Zoomlion ZCC1100H Operator'S Manual Download Page 232

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Operator’s Manual for Crawler Crane

tli

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.

Summary of Contents for ZCC1100H

Page 1: ...ision creates future Add Quantang Industrial 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 CRANE OPERATOR S MANUAL CRAWLER CRANE ...

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Page 3: ...Edition 1 5 2014 ZCC1100H Crawler Crane Operator s Manual ...

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Page 5: ...e crane If the crane becomes the property 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 publication We reserve the right to make changes to this manual at any time without obligation The manual has been translated to be best of our knowledge Zoomlion ass...

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Page 7: ...ilities 1 3 1 7 Safety advice regarding 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 Description of Crane 2 1 Product model 2 1 2 1 1 Product name plate and its position 2 1 2 1 2 Engine type and its manufacturer 2 2 2 1 3 Intended use of the crane ...

Page 8: ...1 Safety instructions for crane operator 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 instructions for crane operating crew 3 7 3 2 6 Electromagnetic influences 3 8 3 2 7 Safety signs 3 9 3 2 8 The potential dangers existing in crane operation 3 17 3 2 9 Inju...

Page 9: ...s 3 34 3 7 3 Notes in connection with 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 of a gas fire 3 36 3 7 7 Notes in connection with underground electric cables 3 37 3 7 8 The consequences of damaging an underground cable 3 37 3 7 9 The measures t...

Page 10: ...4 4 3 Flashing light 4 29 4 4 4 Load 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 Checklist of safety device 4 36 4 5 Crane operation 4 40 4 5 1 Preparation for operation 4 40 4 5 2 Inspection during operation 4 40 4 5 3 Valid area of control leve...

Page 11: ...le boom configurations 5 34 5 4 Boom 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 59 5 5 3 Electrical connection to main boom 5 66 5 5 4 Erecting main boom 5 68 5 5 5 Lowering and dismantling main boom 5 70 5 6 Assembly and dismantling of main bo...

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Page 13: ...履带起重机操作手册第一章安全操作说明 Operator s Manual for Crawler Crane Chapter 1 Safety ...

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Page 15: ...ane and all the relevant parameters specified by 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 the rated capacity specified in the documents associated with the crane h End user should comply with requirements in 29CRS OSHA about CC section 1 1 2 Al...

Page 16: ...ironment which is also illegal 5 Potentially 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 containers that may mislead someone into drinking or eating them 7 Do not pour waste into the ground into sewer system or into any water source 8 Ensure that all consumab...

Page 17: ...arts Remove grease oil and debris in time f Disconnect 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 on machine h During maintenance only use the correct tool for the job i Never make any modifications additions or changes which might affect safety with...

Page 18: ...reach into unguarded machinery Your arm 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 erected to reduce the risk of potential mechanical hazards such as falling lifted loads 1 8 Special Hazards 1 8 1 Electrical power a External considerations and hazar...

Page 19: ... handled by authorized persons dampened placed 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 authorized as there may be a risk of explosion and fire b No welding that will affect its structural integrity should be undertaken on this crane c Avoid all n...

Page 20: ...e interchanged The fittings lengths 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 under pressure can penetrate the skin and cause serious injury i Once the fluid is injected under into the skin seek medical help immediately ...

Page 21: ...履带起重机操作手册第二章起重机的描述 Operator s Manual for Crawler Crane Chapter 2 Description of Crane ...

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Page 23: ... Operator s Manual for Crawler Crane 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 of product name plate ...

Page 24: ...g loads non continuous use of crane 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 liable for any damage caused The operator bears full responsibility for this type of misuse The use of two hoisting winches for lifting loads twin hook operation is only...

Page 25: ...h with free fall function is M6 and group 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 assembly crane The load capacity charts specified for the crane are for assembly operation only General cargo handling or grab operation can only be permitted followi...

Page 26: ... 50 of crane s load cycles in the crane 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 Under these circumstances assuming that maintenance work is carried out properly the theoretical service life can be more than 20 years Harder operating conditions le...

Page 27: ...figuration no Description Length of main 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 main boom S 3 Main boom with tip boom 42 8 13m 200 2 61m No SF 1 Main boom with fixed jib 101 9 31m 180 5 55m 19 8 6m 59 18m The load is attached onto fixed jib SF...

Page 28: ...over 2 2 1 2 Assembly mode There exists 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 used to lift a load The maximum lifting capacity of mounting cylinder is 26460lb 12t The assembly mode of crane is shown in figure 2 4 however when the crane is att...

Page 29: ...s in assembly mode Figure 2 4 Assembly mode CAUTION Whenever using mounting cylinder on the boom to lift the load be sure to make the crane in assembly mode According to actual requirements there are five working modes and an assembly mode available for this crawler crane For the details please refer to relevant documents of load moment limiter L ...

Page 30: ...e table 2 3 Figure 2 5 Components on 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 Fuel tank 3 Hydraulic oil tank 11 Hoisting winch 1 4 Hoisting winch 2 12 Engine 5 Main valve 13 Hoisting winch 3 optional 6 Battery box 14 Derricking winch 7 Tool bo...

Page 31: ...2 3 4 5 6 7 8 9 10 1 1 12 13 14 Figure 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 carrier 9 Support plate optional 3 Track roller 10 Support cylinder optional 4 Track carrier roller 11 Central counterweight 5 Track pad 12 Undercarriage central secti...

Page 32: ... backwards turning on the spot Drive 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 to undercarriage via a single row roller four point connecting slewing ring for 360 continuous rotation Crane engine 6 cylinder diesel engine manufactured by Cumm...

Page 33: ...ns are controlled by two 4 way control 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 mechanism Hydraulically powered by axial piston variable displacement pump and planetary gear with spring loaded multi disc brake Infinitely variable speed from 0 to ...

Page 34: ...erall dimensions Unit ft mm 4700 3330 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 dimensions of the crane Extended retracted Extended retracted ...

Page 35: ...30 Rope speed of hoisting winches 1 and 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 On the 4 th rope layer Max rated single rope force of hoisting winches 1 and 2 With free fall function Lbs t 44100 29988 20 13 6 On the 1st rope layer Without fre...

Page 36: ...bs ft RPM N m RPM 1050 1500 1424 1500 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 Crawler carrier extended Note 1 The max single rope force mentioned in above table is not decided by the strength of wire rope The rope speed and travelling speed o...

Page 37: ...act signed with the customer 2 4 3 Performance 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 working with fixed jib the hoisting rope reeving is 1 Table 2 7 Hoisting rope reeving and wire rope length in main boom configuration Length of main boom ft m Reevi...

Page 38: ...oisting winch 3 is mounted its wire rope 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 hoisting winch 3 The maximum single rope force is not determined by the strength of the wire rope The speed in the table refers to the wire rope speed Table 2 9 Par...

Page 39: ... t Rated single rope force kips t Winch 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 5 6 190 58 92 28 5 11 4 5 2 11 4 5 2 203 62 99 30 6 10 8 4 9 10 8 4 9 216 66 105 32 Table 2 12 Parameters of hoisting winch 3 optional Working layer of wire rope Ma...

Page 40: ... The boom lifting height curve is drawn 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 10 67 80 70 60 50 40 30 20 6 1 40 12 2 60 18 3 80 24 4 100 30 5 120 36 6 140 42 7 160 48 8 180 54 9 200 61 Working radius ft m Slewing center 40 12 2 60 18 3 80 24 4...

Page 41: ...e Y axis indicates the lifting height 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 39 4 31 12 101 9 59 31 18 180 5 19 8 55 6 180 5 39 4 55 12 180 5 59 55 18 40 12 2 60 18 3 80 24 4 100 30 5 120 36 6 140 42 7 160 48 8 180 54 9 200 61 220 67 1 240 ...

Page 42: ...t 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 39 4 31 12 101 9 59 31 18 180 5 19 8 55 6 180 5 39 4 55 12 180 5 59 55 18 40 12 2 60 18 3 80 24 4 100 30 5 120 36 6 140 42 7 160 48 8 180 54 9 200 61 220 67 1 240 73 2 30 Boom configuration Lifting h...

