Zoomlion ZCC2600CR Operator'S Manual Download Page 1

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Zoomlion Heavy Industry Science & Technology Co.,Ltd.

Address: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Changsha, Hunan Province, China

Postcode: 410131

Website: http://www.zoomlion.com Email: [email protected]

CRAWLER CRANE

OPERATOR’S MANUAL

Summary of Contents for ZCC2600CR

Page 1: ...Industrial Park No 1636 2nd Yuanda Road Changsha Hunan Province China Postcode 410131 Website http www zoomlion com Email Sos service zoomlion com Copyright 2015 Zoomlion Heavy Industry Science Techno...

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Page 3: ...Edition 1 July 2018 ZCC2600CR Crawler Crane Operator s Manual...

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Page 5: ...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...

Page 6: ...The meanings of the terms are as follows DANGER Refers to a dangerous situation which if you do not prevent will cause death or injury WARNING Refers to a possible dangerous situation which if you do...

Page 7: ...onsibilities 1 4 1 10 Safety advices regarding specific operation phases 1 4 1 11 Special Hazards 1 4 1 11 1 Electrical energy 1 4 1 11 2 Gas dust steam smoke and noise 1 5 1 11 3 Welding or naked fla...

Page 8: ...ter 3 Safety Guidelines 3 1 Operational planning 3 1 3 1 1 State of the Art Technology 3 2 3 1 2 Appropriate use of the crane 3 2 3 1 3 Results of inappropriate use 3 2 3 1 4 Areas of responsibility 3...

Page 9: ...3 32 3 5 6 Load angle factor chart 3 32 3 5 7 Sling safety 3 33 3 5 8 Sling safety guide 3 34 3 5 9 Taglines 3 34 3 5 10 Load center of gravity 3 35 3 5 11 Sling hook up center of gravity 3 35 3 5 12...

Page 10: ...s 4 25 4 4 1 Emergency stop button 4 25 4 4 2 Battery master switch 4 25 4 4 3 Load moment limiter 4 26 4 4 4 Boom angle indicator 4 29 4 4 5 Derrick limiter 4 30 4 4 6 Lowering limiter 4 31 4 4 7 Hoi...

Page 11: ...Unloading of basic machine 5 13 5 3 2 Attaching the first crawler carrier 5 16 5 3 3 Attaching the second crawler carrier 5 18 5 3 4 Connecting the hydraulic lines to the crawler carrier 5 19 5 4 Att...

Page 12: ...rt 5 169 Chapter 6 Appendix 6 1 Description of special heavy fixed jib on heavy duty boom 6 1 6 1 1 Terminology 6 1 6 2 Assembly of special heavy fixed jib on heavy duty boom 6 14 6 2 1 Preparations 6...

Page 13: ...Chapter 1 Safety Operator s Manual for Crawler Crane...

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Page 15: ...e personal risk g Only trained personnel can be allowed to install set operate maintain and commission this crane 1 1 2 Alarms and warnings a As to the potential danger mentioned in this manual affix...

Page 16: ...nment 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 the fluids Do not use food or...

Page 17: ...ified operator who holds a current license in line with national or international legislation b Understand the service procedure before doing work Keep working area clean and dry c Never lubricate cle...

Page 18: ...d exhaust devices are in place and fully functional 3 Erect barrier guards in proper positions to stop unauthorized entry to this crane 4 Before starting the engine ensure it is safe to do so b Malfun...

Page 19: ...on and fire b No welding should be undertaken on this crane as it will affect its structural integrity c Avoid all naked flames in the vicinity of this crane 1 11 4 Hydraulic equipment a The work on h...

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Page 21: ...Chapter 2 Description of Crane Operator s Manual for Crawler Crane...

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Page 23: ...many cases there have been serious injuries when people have been transported using this equipment or even on the hook or on the loads Under such circumstances they have no control over the crane mov...

