawings 2 When assembling boom sections make sure that the intermediate sections are assembled in their specified positions...

Page 243: ...oom intermediate section 3m main boom intermediate section G13 9 10 6m main boom intermediate section G14 19 8 and 9m main boom intermediate section G15 29 6 The longest main boom of 219 10 67m overvi...

Page 244: ...2 22m G11 G15 G12 170 7 52m G11 G13 4 G15 G12 82 25m G11 G13 G15 G12 180 5 55m G11 G14 4 G15 G12 91 10 28m G11 G14 G15 G12 190 4 58m G11 G13 G14 4 G15 G12 101 9 31m G11 G13 G14 G15 G12 200 2 61m G11...

Page 245: ...sembled according to the figures 5 39 5 40 5 41 G14 G12 G12 G11 G12 G13 G11 G11 G11 G15 G12 Figure 5 39 Assembly of main boom G15 G12 G13 G11 G14 G11 G15 G12 G15 G14 G13 G11 G15 G13 G11 G15 G12 G12 42...

Page 246: ...G12 G15 G12 G15 G15 G15 G12 Figure 5 40 Assembly of main boom G12 G15 G15 G13 G11 G13 G11 G14 G15 G15 G15 G15 G12 G14 G11 G13 G11 G15 G15 G14 G15 G15 G15 G15 G12 G15 G15 G15 G12 121 5 37m 131 3 40m 14...

Page 247: ...G15 G12 G15A G15 G15 G15 G15A G15 G12 G12 Figure 5 41 Assembly of main boom DANGER 1 The combination of 219 10 67m main boom in above figure is preferable combination 2 No person is allowed to stand...

Page 248: ...0 67m main boom anchoring rods Please see the figure 5 42 1 2 3 4 8 9 5 6 7 7 7 22 3 5700mm 8 10 2700mm 10 270mm 22 3 700mm 6x29 6 177 1 6x9000mm 19 8 6000mm 9 10 3000mm 10 270mm 22 3 5700mm Figure 5...

Page 249: ...5 9 Components of main boom anchoring rods No Names of the components Illustration 1 Double anchoring rod 2 52 64mm 10 63 270mm 1 89 48mm 1 97 50mm 1 57 40mm 0 95 24mm 2 Single anchoring rod 22 3 570...

Page 250: ...indle 1 57 40mm 4 72 120mm 9 Pin spindle 1 57 40mm 2 76 70mm DANGER 1 The component numbers of main boom anchoring rods given in the figure 5 42 Combination of 219 10 67m main boom anchoring rods are...

Page 251: ...m length increases by 9 10 3m anchoring rods length will also increase 9 10 3m which includes a 11 8 300mm long anchoring rod and a 8 10 2700mm anchoring rod When main boom length increases by 19 8 6m...

Page 252: ...19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 6 34 270mm 5x29 6 9000mm 147 7 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 1...

Page 253: ...tion A code G15A length 29 6 must be used Its position is shown in the figure 5 44 G12 G15A G15 Figure 5 44 Position of 9m main boom intermediate section A Installation of intermediate tensioner is sh...

Page 254: ...Names of the components Illustration 1 Double anchoring rod 2 28 58mm 2 1 57 40mm 10 63 270mm 2 Double anchoring rod 1 57 40mm 1 18 30mm 1 65 42mm 1 10 560mm 3 Double anchoring rod 0 47 12mm 2 1 18 3...

Page 255: ...Pin spindle 1 38 35mm 2 64 67mm DANGER The component numbers of intermediate tensioner given in the figure 5 45 Installation of intermediate tensioner are consistent with those in the table 5 10 so th...

Page 256: ...6m long The fixed jib can be mounted in the angle of either 10 or 30 to main boom When fixed jib of different length is required the operator only needs to disconnect fixed jib pivot section from fixe...