Page 43: ...tained from the calculation when the 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 chart is the lifting capacity when the crane is working with 61740Lbs 28t rear counterweight and 22050lbs 10t central counterweight in 360 range The crawler carriers of...

Page 44: ...7 20 6 1 25 7 6 89 3 40 5 89 1 40 4 89 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 3 25 1 55 3 25 1 55 1 25 0 54 9 24 9 54 7 24 8 54 5 24 7 54 2 24 6 35 10 7 40 12 2 47 0 21 3 46 7 21 2 46 7 21 2 46 5 21 1 46 3 21 0 46 1 20 9 45 9 20 8 45 6 20 7...

Page 45: ... 2 20 1 9 1 19 9 9 0 19 4 8 8 19 1 8 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 9 12 8 5 8 90 27 4 100 30 5 12 8 5 8 12 6 5 7 12 3 5 6 12 1 5 5 11 9 5 4 11 7 5 3 11 5 5 2 11 0 5 0 10 8 4 9 10 6 4 8 100 30 5 110 33 5 11 2 5 1 10 8 4 9 10 6 4 8...

Page 46: ... which is not in the lifting capacity 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 hook and so on 4 The value in the chart is the lifting capacity of the crane without a tip boom When main boom is fitted with tip boom the lifting capacity must inc...

Page 47: ...3 29 1 64 29 63 4 28 7 62 7 28 4 62 3 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 13 5 29 3 13 3 28 7 13 28 2 12 8 50 15 2 60 18 3 23 2 10 5 23 2 10 5 22 3 10 1 22 3 10 1 21 4 9 7 20 9 9 5 60 18 3 70 21 3 18 5 8 4 18 5 8 4 17 6 8 17 4 7 9 16 5 7...

Page 48: ...23 50 5 22 9 49 8 22 6 49 4 22 4 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 22 3 10 1 22 1 10 21 2 9 6 20 7 9 4 60 18 3 70 21 3 18 3 8 3 18 3 8 3 17 4 7 9 17 2 7 8 16 5 7 5 16 1 7 3 70 21 3 80 24 4 14 6 6 6 14 6 6 6 13 9 6 3 13 7 6 2 12 8 5 ...

Page 49: ...7 6 21 6 35 10 7 40 12 2 41 7 18 9 41 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 21 3 18 1 8 2 18 1 8 2 17 2 7 8 17 2 7 8 16 3 7 4 16 1 7 3 70 21 3 80 24 4 14 3 6 5 14 3 6 5 13 7 6 2 13 4 6 1 12 8 5 8 12 3 5 6 80 24 4 90 27 4 11 9 5 4 11 9 5 4 ...

Page 50: ...5 40 4 18 3 39 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 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 15 9 7 2 70 21 3 80 24 4 14 3 6 5 14 3 6 4 13 4 6 1 13 2 6 12 6 5 7 12 3 5 6 80 24 4 90 27 4 11 7 5 3 11 7 5 3 10 8 4 9 10 8 4 9 9 9 4 5 9 7 4 4 90 27 4 100 30 5 9 5...

Page 51: ...18 2 39 7 18 38 8 17 6 40 12 2 50 15 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 3 80 24 4 14 1 6 4 13 9 6 3 13 2 6 13 5 9 12 3 5 6 12 1 5 5 80 24 4 90 27 4 11 5 5 2 11 5 5 2 10 6 4 8 10 6 4 8 9 7 4 4 9 5 4 3 90 27 4 100 30 5 9 3 4 2 9 3 4 2 8 ...

Page 52: ...2 5 50 15 2 60 18 3 22 3 10 1 22 1 10 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 2 5 1 10 4 4 7 10 4 4 7 9 7 4 4 9 5 4 3 90 27 4 100 30 5 9 0 4 1 9 0 4 1 8 4 3 8 8 1 3 7 7 5 3 4 7 3 3 3 100 30 5 110 33 5 7 3 3 3 7 3 3 3 6 6 3 6 6 3 5 7 2 6 5 5...

Page 53: ... 7 13 28 5 12 9 27 8 12 6 27 3 12 4 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 5 3 80 24 4 90 27 4 11 5 11 5 10 4 4 7 10 2 4 6 9 5 4 3 9 3 4 2 90 27 4 100 30 5 8 8 4 8 8 4 8 2 3 7 7 9 3 6 7 3 3 3 7 1 3 2 100 30 5 110 33 5 7 1 3 2 7 1 3 2 6 4 ...

Page 54: ...15 2 60 18 3 21 8 9 9 21 6 9 8 20 9 9 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 6 9 9 4 5 9 3 4 2 9 1 4 1 90 27 4 100 30 5 8 4 3 8 8 4 3 8 7 7 3 5 7 5 3 4 6 8 3 1 6 6 3 100 30 5 110 33 5 6 8 3 1 6 8 3 1 6 2 2 8 6 2 2 8 5 3 2 4 5 3 2 4 110 33 ...

Page 55: ... 2 7 6 2 7 110 33 5 120 36 6 5 3 2 4 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 lifting capacity determined by the strength of the machine while the values that are not in bold are the lifting capacity determined by the stability of the machine 2 Th...

Page 56: ...is working with 61740 Lbs 28t rear counterweight and 22050lbs 10t central counterweight in 360 range 5 The value in the chart is the maximum lifting capacity of the crane including the weight of lifting device hook wire rope at the end of hook and so on 6 The crawler carriers are extended completely The hook on the fixed jib is nearest to the jib head ...

Page 57: ...8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 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 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 17 6 8 40 12 2 50 15 2 17 6 45 8 13 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 50 15 2 60 18 3 17 6 55 8 16 8 17 6...

Page 58: ... 3 4 7 10 1 4 6 9 9 4 5 9 7 4 4 9 3 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 5 3 2 4 5 3 2 4 5 3 2 4 5 3 2 4 4 6 2 1 4 4 2 4 2 1 9 130 39 6 140 42 7 4 2 1 9 4 2 1 9 4 1 8 3 8 1 7 3 6 1 6 3 4 1 5 140 42 7 150 45 7 3 5 145 1 6 44 2 3 1 1 4 2 9...

Page 59: ... is working with 61740Lbs 28t rear counterweight 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 including the weight of lifting device hook wire rope at the end of hook and so on 7 Choose the type of hook on the main boom before the system is switched to S 3 configur...

Page 60: ...5 2 17 6 8 17 6 8 17 6 8 13 2 6 0 50 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 14 6 6 6 14 3 6 5 15 0 6 8 12 6 5 7 11 2 5 1 6 8 3 1 90 27 4 100 30 5 12 3 5 6 12 3 5 6 12 8 5 8 11 0 5 10 6 4 8 6 4 2 9 100 30 5 110 33 5 10 6 4 8 11 0 5 10 8 4 9...

Page 61: ...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 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 7 5 3 4 90 27 4 100 30 5 11 9 5 4 12 3 5 6 12 1 5 5 11 9 5 4 10 8 4 9 6 6 3 100 30 5 110 33 5 10 4 4 7 10 6 4 8 10 8 4 9 10 8 4 9 10 1 4 6 6 4 2 9 110 33 5 120 36...

Page 62: ...3 7 4 13 2 6 60 18 3 70 21 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 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 12 1 5 5 12 1 5 5 12 6 5 7 11 0 5 0 6 6 3 100 30 5 110 33 5 10 1 4 6 10 4 4 7 10 4 4 7 10 8 4 9 10 1 4 6 6 4 2 9 110 33 5 120 36 6 8 6 3 9 8 8 4 9 0 4 1 9 3 4 2 9 3...

Page 63: ...0 21 3 17 6 8 17 6 8 17 6 8 15 9 7 2 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 11 2 5 1 7 1 3 2 100 30 5 110 33 5 9 7 4 4 9 9 4 5 10 4 4 7 10 6 4 8 10 1 4 6 6 6 3 110 33 5 120 36 6 8 4 3 8 8 6 3 9 8 8 4 9 0 4 1 9 3 4 2 6 2 2 8 120 36 6 130 39...

Page 64: ... 4 15 9 7 2 16 5 7 5 16 8 7 6 15 0 6 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 10 6 4 8 10 1 4 6 6 6 3 110 33 5 120 36 6 8 2 3 7 8 4 3 8 8 6 3 9 9 0 4 1 8 8 4 6 4 2 9 120 36 6 130 39 6 7 1 3 2 7 1 3 2 7 3 3 3 7 7 3 5 7 5 3 4 6 2 2 8 130 39 6 1...