Page 24: ...of the crane The crane is classified as follows in accordance with ISO 4301 2 GB T 3811 and GB T 14560 standards a Operating class U1 b Load collective class Q2 c Crane group A1 All important componen...

Page 25: ...load handling devices for example lifting load load hook sling Under these circumstances assuming that the maintenance work is carried out properly the theoretical service life can be more than 20 ye...

Page 26: ...rations Table 2 1 Description of boom configurations Configuration No Description Parameters S Heavy duty boom 20m 83m SL Light duty boom 86m 95m SW Luffing jib on heavy duty boom S boom 23m 62m W jib...

Page 27: ...Description of Crane Operator s Manual for Crawler Crane 2 2 2 Description of crane components Figure 2 3 Names of the components 2 5...

Page 28: ...scription Part No Description 1 Counterweight 10 Central counterweight 2 Drive sprocket 11 Hoisting winch 1 3 Crawler carrier 12 Hoisting winch 2 4 Track roller 13 Slewing reducer 5 Track carrier roll...

Page 29: ...ng mechanism consists of concealed dual variable displacement axial piston motor dual gear reducer normally closed slewing brake and pinion gear as well as slewing ring The superstructure can realize...

Page 30: ...echanism The counterweight fitting removal mechanism is composed of counterweight base plate counterweight plate counterweight lifting cylinder assembly chain and counterweight bolting cylinder The co...

Page 31: ...s allowed for a short period of time Allowed in service wind speed 9 8 m s Allowed out of service wind speed 13 8 m s The requirements for the ground when the crane is traveling with a load a Ground i...

Page 32: ...eed of single rope the 6th rope layer 28 mm Hoisting winch 2 130 m min maximum speed of single rope the 6th rope layer 28 mm Main boom derricking winch 2 40 m min maximum speed of single rope the 6th...

Page 33: ...le hoisting rope load must be checked to make sure that the max permissible load capacity of single hoisting rope is not exceeded 2 Maximum permissible load capacity of single rope is 15000 kg 3 If th...

Page 34: ...ight on S SL boom 0m 10 20 30 40 50 60 70 80 90 10 20 30 40 50 60 70 80 90 100 23 29 35 41 47 53 59 65 71 77 83 89 95 83 80 70 60 50 40 30 Figure 2 8 Lifting height on S SL boom CAUTION 1 The X axis i...

Page 35: ...3 47 41 35 29 0m 10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 70 80 90 100 110 Figure 2 9 Lifting height on SF boom CAUTION 1 The X axis indicates the working radius in meters and the Y axis indic...

Page 36: ...53 47 41 35 29 0m 10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 70 80 90 100 110 Figure 2 10 Lifting height on SFV boom CAUTION 1 The X axis indicates the working radius in meters and the Y axis in...

Page 37: ...60 70 80 90 100 110 120 15 25 35 45 55 65 75 65 75 85 26 32 38 44 50 56 62 24 30 36 42 48 54 60 Figure 2 11 Lifting height on SW boom CAUTION 1 The X axis indicates the working radius in meters and th...

Page 38: ...stance from central axle of slewing ring to centerline of hook when the crane is loaded d For SF boom configuration if main load hook is not detached from main boom head the actual lifting capacity on...

Page 39: ...10 or 30 G4 Auxiliary load hook Figure 2 13 Actual lifting capacity calculation when main boom is with jib f The rated total lifting capacity indicates the crane s lifting capacity under different bo...

Page 40: ...Description of Crane Operator s Manual for Crawler Crane CAUTION For your safety using both load hooks is prohibited during lifting operation 2 18...

Page 41: ...Chapter 3 Safety Guidelines Operator s Manual for Crawler Crane...

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Page 43: ...ng g Number weight dimensions material 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 and its flatness j Height and...

Page 44: ...n function normally d Proper use of all fuels and lubricants as specified in relevant manual Appropriate use also includes proper maintenance and inspection of the crane Any other use of the crane wit...

Page 45: ...maintain the crane b Assign the duties and responsibilities to the operator and maintenance personnel c Provide necessary protecting device for the operator and maintenance personnel d Regularly remin...