Page 257: ...boom length in Main boom with fixed jib configuration varies from 101 9 31m to 180 5 55m For the detailed information refer to Section 5 4 1 G33 G32 G31 G33 G31 G31 G32 G32 G33 Figure 5 47 Assembly o...

Page 258: ...gure 5 48 2 3 3 4 3 3 5 6 7 8 11 8 300mm 8 82 224mm 11 8 300mm 9 2720mm 11 8 300mm 11 8 300mm 17 11 5460mm 18 10 5760mm 11 8 300mm 18 10 5760mm 17 11 5460mm 20 9 6340mm 9 2720mm 1 Figure 5 48 Combinat...

Page 259: ...horing rods No Names of the components Illustration 1 Pin spindle 2 1 53mm 1 38 35mm 2 Retaining pin 3 Double anchoring rod 2 1 38 35mm 0 63 16mm 11 8 300mm 4 Anchoring rod 17 11 5460mm 2 1 38 35mm 5...

Page 260: ...anchoring rods can be found by referring to the component numbers during assembling Principle for determining the length of fixed jib front anchoring rods When fixed jib is 19 8 6m long the length of...

Page 261: ...t anchoring rods must be inserted outwards Fixed jib rear anchoring rods The diameter of pin spindle for fixed jib rear anchoring rods is 1 181 30mm Since fixed jib can be mounted in the angle of eith...

Page 262: ...of fixed jib rear anchoring rods No Names of the components Illustration 1 Pin spindle 2 09 53mm 1 38 35mm 2 Retaining pin 3 Double anchoring rod 2 1 38 35mm 0 63 16mm 11 8 300mm 4 Reducing anchoring...

Page 263: ...ng piece 2 36 60mm 1 38 35mm 2 75 70mm 17 2 228mm 10 9 277mm 8 Double anchoring rod 2 1 38 35mm 4 7 1400mm 0 63 16mm 9 Coupling link 20 4 518mm 2 1 38 35mm 5 1545mm 5 5 1665mm 1 38 35mm 10 Single anch...

Page 264: ...erent from that when fixed jib is mounted in the angle of 30 to main boom When fixed jib is mounted in the angle of 10 to main boom a 2 11 900mm anchoring rod must be removed When fixed jib angle is 3...

Page 265: ...ction are lifted by an auxiliary crane at least two pieces of lifting chain with a breaking force 11025 lb 15t should be used 5 Do not stand on the lattice boom when it is assembled 6 Do not stand ben...

Page 266: ...ion attached to the preassembled main boom c Operate derricking winch in such a way see Section 4 6 4 that the upper connecting holes in main boom pivot section are aligned with those in adjacent main...

Page 267: ...connect main boom sections No Names of the components Illustration 1 Double tapered pin 7 52 191mm 4 13 105mm 1 77 45mm 2 Retaining pin DANGER 1 The connecting pin must always be fitted from outside i...

Page 268: ...section 5 4 1 2 Detach derricking traveling block from main boom pivot section and then connect it to the assembled main boom anchoring rods See the figure 5 54 Figure 5 54 Assembly of main boom anch...

Page 269: ...m head and then reeve the hoisting rope between hook block and rope pulley on main boom head in accordance with the rope reeving plan for the details please refer to section 4 6 rope reeving in Chapte...

Page 270: ...he derricking travelling block will move above the guide board part 2 Continue to unwind the derricking rope so that the guide rod part 1 on the derricking travelling block comes into contact with the...

Page 271: ...erricking traveling block No Description No Description 1 Guide rod 4 Cross coupling 2 Guide board 5 Pin spindle 3 Derricking travelling block WARNING Only after the cross coupling on the derricking t...

Page 272: ...assy Connect the slewing table cable and junction box on the main boom head 2 Fixed jib cable drum assy Connect the junction box on the main boom head to the junction box on the fixed jib head 3 Anemo...

Page 273: ...mentioned above should be adhered to what is described in the figure 5 61 5 5 3 3 Function check Insert the ignition key into the ignition start switch and then rotate it clockwise to the 1st position...