Page 65: ...3 7 4 16 3 7 4 15 4 7 12 6 5 7 8 3 3 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 6 8 3 1 110 33 5 120 36 6 7 9 3 6 8 2 3 7 8 4 3 8 8 6 3 9 8 6 3 9 6 6 3 120 36 6 130 39 6 6 8 3 1 6 8 3 1 7 1 3 2 7 5 3 4 7 5 3 4 6 4 2 9 130 39 6 140 42 7 5 7 2 6 ...

Page 66: ...12 6 5 7 8 4 3 8 80 24 4 90 27 4 13 0 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 7 3 5 7 9 3 6 7 9 3 6 8 6 3 9 8 4 3 8 6 6 3 120 36 6 130 39 6 6 6 3 6 6 3 6 8 3 1 7 3 3 3 7 1 3 2 6 4 2 9 130 39 6 140 42 7 5 5 2 5 5 7 2 6 5 7 2 6 6 2 2 8 6 0 2 ...

Page 67: ... 7 12 8 5 8 8 4 3 8 80 24 4 90 27 4 12 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 3 3 7 7 3 5 7 9 3 6 8 4 3 8 8 2 3 7 6 6 3 120 36 6 130 39 6 6 2 2 8 6 4 2 9 6 6 3 7 1 3 2 6 8 3 1 6 4 2 9 130 39 6 140 42 7 5 3 2 4 5 3 2 4 5 7 2 6 6 0 2 7 6 0 2 7...

Page 68: ...0 39 6 6 0 2 7 6 2 2 8 6 4 2 9 6 8 3 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 7 4 4 2 160 48 8 170 51 8 2 9 1 3 2 6 1 2 3 1 1 4 3 1 1 4 3 1 1 4 3 5 1 6 170 51 8 180 54 9 2 0 0 9 2 4 1 1 2 4 1 1 2 4 1 1 2 9 1 3 180 54 9 190 57 9 1 8 0 8 1 8 0...

Page 69: ...crane may topple over or be damaged 4 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 maximum lifting capacity of the crane including the weight of lifting device hook wire rope at the end of hook and so on 6 The crawler carriers of the crane are extend...

Page 70: ...5 2 17 6 8 17 6 8 17 6 8 13 2 6 0 50 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 27 4 13 5 9 12 8 5 8 13 7 6 2 12 6 5 7 11 2 5 1 6 8 3 1 90 27 4 100 30 5 10 8 4 9 10 8 4 9 11 5 5 2 11 0 5 10 6 4 8 6 4 2 9 100 30 5 110 33 5 9 0 4 1 9 7 4 4 9 5 4 ...

Page 71: ...5 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 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 7 5 3 7 5 3 4 90 27 4 100 30 5 10 4 4 7 10 8 4 9 10 8 4 9 10 6 4 8 10 8 4 9 6 6 3 100 30 5 110 33 5 8 8 4 9 0 4 1 9 5 4 3 9 5 4 3 9 0 4 1 6 4 2 9 110 33 5 120 36 6 ...

Page 72: ...7 6 8 16 3 7 4 13 2 6 60 18 3 70 21 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 7 10 6 4 8 10 8 4 9 11 2 5 1 9 9 4 5 6 6 3 100 30 5 110 33 5 8 6 3 9 8 8 4 9 4 1 9 5 4 3 9 0 4 1 6 4 2 9 110 33 5 120 36 6 7 1 3 2 7 3 3 3 7 7 3 5 7 9 3 6 8 2 3 7 ...

Page 73: ...8 3 70 21 3 16 1 7 3 16 1 7 3 16 3 7 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 11 2 5 1 9 9 4 5 7 1 3 2 100 30 5 110 33 5 8 2 3 7 8 4 3 8 9 4 1 9 3 4 2 8 8 4 6 6 3 110 33 5 120 36 6 6 8 3 1 7 1 3 2 7 5 3 4 7 7 3 5 7 9 3 6 6 2 2 8 120 36 6 130 ...

Page 74: ... 21 3 80 24 4 14 3 6 5 15 6 8 15 4 7 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 3 4 2 8 8 4 6 6 3 110 33 5 120 36 6 6 6 3 6 8 3 1 7 3 3 3 7 7 3 5 7 5 3 4 6 4 2 9 120 36 6 130 39 6 5 5 2 5 5 5 2 5 6 2 7 6 4 2 9 6 2 2 8 6 2 2 8 130 39 6 140 42 7...

Page 75: ...6 5 14 8 6 7 14 8 6 7 15 4 7 12 6 5 7 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 8 3 1 110 33 5 120 36 6 6 4 2 9 6 6 3 7 1 3 2 7 3 3 3 7 3 3 3 6 6 3 120 36 6 130 39 6 5 3 2 4 5 3 2 4 5 7 2 6 6 2 2 8 6 2 2 8 6 4 2 9 130 39 6 140 42 7 4 2 1 9 4 ...

Page 76: ... 6 7 15 4 7 12 6 5 7 8 4 3 8 80 24 4 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 36 6 6 2 2 8 6 4 2 9 6 6 3 7 3 3 3 7 1 3 2 6 6 3 120 36 6 130 39 6 5 1 2 3 5 1 2 3 5 5 2 5 6 2 7 5 7 2 6 6 4 2 9 130 39 6 140 42 7 4 1 8 4 2 1 9 4 4 2 4 9 2 2 4 6 ...

Page 77: ...6 4 14 6 6 6 14 1 6 4 12 8 5 8 8 4 3 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 33 5 120 36 6 5 7 2 6 6 2 2 8 6 6 3 7 1 3 2 6 5 3 1 6 6 3 120 36 6 130 39 6 4 6 2 1 4 9 2 2 5 3 2 4 5 8 2 6 5 5 2 5 5 3 2 4 130 39 6 140 42 7 3 7 1 7 3 7 1 7 4 4 ...

Page 78: ... 120 36 6 5 5 2 5 6 2 7 6 2 7 6 8 3 1 120 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 48 8 170 51 8 1 8 0 8 1 7 0 8 170 51 8 CAUTION 1 The value in bold is the lifting capacity determined by the strength of the machine while the value that is not in ...

Page 79: ...he crane are extended completely 2 4 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 Table 2 18 Lifting capacity chart in assembly mode Radius ft m Main boom angle Lifting capacity kip t 7 2 15 84 26 4 12 8 2 2 5 79 6 26 4 12 9 10 3 73 26 4 12 11 5 3 5...

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Page 81: ...履带起重机操作手册第三章安全准则 Operator s Manual for Crawler Crane Chapter 3 Safety Guidelines ...

Page 82: ......

Page 83: ...another crane nearby in working g Number material 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 leading to the site k Other factors affecting the site e g weather live lines etc l Communication means adopted between signalman and crane operator m Take appro...

Page 84: ...e sole responsibility of the operator 3 1 2 Possible 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 The equipment and property will be damaged 3 The manufacturer will stop its maintenance for the equipment in warranty period b Improper use of crane include...

Page 85: ...ons 7 Inspect the crane according to the requirement 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 performance in a better way 10 Make operating plan c Responsibility of the crane operator 1 Be responsible for the safety of the crane 2 Be equipped with necessa...

Page 86: ...ing environment the following requirements should 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 cab d No articles is allowed to put on the thoroughfare such as clothes protecting device personal article etc e Snow ice or other obstacles should not be ...

Page 87: ...s no matter who gives it He should refuse to 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 crane e Crane operator and signalman should be familiar with safety rules signals and symbols Operating the crane after drinking is prohibited f Be qualified w...

Page 88: ...d which may damage the boom or turn over the 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 instructions for the rigger The rigger is responsible for ensuring that the load is slung or released safely and carefully using the lifting device and component co...

Page 89: ...action d Be able to estimate the distance height 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 send out correct and clear oral order g Be capable of conducting the crane to move the load safely h Position himself in a safe location from where he can se...