Page 46: ...orized startup j Keep the operator s cab windshield platform and step clean and free from any debris 3 1 5 Personal protective gear The operator must always wear appropriate protective clothing before...

Page 47: ...can t leave the cab at any time when the crane is working In order to build a safe and comfortable working environment the following requirements should be followed a Keep the cab clean Clean the foot...

Page 48: ...iolates operation regulations Stop the crane immediately if somebody is found climbing the crane 4 Operator who is in low spirits or poor health is not allowed to operate the crane 5 Crane operator an...

Page 49: ...eyesight and reaction ability 4 Be able to estimate the distance height and clearance correctly 5 Be trained in hand signals for operating and familiar to use them 6 Use standard hand signals for cra...

Page 50: ...loads DANGER The most essential requirement for safe crane operation is working on firm ground with the capacity to support your loads 3 2 3 Slopes and trenches The crane may not be set up too close...

Page 51: ...ed sand 1 5 2 2 From coarse grained sand to gravel 2 3 Cohesive soil 3 1 Loamy 0 3 2 Soft 0 4 3 3 Stiff 1 0 3 4 Semi solid 2 0 3 5 Hard 4 0 4 Hard rock with few fissures in healthy weatherproof condit...

Page 52: ...that the ladder cab and cable pulleys are grounded b All personnel working on the crane or with large metal objects must protect themselves from burns by wearing non conductive gloves and clothing wh...

Page 53: ...due to handling of large metal parts Use only rubber hoses to refuel n Any accidents and unexpected events must be reported immediately to the local project manager or the safety engineer CAUTION Thes...

Page 54: ...igure 3 45 Warning Risk of falling Figure 3 46 Danger Snagging dragging Figure 3 47 Danger Risk of burn Figure 3 48 Prohibited No access for unauthorized personnel Figure 3 49 Prohibited Access prohib...

Page 55: ...delines Operator s Manual for Crawler Crane Figure 3 52 Note First aid kit Figure 3 53 Note Fire extinguisher Figure 3 54 Warning Do not stand under boom Figure 3 55 Caution Be careful in the working...

Page 56: ...Safety Guidelines Operator s Manual for Crawler Crane 15 9 12 1 2 9 6 9 6 2 2 9 6 9 6 2 15 13 9 Figure 3 56 Position of safety sign 3 14...

Page 57: ...Safety Guidelines Operator s Manual for Crawler Crane 13 9 3 4 11 16 11 4 Figure 3 57 Position of safety sign 3 15...

Page 58: ...t is forbidden to cover or take off safety signs 3 If the safety sign is covered with dust and dirt clean it in time 4 The operator s cab should be equipped with an emergency hammer which can be used...

Page 59: ...alling such as wearing non slip boots 5 Do not walk on the roof of the operator s cab Figure 3 62 6 Secure open sliding doors or the front windscreen of the cab as well as the open engine compartment...

Page 60: ...jects that fall into the fan will be shredded or hurled out which can cause serious injury 3 2 9 Injuries due to hydraulic energy These safety instructions and preventive measures can protect against...

Page 61: ...moving the cap c Avoid touching 1 Coolant or parts coated with hydraulic oil 2 Hot hydraulic and or engine oil 3 Hot exhaust and the turbocharger d Carry out the cleaning and maintenance work only aft...

Page 62: ...rge the battery 3 2 11 Risk of fire and explosion Procedure in case of a fire a Switch off the engine immediately b If possible use a radio to call for help c Turn ignition key to the 0 position and l...

Page 63: ...must be turned off 1 The engine 2 The cab s heater 3 The auxiliary heating d While filling the fuel tank or the hydraulic tank smoking and the use of fire or open flames is strictly prohibited Figure...

Page 64: ...e j Never use any combustible liquids to clean the crane k In the center power unit area Never store cleaning cloths rags etc Always remove flammable residues and deposits for example pools of oil dry...