Page 274: ...itches have been correctly fitted and are fully operational e All pinned connections have been secured f The hoisting rope is properly placed in the rope pulleys and is secured with rope guard tube to...

Page 275: ...r main boom is raised to 30 position the hook can be lifted away from the ground 3 The boom raising movement should be performed slowly and stably And during the operation the crane operator must obse...

Page 276: ...al position to stop operation 5 5 5 2 Dismantling boom sections and anchoring rods After the anchoring rods are lowered down on the nylon support plate on the relevant boom sections remove the pin spi...

Page 277: ...visations are prohibited Otherwise there is a danger of falling down 2 Do not stand beneath the boom when it is being pinned or unpinned 5 6 2 Assembly of fixed jib During transportation fixed jib piv...

Page 278: ...fixed jib intermediate sections G33 All fixed jib intermediate sections are connected with double tapered pins 5 secured the pins on both sides with retaining springs 6 as follows 6 5 G33 G31 G32 Figu...

Page 279: ...ouble tapered pin 5 12 130mm 1 18 30mm 6 Retaining spring 85mm 3 35 d Assemble main boom anchoring rods according to the length of assembled main boom for the details see Section 5 4 1 Pre assemble so...

Page 280: ...which is shown in the figure 5 67 g Push left control lever forwards to unwind the hoisting rope from the hoisting winch 2 and then pull the rope forwards to the rope pulley at the fixed jib head thro...

Page 281: ...he hoisting rope near the boom head is not exposed to crushing force during rope reeving and boom raising process 3 Ensure that the nylon guide on fixed jib head is always rolling on the ground before...

Page 282: ...ight on the boom head Measure the wind speed and send a warning in the air 3 hoisting limit switch for H2 winch Prevent winch 2 from over hoisting After the installation of main boom and fixed jib pul...

Page 283: ...is fixed with a load hook Support and hold the hoisting limit switch weight for H1 to ensure that the switch is triggered and then check whether the icon upper limit switch on H1 on the screen will f...

Page 284: ...he counterweight plates have been attached in accordance with the load capacity charts c Required boom sections have been attached in accordance with load capacity charts d All limit switches have bee...

Page 285: ...ed jib 1 The boom should be positioned straight ahead of the crawler crane i e the drive sprocket is at the back of crane 2 Before erecting the boom a certain length of hoisting rope should be unwound...

Page 286: ...liary crane tilt the FA frame forwards to appropriate position and dismantle the rear and front anchoring rods of fixed jib f Dismantle the fixed jib sections orderly from fixed jib head to the pivot...

Page 287: ...ith the A hole in main boom head Insert pin spindle part 2 and secure it with cotter pin part 1 Align the lower connecting hole with the B hole in main boom head Insert pin spindle part 3 and secure i...

Page 288: ...e 5 19 Transport weights and dimensions of main components Names of the components Dimensions Weight lb 1000 Qty Remarks Basic machine with crawler carrier 99 7 45 2t 1 Width 11 2 3400mm Basic machine...

Page 289: ...pivot section 2 8 1 25t 1 Main boom head 2 6 1 2t 1 3m main boom intermediate section 0 55 0 25t 1 6m main boom intermediate section 1 0 44t 1 9m main boom intermediate section 1 5 0 68t 4 Fixed jib p...

Page 290: ...antling 5 84 Names of the components Dimensions Weight lb 1000 Qty Remarks Load hook 100T 3 35 1 52t 1 Load hook 50T 2 71 1 23t 1 Load hook 30T 1 72 0 78t 1 Load hook 8T 0 57 0 26t 1 For reference onl...

Page 291: ...rod of A frame should be secured on the rear end of slewing table d To understand the detailed transport means please consult our company 5 9 2 Other requirements If the crane is not put into use for...

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Summary of Contents for ZCC1100

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Zoomlion ZCC1100, Operator'S Manual, Page: 232 / 291

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Summary of Contents for ZCC1100

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