Page 90: ...n the tools structural steel member or support 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 hotter e Contacting with other crane loads arcing is not permitted when moving the crane Since defects caused by burns can reduce rope carrying capacity any s...

Page 91: ...ust be reported immediately to the local project 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 the crane i e near the ladder on the slewing table is shown in the figure 3 1 The arrangement of safety signs on the other side of the crane i e near the o...

Page 92: ...idelines 3 10 ZCC1100H Crawler Crane Figure 3 2 Arrangement of safety signs on the other side of the crane near the operator s cab Table 3 1 Description of safety signs near the ladder and operator s cab Figure 3 1 Figure 3 2 Safety signs Description 1 Risk of burn ...

Page 93: ...or s cab Figure 3 1 Figure 3 2 Safety signs Description 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 controlling crane operation For the details please refer to section 10 of chapter 3 5 Required safety distance when working near the high voltage power li...

Page 94: ...iption of safety signs near the ladder and operator 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 12 Keep away from moving parts 10 11 No access for unauthorized personnel ...

Page 95: ...rane Safety Guidelines ZCC1100H Crawler Crane 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 supports 13 15 7 9 Keep away from moving parts ...

Page 96: ...n the slewing table is shown in the figure 3 3 and the description of safety signs is shown in the table 3 2 Figure 3 3 Arrangement of safety signs on the slewing table Table 3 2 Description of safety signs on the slewing table No Safety signs Description 1 Step off 2 Access prohibited 3 4 5 Keep away from moving parts 6 Risk of burn ...

Page 97: ...e figure 3 4 and the description of safety signs 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 Risk of falling 2 Never climb the machine during operation 3 Keep clear of swinging area to prevent serious body injury 4 Pull out the fixed pin spindle befor...

Page 98: ...nt of safety signs at the rear side of slewing 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 radius Arrangement of safety signs on the derricking traveling block is shown in the figure 3 6 and the description of safety signs is shown in the table 3 5...

Page 99: ...tial dangers existing in crane operation a Do 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 To carry out assembly maintenance or service work With appropriate safety measures against falling such as wearing non slip boots Do not walk on the roof ...

Page 100: ...nst injuries a Repairs to hydraulic equipment 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 to be opened c When leaks are small it is sometimes hardly possible to see the hydraulic oil seeping out Never try to locate the leak with your bare hand a...

Page 101: ...ia can reach an operating temperature of over 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 burns a First aid after contacting with battery acid 1 Acid spayed into the eyes or on the skin must be rinsed away as quickly as possible with a lot of clea...

Page 102: ... Procedure in case of a fire a Switch off the 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 personal safety you must attempt to fight the fire e Use the fire extinguishers equipped on the crane to fight the fire f Find the seat of the fire Only s...

Page 103: ...een removed 3 Auxiliary staff is no longer in 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 provided for this purpose j Never use any combustible liquids to clean the equipment k In the center power unit area Never store cleaning cloths rags etc Always r...

Page 104: ...when rescuing unconscious persons Ventilate closed 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 operate the auxiliary heating equipment in an enclosed area c In areas where there are hazardous materials always wear suitable protective gear d If a bre...

Page 105: ...th a binding agent c Comply with the environmental 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 leak and are resistant to oil fuel and other chemicals e Use separate containers to collect and dispose of the different fuels and lubricants CAUTION Fuels ...

Page 106: ... weight put on the hook bearing point from the 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 cause failure of hooks 3 3 2 Rigging introduction Care and attention to the rigging is a fundamental part of the operation safety a Perform frequent and period...

Page 107: ...fication tags all slings should be labeled with 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 types of sling used 5 Lifting angle the load rating is based 3 3 4 Sling safety a Before making a lift check to be certain that the sling is properly secure...

Page 108: ...ss of their rated capacities d Slings using a 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 loads must be kept clear of all obstructions h All personnel must be kept clear of loads that is about to be lifted and of suspended loads i Hands or fingers ...

Page 109: ...s be located above the center of gravity Exert 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 above the hook is unstable and will cause the load to flip as the load will attempt to find the center of gravity during lifting process Similarly loads which...

Page 110: ...DANGER The most essential requirement for safe 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 from them depending on the type of soil Figure 3 8 Safety distance from slopes and trenches CAUTION Safety distance is measured from the foot of the trenc...

Page 111: ... B Natural soil without apparent disturbance 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 0 4 3 3 Stiff 1 0 3 4 Semi solid 2 0 3 5 Hard 4 0 4 Rock with few fissures in healthy un weathered condition and in a favorable location 4 1 In cohesive la...

Page 112: ...load should be close to the ground as possible 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 if necessary the load should be fastened on the rope f The ground must be firm and flat and can provide adequate load bearing capacity g The largest wind ve...

Page 113: ... forces 3 Slippery ground can cause the crane 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 turning 5 The maximum permissible wind velocity is 9 8m s 6 Side incline is not permitted 7 Travel slowly and perform all acceleration and deceleration mo...

Page 114: ...d in normal operations as a device shutting down 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 strikes The cab can deflect the lightning strike over the entire unit If the working site is attacked by windstorm frequently or the operation range is lim...

Page 115: ...em Damage to local welding spots or bearings 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 there exists a danger The following dangerous circumstances may occur The protective wire is damaged caused by old wire or improper installation The wire conn...

Page 116: ...ctricity gas and water 2 Cable users telecom 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 localize the underground cables around the site using a locating device f The relevant utility companies cable users and public authorities Must be informed...

Page 117: ...cessible fittings valve boxes manhole covers 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 affected area b Can strike personnel or equipment if it is under high pressure c Not only endangers personnel and equipment on the site but also passers by ...

Page 118: ...nocking personally or calling loudly Do not ring 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 not operate any electrical systems or equipment Open all doors and windows widely for ventilation purposes and leave the building immediately h In the even...

Page 119: ...tion the machine can become charged with a dangerously 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 resistance area may form around the fault location WARNING 1 The safety devices of the various national electricity networks react differently in the event of a fau...

Page 120: ...achine before resuming operation d If the control 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 arrange for the power lines to be switched off by the relevant power station CAUTION Only leave the driver s cab if you have reliable confirmation that the un...

Page 121: ...s and the hydraulic oil lines for leakage g Check 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 performance by lifting a load away from the ground and holding it in the air for a moment j Check if there lacks lubricant grease or antifreeze fluid k Check if sund...

Page 122: ... weight and dimensions of the load before operating 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 the actually lifted load won t exceed the rated lifting capacity referring to table 3 7 Table 3 7 Calculation of lifting capacity Items Weight lb t Rated l...

Page 123: ...ob site should be firm and flat and the gradient 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 track pad 3 The permitted temperature range for crane operation is 20 40 Relative humidity should not exceed 85 however high humidity up to 100 is only pe...

Page 124: ...f smoke not by the wind sock 2 Light breeze 1 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 dust and loose paper moves twigs and thin branches 5 Fresh breeze 8 10 6 Small deciduous trees begin to sway foam forms at sea 6 Strong breeze 10 8 13 7 Thick...

Page 125: ...earance m 1 5 3 4 5 6 3 9 2 2 Instructions for 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 stand under the boom or on the slewing table when the crane is operated 2 It is forbidden to lift load over people 3 It is forbidden to lift the load when s...

Page 126: ...ction The distance from the load to the ground 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 vicinity of transmission systems e g transmitters strong electromagnetic field will be generated there so measures should be taken to protect the crane against hi...

Page 127: ... on the hoisting drum 10 When a load is suspended 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 When actual load reaches 90 of the rated one the load moment limiter will sound an alarm to which great attention should be given 13 Getting on and off the c...

Page 128: ...permission otherwise you should take the consequences Stop the crane operation if one of the conditions in the table 3 12 occurs Table 3 12 Conditions to stop and inspect the crane S N Conditions to stop the crane 1 The crane is overloaded or the weight of load is uncertain 2 The load falls down due to bad binding or hanging 3 No protective mat is added between the edges of load and wire rope ...

Page 129: ... will impair safe operation for example the brake 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 be hurt by crane counterweight due to narrow distance between counterweight and surrounding building 8 Keep the windows of crane operator s cab clean to en...

Page 130: ...fore a careful calculation must be made before 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 actual lifting capacity of the crane can not exceed the rated lifting capacity 2 Ensure that each lifting tackle can bear specified load weight which is ca...