Page 65: ...es not rise 3 2 13 Operating near energized lines If the power to the lines cannot be cut the most important precaution that can be taken is to maintain the absolute limit of approach a A crane s abso...

Page 66: ...es etc may also cause the control system to malfunction Sensitive electronic devices or electronically driven medical implants can also malfunction in the vicinity of the equipment c The owner of the...

Page 67: ...a binding agent c Always comply with state and local environmental regulations before disposing of fuels and lubricants d Use only adequate containers when draining fluids that do not leak and are re...

Page 68: ...ntain rigging hardware frequent and periodic inspections are required 3 3 3 Hooks Use a The hook must be selected to work with the cable the chain or the strap used in the lifting device b The hook ne...

Page 69: ...Safety Guidelines Operator s Manual for Crawler Crane Figure 3 67 Hook 3 27...

Page 70: ...roups with each type having its own particular advantages and disadvantages 1 Chain 2 Wire and mesh rope 3 Fiber rope and fiber web rope d Factors that must be taken into consideration when choosing t...

Page 71: ...ure 3 68 Chain Hitches 3 5 1 Sling hitches The three primary hitches can be used to multiple configurations to further support and stabilize the load Some common ones are listed below Figure 3 69 Slin...

Page 72: ...ure 3 70 Angle of choke 3 5 3 D d ratio a Depending on the hitch used wire rope capacity will experience an efficiency loss when bent b To determine the D d ratio distinguish the diameter of the wire...

Page 73: ...aced on the sling The capacity of a multiple leg sling is directly affected by the angle of the sling leg with the vertical As the angle formed by the sling leg and the horizontal line decreases the r...

Page 74: ...ctor b Multiple the load angle factor by the load weight c Divide the answer by the number of legs d This equals the load share of each sling leg Figure 3 73 Load share 3 5 6 Load angle factor chart W...

Page 75: ...t check to be certain that the sling is properly secured around the load and that the weight and balance of the load have been accurately determined If the load is on the ground do not allow the load...

Page 76: ...cities d Slings used in 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 th...

Page 77: ...to equipment and workers The lifting force must always be located above the center of gravity and exert a straight vertical pull to prevent swinging of the load e In all crane lifts the center of gra...

Page 78: ...g weights a Acceptable methods of determining weight 1 Data on manufacturing label plates 2 Manufacturer s documentation 3 Blueprints or drawings 4 Shipping receipts 5 Weigh the item 6 Stamped or writ...

Page 79: ...its supporting surface the weight of the crane causes pressure on the ground Pressure is exerted through its outriggers or through its tracks to the ground How much pressure it exerts depends on the t...

Page 80: ...all sensitive parts such as limit switches guides etc CAUTION Snow and ice deposits on the boom 1 Increase the boom weight 2 Increase the surface area the wind blows on These factors can lead to a pr...

Page 81: ...specting a lightning strike on the crane a Thoroughly check the crane check for any damaged cables or lines for leaks b Check the entire control system c Slowly move the slewing gear and listen for un...

Page 82: ...s must be used to restrict the working area of the equipment in order to maintain a safe distance from the power line CAUTION If the equipment touches a high voltage power line it could cause a fatal...

Page 83: ...and nominal voltage Low voltage supply up to 1000 V Medium voltage supply from 1000 V up to 30 kV High voltage supply over 30 kV A frame 1 form Wooden Mostly wooden A frame 1 occasionally concrete or...

Page 84: ...uipment from a position that he has a clear all round view and must be able to contact the operator each time the equipment comes dangerously close to the power line e Never remove shift or cross any...

Page 85: ...or grounding fault The equipment or a torn down conductor cable can therefore still be under hazardous voltage levels and form a resistance area even if there is no flashover smoke formation or crack...

Page 86: ...nce of at least 10 m 33 ft between it and any torn conductor cable lying on the ground 3 Inform the competent power company of the accident Secure the area around any torn down conductor cable to prev...