Page 131: ...between the operator and rigger k Estimate the 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 support expected loads m Ensure that no obstacles are within working radius and the operator can see the load clearly from the cab Check if the communicat...

Page 132: ... be adhered to The loads given in the load lifting 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 slewing or travelling of the load to be lifted which is still in contact with the ground is prohibited f It should be avoided that the load or auxiliary lift...

Page 133: ...can not fulfill its function as a safety device 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 can cause it to jerk back violently p Make sure that the loads and working radius contained in the lifting capacity tables are not exceeded q When working in...

Page 134: ...if there is leakage in some place and repair 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 is prohibited to operate the crane with fault g Record the operating conditions and abnormal symptoms h Check if the quantity of tools and accessories meet ...

Page 135: ...hed out over the head the palm facing forwards 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 No 4 5 6 Signal Hoist Lower Raise load slowly Description Bend the right arm and hold it upwards The palm faces forwards The hand makes small circular move...

Page 136: ...g at the direction of rotation With arm extended 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 left With right forearm vertical the palm of the hand facing outwards move forearm horizontally and repeatedly fingers pointing at the direction of rotation T...

Page 137: ...tally thumb pointing downwards the remaining 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 Description Bend the left arm Move the thumb up and down pointing downwards Place the right arm below it Stretch out one arm horizontally The palm faces down...

Page 138: ...according to the signal given by the signal man 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 However users can decide on their own hand signals depending on actual condition as different countries and regions may differ in the expression of hand signal...

Page 139: ...履带起重机操作手册第四章起重机的操作 Operator s Manual for Crawler Crane Chapter 4 Crane Operation ...

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Page 141: ...rview The arrangement of operating and 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 Remarks 1 Winch monitoring system Monitor the working status of the winch and the condition behind the crane 2 Digital display system One is LCD screen of load mom...

Page 142: ...d at the back of the cab For details 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 Control the braking of hook in free fall mode Only when the crane has free fall function can this pedal is fitted 13 Safety lever Pull up the safety lever before the oper...

Page 143: ...fter overloading warning is triggered 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 shut down the engine 4 Engine preheating switch When ambient temperature is less than 20 press this switch to preheat the engine 5 Derricking bypass switch After over...

Page 144: ... is sent never spool up the hoisting 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 ignition starter switch to the initial position after 30s Otherwise the work hour of engine this time can not be saved 2 Return the shutdown switch to initial posit...

Page 145: ... forwards extend mounting cylinder 3 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 right slew the superstructure to right 5 Retract mounting cylinder Pull left control lever backwards retract mounting cylinder 6 Spool up H2 Pull left control lever...

Page 146: ...ht control lever No Meaning of the symbol 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 right button on the top of control lever It is used to control the high speed operation of H1 winch H3 winch and right travel gear 4 Reel off H3 Move right control...

Page 147: ...table 4 5 Table 4 5 Description of left 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 order to carry out free fall operation of H1 winch the operator must first turn on free fall master switch and then switch on H1 free fall switch 3 H2 free fall sw...

Page 148: ...ble 4 6 Description of right control 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 key to the 2 nd position then the engine is started 2 Accelerator control knob The engine rotational speed is adjusted through the knob under the manual accelerator m...

Page 149: ...e started after automatic preheating 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 operator s cab Refer to figure 4 7 for the position of control panel on the roof of operator s cab and refer to figure 4 8 for details Control panel ...

Page 150: ...d on 2 nd position It will control all 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 pawl switch and then reel off derricking winch slowly until ratchet pawl is engaged into the ratchet wheel completely At this time the derricking rope can not be unwo...

Page 151: ...ame time 10 Oil cooling fan switch Turn 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 gear switch Turn on this switch to operate the travel gear CAUTION 1 Never operate H2 winch and mounting cylinder at the same time 2 Never operate derricking winch ...

Page 152: ...ormation about crane such as current 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 real time When abnormal conditions occur the corresponding warning icons on the screen will flash Monitor the main parameters of the crane and engine and set the pa...

Page 153: ... Status Enter 0 0 0Bar 0 0 1 1 2 2 Y 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 MPa 0 0 MPa 1 Free fall alarm 2 3 Figure 4 10 Main screen of electrical system The main screen is subdivided into five main areas a Alarm functions b Engine inform...

Page 154: ... When the slewing fixing pin is not 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 H3 winch this icon will flash 7 Icon Lower limit switch on H2 winch When there are only three windings of wire rope left on H2 winch this icon will flash 8 Icon Up...

Page 155: ... 12 Screen of engine information The 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 current engine speed and total working hours 2 Engine coolant temperature Show engine coolant temperature 3 Engine oil pressure Show engine oil pressure 4 Fuel level Sho...

Page 156: ...rks 1 Free fall function warning The 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 warning The icon will flash after H2 free fall switch No 3 in figure 4 5 is turned on 4 H3 free fall warning The icon will flash after H3 free fall switch No 4 in fi...

Page 157: ...essure monitoring of hydraulic system 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 of derricking winch 4 Control pressure Show the control oil pipeline pressure of hydraulic system 5 H2 pressure Show the oil pipeline pressure of H2 winch 6 Pressur...

Page 158: ...reen Press this key to enter I O screen 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 motions 4 Key Parameter resetting Press this key to enter Parameter resetting screen then you can restore all parameters to the factory setting 5 Key Work status Press ...

Page 159: ... Adjustment of crane operator s seat 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 the adjusting knobs Figure 4 17 Adjustment of armrest ...

Page 160: ...tment of seat d Adjustment of seat height 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 lever upwards the front part of the seat is raised up Pull the right lever upwards the rear part of the seat is raised up Figure 4 19 Adjustment of seat height ...

Page 161: ...zzle c Check the general conditions 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 greased 3 The air inlet of oil coolant radiator is not blocked 4 All cowlings and covers on the sides must be closed and locked 5 No person or object is within the slew...

Page 162: ...and turn it clockwise to the 1st position 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 switch no 5 in the figure 4 2 on the operating console both the LCD screen of load moment limiter and LCD screen of electrical system are started At this time check the...

Page 163: ...should not exceed 21m s when the crane 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 entire boom should be lowered down 3 The inclination range for the superstructure the inclination should be less than 1 in both lateral direction and longitudinal di...

Page 164: ...above the wallboard on the right side 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 the horn can be sounded See the figure 4 24 Figure 4 24 Horn switch Close ball valve Open ball valve Air speed knob Fresh air switch Cooling heating selector switc...

Page 165: ...d check if the following items of engine 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 Items to be inspected a Check if the engine speed is normal b Check if the engine coolant temperature is normal c Check if the engine oil pressure is normal Star...

Page 166: ...starting the engine to avoid black smoke 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 less than 20 start the engine via cold start device Before starting cold start device the operator must first turn off power switch of electrical system No 1 in the...

Page 167: ...s pressed a The electrical control system 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 emergency stop button must only be used in case of emergency and not as a normal procedure for shutting down the diesel engine If an emergency stop is triggered wh...

Page 168: ... the battery box on the slewing table Set battery master switch in OFF position during long time work breaks so as to prevent the electricity of battery from discharging excessively G2 G1 Figure 4 28 Position of battery box G2 G1 Figure 4 29 Position of battery master switch Battery master switch Battery box Battery box ...

Page 169: ...t of load and decide if the crane is 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 the lifting capacity chart Only in this way can it be able to fulfill its protective task If crane operator does not observe this safety obligation the crane may ove...

Page 170: ...the tricolor light sends out red warning 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 derricking bypass switch No 5 in the figure 4 2 clockwise the limited movement derrick boom up is bypassed However derricking speed is reduced the tricolor light s...

Page 171: ...ounds continuously 4 4 4 3 Moment percent 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 speed 2 Press Setup switch the bypass of cutoff is valid After the limited movement is bypassed return the control lever for 10s or press Setup switch again or th...

Page 172: ...h main boom When main boom angle reaches 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 yellow and red warning and the buzzer will sound When main boom angle is less than 2 of the maximum angle the buzzer will sound but main boom can still be raised up b Cr...

Page 173: ...N 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 icon appears on the load moment limiter At this time the limited movement reel off winch is bypassed However the tricolor light sends out red warning and the buzzer sounds continuously 2 Rotate lowering bypass switch No 6 in the figure 4 ...

Page 174: ...ents spool up H1 H2 and H3 and derrick 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 icon appears on the load moment limiter At this time the limited movements are bypassed However the tricolor light sends out red warning and the buzzer sounds continu...

Page 175: ...ds 21m s the entire boom should be placed 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 wind speed displayed on the screen 4 4 10 Crane inclinometer Crawler crane is fitted with an electric inclinometer The crane inclination can be shown on the scree...

Page 176: ...n bypass switch is turned on the speed 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 winch as an example 1 The crane movement lower the hook is cut off 2 The icon flashes on the load moment limiter 3 The tricolor light sends out yellow and red warning...

Page 177: ...llow and red warning and the buzzer sounds 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 light sends out yellow warning and the buzzer sounds continuously 1 When bypass switch is turned on the speed of crane movement decrease 2 When Setup switch is pressed...

Page 178: ...urned on the speed of crane movement 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 details 1 The crane movement raise main boom is cut off 2 The icon appears on the load moment limiter 3 The tricolor light sends out yellow and red warning and the...

Page 179: ...n or the engine stops or the controller 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 electrified again the bypass of cutoff is invalid Table 4 15 Max main boom angle for different boom length No Boom length m Max main boom angle 1 13 82 5 2 16 80 3 19 80 4 22...

Page 180: ...onnel are within the danger zone during 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 temperature is too high during operation press oil cooling fan switch No 10 in the figure 4 8 to cool down the oil b If any warning icons mentioned in section 4 2 2 1 Alarm...

Page 181: ...id area of the control lever 60 60 60 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 areas The gridding areas A B C D in the following figure is the valid areas of the control lever 30 30 30 30 Figure 4 37 Valid area of control lever when operating ...

Page 182: ...lve and central revolving joint Figure 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 forwards and left crawler backwards are controlled by left travel gear pedal and the movements right crawler forwards and right crawler backwards are controlled by rig...

Page 183: ...ring Figure 4 40 Differential steering 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 crawler Differential steering to left Depress right travel gear pedal forwards heavily while depressing left travel gear pedal forwards slightly to make the speed ...

Page 184: ...d to stop traveling or steering return 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 straight ahead and the traveling reducer is behind the slewing table b Traveling on a slope Crawler crane travels forward and left control lever is placed in neutral ze...

Page 185: ...ne is traveling on a slope with permissible 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 flat and level no gradient The subsoil must be capable of bearing the crane s maximum service weight and the weight of suspended load Only minimum traveling spe...

Page 186: ... tangles the operator can not operate 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 load is lifted away off the ground it should first be suspended in the air for a moment Do not lift the load until the operator confirms that there is no safety haza...

Page 187: ...hook e After the winding drum stops completely 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 rotating completely never reset the free fall switch of corresponding winch 2 When using control lever to operate the hoisting winch never turn on any free fall swit...

Page 188: ...mechanism via derricking winch can adjust 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 while the derricking traveling block is on the other end of anchoring rod so the boom angle can be changed with the variation in the length of wire rope between the de...

Page 189: ...self assembly dismantling condition while 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 in the angle of either 10 or 30 to main boom Once the angle is set it can not be changed during operation The main boom can be raised and lowered via derricking win...

Page 190: ...peration will bring great impact on the 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 derrick boom down a little and then operate ratchet wheel mechanism according to the correct methods mentioned above In this way ratchet pawl can be disengaged from ratc...

Page 191: ...w to right Move left control lever to 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 any slewing movements the operator must make sure that there are no persons or obstacles within slewing radius Otherwise there is an increased risk of accidents 3 Lo...

Page 192: ...ting device is a proximity switch which 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 out the fixing pin due to the support At this time operate slewing motion slightly so as to pull out the fixing pin Therefore a bypass switch is specially set Press...

Page 193: ...Operator s Manual for Crawler 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 ...

Page 194: ...ical please release the button The Swing 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 at the same time In this way a side force will be produced on the wire rope to make load hook vertical to boom 2 Ensure that there are no obstacles in the crane sl...

Page 195: ...ough the slewing brake is applied the 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 superstructure 4 5 8 Auxiliary remote control box Auxiliary remote control box is mainly used for self assembly dismantling operation The operator only inserts the connector o...

Page 196: ...ntrol box No Names of the switches Operation 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 carrier extending and retracting support cylinder is selected 2 Left counterweight control switch Push it up Extend left counterweight lifting cylinder Push it down Retra...

Page 197: ...le that the rope must be hand guided 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 person guiding the rope slips on the boom 3 Rope reeving for main boom and tip boom 110USt 100t load hook 5 rope pulleys corresponding rope reevings of 10 9 8 7 6 55US...

Page 198: ...ng to the figure 4 50 to figure 4 52 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 3 rope pulley on the hook Figure 4 50 Reeving 110USt 100t load hook ...

Page 199: ...r Crawler Crane Crane Operation 4 59 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 ...

Page 200: ...om is shown in the figure 4 54 The load 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 rope must be guided over the deflection pulley on the middle position of main boom head and reeved in according to the figure 4 56 Figure 4 55 Rope reeving for tip ...

Page 201: ...ng for main boom with fixed jib is shown 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 derricking rope Rope pulley on A frame Hoisting winch 2 Rope pulley on fixed jib head ...

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

Page 203: ...e 3 and rope lock 2 closely Step 4 Fix 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 the figure 4 61 3 The tightening torque of rope clamp for hoisting rope is 450N m while the tightening torque for derricking rope is 230N m 4 The rope clamp must b...

Page 204: ...rane Crane Operation 4 64 T S Figure 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 ...

Page 205: ...履带起重机操作手册第五章安装说明 Operator s Manual for Crawler Crane Chapter 5 Assembly and Dismantling ...

Page 206: ......

Page 207: ...e operation with fixed jib Reeve hoisting 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 technology requirement of self assembly dismantling operation i Lattice components which are not in contact with the ground during assembly disassembly must be supported...

Page 208: ... j Check the distance between the lifting 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 surrounding structures e g is there another crane nearby in working m Number weight dimensions material of load s to be lifted n Required lifting height and slewing rad...

Page 209: ...ged 5 1 3 2 Checking load hook Check 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 connection of load hook can move easily and the clearance is not too large d Check the easy rotation of load hook Rotate load hook by hand If it is stiff it indicat...

Page 210: ...in boom and fixed jib have been attached 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 from jumping out from the rope groove by rope guard tubes g Ensure that the wire rope end is firmly fastened by the rope clamps and the wire rope properly falls down...

Page 211: ...ty regulations All operators should 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 into assembly mode SA CAUTION When assembling or disassembling the crane the operator must comply with the requirements in OSHA 29CFR1926 standard 5 2 1 2 Unloading th...

Page 212: ... See the figure 5 3 d Remove the pin 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 DANGER 1 Before transportation retract the crawler carrier lay down the A frame and place main boom pivot section flatly and finally lock the slewing mechanism by slew...

Page 213: ...x them via fixing pins Rotate support 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 side in the slewing table Turn on power supply and push Counterweight lifting undercarriage auxiliary device selector switch down to choose undercarriage auxiliary ...

Page 214: ...underneath the support plates Undercarriage 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 board on the protective cover of control lever Insert the plug of auxiliary remote control box into the socket of junction box on the rear right side of slewing tabl...

Page 215: ...ort cylinders according to the operating 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 cylinder NO 4 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 cy...

Page 216: ...f the parts 1 Main boom tilting back 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 preparation of crawler carrier self assembly The operation of erecting A frame refers to Unloading of crane with crawler carrier mentioned above During crane self ...

Page 217: ... position a After derricking mechanism 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 hydraulic connection of mounting cylinder b Adjust the support cylinders to ensure that the inclination of machine does not exceeds 1 and the distance from the base plan...

Page 218: ... crawler carrier the operator must first 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 5 11 to make the piston rod pass through the hole in the middle of crawler carrier After piston rod passes through the retaining plates part 3 in the hole mount a ...

Page 219: ...izontal cylinder Table 5 2 Parts used 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 cylinder g Put the pin spindle part 2 on the bracket at the outside of crawler carrier See the figure 5 13 Figure 5 13 Position of pin spindle ...

Page 220: ...central section by use of mounting cylinder 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 the ground Extend right horizontal cylinder to working position Figure 5 14 Assembly of right crawler carrier DANGER When only one crawler carrier is attached on the...

Page 221: ...d and central counterweight can be assembled 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 connection of folding brackets and tilt support cylinder See the figure 5 16 Figure 5 16 Folding brackets to be dismantled b Dismantle folding brackets by use of moun...

Page 222: ...ontal cylinder crawler carrier anchoring 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 spindle 6 Pin spindle 2 Adjusting block 7 Wedge block 3 Folding bracket 8 Fastening bolt 4 Retaining plate 9 Horizontal cylinder 5 Horizontal anchoring rods A 9 6 7 8 ...

Page 223: ...and Dismantling 5 17 3 1 2 4 7 8 Figure 5 18 Enlarged view of crawler carrier extending retracting mechanism WARNING Inspect the hose of traveling motor before extending and retracting crawler carrier and ensure the hose is not damaged during crawler carrier extending and retracting ...

Page 224: ...tatus and locked status The removed 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 Names of the bolts No Names of the bolts 1 Forward bolt 2 Reverse bolt a Screw out two forward bolts for enough distance via socket wrench b Screw the reverse bolt T...

Page 225: ...mbly and Dismantling 5 19 The locked 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 adjusting block into the required position ...

Page 226: ...ions so that crawler carrier can be 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 can move with the extending of crawler carriers d Extend left horizontal cylinder to push left crawler carrier out After left crawler carrier is extended to the req...

Page 227: ... then fix it well d After the left and 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 Swivel four pairs of folding brackets to proper positions so that the crawler carrier can be retracted completely Fix the folding bracket on the crawler carrier b...

Page 228: ...ll be damaged DANGER 1 When the crane 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 Assembly of central counterweight 5 2 4 1 Components of central counterweight self assembly dismantling mechanism Central counterweight self assembly dismantling ...

Page 229: ... counterweight from the vehicle via mounting 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 central counterweight via mounting cylinder Note The angle of main boom pivot section can not exceed 84 See the figure 5 24 Figure 5 24 Assembly of central counte...

Page 230: ...points until the central counterweight 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 figure 5 26 f Unwind derricking rope properly and then retract mounting cylinder slowly At this time main boom pivot section is pulled down to a proper position with ...

Page 231: ...or Crawler Crane Operator s Manual for 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 ...

Page 232: ...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 machin...

Page 233: ...ng counterweight Put counterweight plates 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 counterweight anchoring rods Lift counterweight to required position via counterweight lifting cylinder and then fix the counterweight at the tail of slewing table ...

Page 234: ...ely before assembling rear counterweight 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 Figure 5 31 Stacking of rear counterweight DANGER Arrange the counterweight plate neatly in a pile Unit ft mm ...

Page 235: ...raveling direction and central line 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 mounting hole of counterweight base plate Connect counterweight anchoring rods See the figure 5 33 Figure 5 33 Connection of counterweight anchoring rods Counterweight ...

Page 236: ... detailed information please see section 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 base plate is aligned with the mounting holes in the front of slewing table Insert two fixing pins into the mounting holes via the lever control mechanism Adjust t...

Page 237: ...r Crawler Crane Operator s Manual for 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 ...

Page 238: ...elf assembly dismantling mechanism is 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 order of assembly 5 2 6 Fixation of mounting cylinder Precondition for fixation of mounting cylinder The crawler carrier folding bracket central counterweight and rear...

Page 239: ...nting cylinder Retract mounting cylinder 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 cylinder at position B on the pivot section underneath the boom Remove the fixable strap Retract the mounting cylinder completely See figure 5 36 B Figure 5 36 Fixat...

Page 240: ...ne Configuration no Description Main 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 main boom S 3 Main boom with tip boom 42 8 13m 200 2 61m No SF 1 Main boom with fixed jib 101 9 31m 180 5 55m 19 8 6m 59 18m The load is attached onto fixed jib SF...

Page 241: ...able 5 7 Table 5 7 Description of components 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 21t G13 3m main boom intermediate section 9 10 3m 562 lb 0 25t G14 6m main boom intermediate section 19 8 6m 972 lb 0 44t G15 9m main boom intermediate section 29 ...

Page 242: ...gurations and anchoring rods combination 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 Otherwise there is a risk of accidents CAUTION 1 The principles for boom section combination and anchoring rods combination under SF 1 boom configuration are the s...

Page 243: ... 21 4 There are three types of main boom 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 overview Code Names of components Qty G11 Main boom pivot section 21 4 1 G12 Main boom head 21 4 1 G13 3m main boom intermediate section 9 10 1 G14 6m main boom intermed...

Page 244: ...2 160 9 49m G11 G13 G14 3 G15 G12 72 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 G13 3 G15 G15A G15 G12 111 7 34m G11 G13 2 G15 G12 210 64m G11 G14 3 G15 G15A G15 G12 121 5 37m G11 G14 2 G15 G12 219 10 67m G11 G13 G14 3 G15 G15A G15 G12 131 3 40...

Page 245: ...n boom of different length can be assembled 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 8 13m 52 6 16m 62 4 19m 72 2 22m 82 25m 91 10 28m 101 9 31m 111 7 34m ...

Page 246: ... G14 G15 G15 G15 G15 G14 G15 G15 G12 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 141 1 43m 150 11 46m 160 9 49m 170 7 52m 180 5 55m 190 4 58m ...

Page 247: ...G14 G15 G13 G15 G15 G15 G15 G15 G15A 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 inside the boom or beneath it during the assembly of main boom 200 2 61m 210 64m 219 10 67m ...

Page 248: ...ate the connecting methods for 219 10 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 42 Combination of 219 10 67m main boom anchoring rods To main boom head To derricking pulley block ...

Page 249: ...2 is shown in the table 5 9 Table 5 9 Components of main boom anchoring rods No Names of the components Illustration 1 Double anchoring rod 2 52 64mm Ø Ø 10 63 270mm 1 89 48mm 1 97 50mm 1 57 40mm 0 95 24mm 2 Single anchoring rod 22 3 5700mm 2 Ø1 57 40mm 3 Double anchoring rod 1 87 22mm 2 Ø1 57 40mm 11 8 300mm 4 Single anchoring rod 2 Ø1 57 40mm 8 10 2700mm ...

Page 250: ...m 4 41 112mm 7 Retaining pin 8 Pin spindle Ø1 57 40mm 4 72 120mm 9 Pin spindle Ø1 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 consistent with those in the table 5 9 so the components of anchoring rods can be found by referring to the component numbers 2 The pin spindle must be inserted ...

Page 251: ... 3m 19 8 6m and 29 6 9m When main boom 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 anchoring rods length will also increase 19 8 6m which includes a 11 8 300mm long anchoring rod and a 18 8 5700mm anchoring rod The diameter of pin spindle for ma...

Page 252: ...270mm 4x29 6 9000mm 118 1 6 34 270mm 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 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 6 34 270mm 6 34 270mm 6x29 6 9000mm 177 1 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 19 8 6000mm 9 10 3000mm 19...

Page 253: ...s time 9m main boom intermediate section 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 shown as follows 10 63 270mm 1 10 560mm 9 230mm 3 5 1060mm 2 3 700mm 1 2 3 4 5 6 5 Figure 5 45 Installation of intermediate tensioner The component numbers in the fig...

Page 254: ...onents of intermediate tensioner No Names of the components Illustration 1 Double anchoring rod 2 28 58mm 2 Ø1 57 40mm 10 63 270mm 2 Double anchoring rod Ø1 57 40mm Ø1 18 30mm 1 65 42mm 1 10 560mm 3 Double anchoring rod 0 47 12mm 2 Ø1 18 30mm 9 230mm 4 Pin spindle 1 57 40mm 3 1 78mm ...

Page 255: ...ents Illustration 5 Retaining pin 6 Pin spindle Ø1 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 the components of intermediate tensioner can be found by referring to the component numbers ...

Page 256: ...ed jib intermediate section is 19 8 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 fixed jib head and then install fixed jib intermediate sections between them In this way the fixed jib can be assembled to required length Main boom sections in this bo...

Page 257: ... in main boom configuration The main 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 of fixed jib 5 4 2 2 Components of fixed jib anchoring rods The anchoring rods under main boom with fixed jib configuration comprises main boom anchoring rods fixed ...

Page 258: ...llowing components as shown in the figure 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 Combination of fixed jib front anchoring rods The explanation of component numbers in the figure 5 48 is shown in the table 5 12 To FA frame To fixed jib ...

Page 259: ... Components of fixed jib front anchoring rods No Names of the components Illustration 1 Pin spindle 2 1 53mm Ø1 38 35mm 2 Retaining pin 3 Double anchoring rod 2 Ø1 38 35mm 0 63 16mm 11 8 300mm 4 Anchoring rod 17 11 5460mm 2 Ø1 38 35mm 5 Single anchoring rod 2 Ø1 38 35mm 9 2720mm 6 Pin spindle 2 87 73mm Ø1 38 35mm ...

Page 260: ...n the above table so the components of 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 fixed jib front anchoring rods must be 22 1 367 6740mm When fixed jib length increases by 19 8 6m a 18 10 783 5760mm anchoring rod part 9 must be added according...

Page 261: ...UTION The pin spindle of fixed jib front 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 either 10 or 30 to main boom fixed jib rear anchoring rods can be combined in two different ways Now we will illustrate the combination of fixed jib rear anchoring r...

Page 262: ...table 5 13 Table 5 13 Components of fixed jib rear anchoring rods No Names of the components Illustration 1 Pin spindle 2 09 53mm Ø 1 38 35mm 2 Retaining pin 3 Double anchoring rod 2 Ø1 38 35mm 0 63 16mm 11 8 300mm 4 Reducing anchoring rod 11 281mm Ø1 38 35mm 19 7 500mm Ø2 36 60mm 0 63 16mm 5 Pin 6 3 80 6 Pin spindle Ø 2 36 60mm 2 56 65mm ...

Page 263: ...e components Illustration 7 Reducing piece Ø2 36 60mm Ø1 38 35mm 2 75 70mm 17 2 228mm 10 9 277mm 8 Double anchoring rod 2 Ø1 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 anchoring rod 12 3847mm 2 Ø1 38 35mm 11 Single anchoring rod 2 Ø1 38 35mm 23 6 600mm ...

Page 264: ...the angle of 10 to main boom is different 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 30 or 10 the combination of fixed jib rear anchoring rods is shown in the figure 5 51 4 11 1513mm 26 5 8060mm 23 6 7160mm 19 7 500mm 11 8 300mm 11 281mm 5 1545mm 1 1...

Page 265: ...om sections 4 If the ends of boom section 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 beneath the boom when it is being pinned or unpinned 7 The use of squared timbers or pad block to support the chord in the middle position or web members is prohibited...

Page 266: ...ic machine with main boom pivot section 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 boom intermediate section See the figure 5 53 d Join the upper connecting holes with double tapered pins 1 and secure the pins properly with retaining pins 2 e Ope...

Page 267: ... 5 53 Table 5 14 Components used to 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 inwards during assembly 2 It is prohibited to put hand or fingers into the connecting hole during assembly 3 No person is allowed to stand beneath or in the boom dur...

Page 268: ...n boom anchoring rods are detailed in 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 anchoring rods a Reel off hoisting winch 1 pull the hoisting rope to main boom head and reserve a certain length of rope for load hook reeving as shown in the figure 5...

Page 269: ...the load hook directly under main boom 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 Chapter 4 finally secure the rope end point with rope lock and rope thimble referring to the figure 5 57 Figure 5 57 Reeving in load hook CAUTION The working personnel w...

Page 270: ...ulling of main boom anchoring rods the 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 oblique plane of guide board part 2 thus guiding the derricking travelling block to lower down to the required position When the pin spindle part 5 on the derricki...

Page 271: ...veling block Table 5 15 Fixation of derricking 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 travelling block is fastened can the main boom pivot section be raised otherwise the boom frame may be damaged ...

Page 272: ... Instructions 1 Main boom cable drum 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 Anemometer and warning light on the boom head Measure wind speed and send a warning in the air 4 Main boom junction box Establish electrical connection to various elect...

Page 273: ... connections the connection sequence 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 the power is connected a Check the warning light on the boom head The warning light is solar lamp which can adjust its light according to environments Cover the w...

Page 274: ... connected and secured d All limit switches 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 prevent against jumping out from rope groove g No person is present in the danger zone h There are no loose parts on main boom or fixed jib i In winter main boom ...

Page 275: ...ok is in contact with the ground After 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 observe the data shown on the screen while other workers should pay attention to environmental changes 4 Standing beneath the boom frame is prohibited 5 Working radius...

Page 276: ...ove right control lever to the neutral 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 spindles on anchoring rods and then secure the anchoring rods on the supports with pin spindles for transportation a Dismantle boom sections using an auxiliary crane b...

Page 277: ...orking platform should be used Improvisations 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 pivot section G31 FA frame G37 front tilting back support of fixed jib G74 and rear tilting back support of fixed jib G75 are assembled together See the following figu...

Page 278: ...tion choose and assemble several 6m fixed jib intermediate sections G33 All fixed jib intermediate sections are connected with double tapered pins 5 secured the pins on both sides with retaining springs 6 as follows 6 5 G33 G31 G32 Figure 5 65 Assembly of fixed jib The components used to assemble fixed jib are shown in the figure 5 17 ...

Page 279: ... 4 Bolt ISO 4017 1999 M12X45 8 8 5 Double 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 some fixed jib rear anchoring rods to FA frame according to the required angle of fixed jib for the details see Section 5 4 2 2 Connect fixed jib front anchoring rods...

Page 280: ...est to rear tilting back support G75 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 through the rope pulley on the FA frame and reserve a certain length of rope for reeving load hook h Move right control lever to the left to wind derricking rope then ...

Page 281: ...b may topple over 2 Make sure that the 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 fixed jib is lifted away from the ground 4 Take great care to connect rear titling back support of fixed jib to main boom head 5 Install the pin spindle correctly ...

Page 282: ... jib head 2 Anemometer and warning light 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 pull the cable plug of fixed jib cable drum part 2 in figure 5 60 along the boom frame to the fixed jib head and then connect it with fixed jib junction box part 1 in ...

Page 283: ... limit switch for H1 if the main boom 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 flash and the buzzer will sound c Check hoisting limit switch for H2 Support and hold the hoisting limit switch weight for H2 to ensure that the switch is triggered...

Page 284: ... fixed jib a The crane is leveled b The 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 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 w...

Page 285: ...ting and lowering main boom with fixed 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 to guarantee that the load hook is still in contact with the ground before the boom angle has reached 30 Before lowering the boom a certain length of hoisting rope...

Page 286: ...winding drum e With the help of auxiliary 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 section g Dismantle the fixed jib assembly unit from main boom head CAUTION 1 The boom lowering movement should be performed slowly and stably And during the operat...

Page 287: ...e upper connecting hole of tip boom with 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 it with cotter pin part 1 The procedure for dismantling tip boom is the opposite of assembly CAUTION Slowly raise and lower main boom with tip boom to prevent tip b...

Page 288: ...ane are shown in the table 5 19 Table 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 59 5 29t 1 Crawler carrier 19 8 9t 2 Counterweight base plate 14 1 6 4t 1 Height 8 200mm Counterweight plate 7 9 3 6t 6 Height 2 600mm Central counterweight 11 5t ...

Page 289: ...eight lb 1000 Qty Remarks Main boom 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 pivot section FA frame 1 32 0 6t 1 fixed jib intermediate section 0 4 0 16t 2 Fixed jib head 0 5 0 22t 1 ...

Page 290: ... for Crawler Crane Assembly and Dismantling 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 ...

Page 291: ...d on A frame and the rear anchoring 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 a long time over 6 months take the following protective measures a Wipe off the dust and oil dirt to keep the crane clean b Retract all the piston rods of the cylin...

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Zoomlion ZCC1100H, Operator'S Manual

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