Page 87: ...Procedure for high voltage incidents a Jump away from the equipment landing on both feet at the same time b Jump in a direction that avoids any contact with metal objects that are touching the equipme...

Page 88: ...1 Inform them of the exact location of the accident 2 Arrange for the power lines to be switched off 3 Request the assistance of trained personnel from the power company 4 Ensure that they at least ph...

Page 89: ...red persons 5 Your name and telephone number b Notify the relevant power company if this has not already been done by the rescue service or fire department 1 Inform them of the exact location of the a...

Page 90: ...rvision of a trained personnel from the relevant power company c Administer first aid until the rescue services or the emergency paramedics arrive DANGER In the case of accidents involving high voltag...

Page 91: ...ephone companies factories transport companies 3 Building authorities c Only use the latest up to date plans d If there are any deviations or extensions to a project initiate new inquiries e If in dou...

Page 92: ...ot be covered rearranged or removed What happens if a gas pipe is damaged The escaping gas a Forms an inflammable gas air mixture around the affected area b Can strike personnel or equipment if escapi...

Page 93: ...se 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 event of major damage evacuate the occupant...

Page 94: ...al networks react differently in the event of a fault Therefore it cannot be assumed that there will be an automatic and lasting shut down following damage to an underground cable The equipment and th...

Page 95: ...nd tell them to keep at least 10 m 33 ft from the danger zone 2 To arrange for the power lines to be turned off by the relevant power company DANGER Even an underground cable that appears to be turned...

Page 96: ...ensions of the load before operating the crane d Load handling devices lifting equipment and hook block must be used in accordance with specified requirements e Make sure that the weight of load handl...

Page 97: ...ground must be able to support possible ground pressure 2 The friction coefficient between roadway and track pad must be large enough to produce enough drive forces 3 Slippery ground can cause the cra...

Page 98: ...es the uphill direction Heavy duty boom length 72 m 75 2 comprehensive 2 Luffing jib on heavy duty boom configuration Table 3 16 Luffing jib on heavy duty boom configuration Boom length Main boom angl...

Page 99: ...over if the ground clearance is larger than this value i The load can be put down stably for any possible mistakes j If necessary the ground must be leveled k The operation must be stable and never i...

Page 100: ...dient Prerequisite Light duty boom length 72 m 1 The largest travelling speed is 0 5 km h and the lifting capacity is reduced by 20 2 The largest travelling speed is 0 5 km h and the lifting capacity...

Page 101: ...L of the transfers is calculated from the existing incline angle and the length of the crawlers LC L 0 5 LC L Ground length of required transfer angle of incline in degrees LC length of crawler betwee...

Page 102: ...k of accident Ensure enough length to transfer between the horizontal and the incline and never make the two ends of the crawler carrier bear force and the middle part suspends Otherwise the crawler c...

Page 103: ...great and the working speed should not be too high The maximum lifting load cannot exceed 80 of its rated load And the maximum working speed is forbidden Figure 3 79 2 The ground on jobsite should be...

Page 104: ...time The crane should be operated and supported on a ground lower than 1000 m above sea level Figure 3 81 4 The permitted wind velocity for crane operation is at most 9 8 m s when the crane is working...

Page 105: ...reeze 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 Thicker branches move t...

Page 106: ...5 15 V 40 40 V 100 100 V 200 Safe clearance m 1 5 3 4 5 6 6 Only the crane without fault is allowed to work Figure 3 84 b Instructions for safe operation 1 No person is allowed to stand under the boom...

Page 107: ...r s Manual for Crawler Crane Figure 3 86 4 It is forbidden to lift the load when someone stands on it Figure 3 87 5 Overloading operation and lifting staggered load is prohibited Never pull the load o...

Page 108: ...t should not be more than 5 1000 The driving speed must be less than 0 5 km h Main boom must be located in the traveling direction Figure 3 90 8 If the crane is operated in the vicinity of transmissio...

Page 109: ...r Crawler Crane Figure 3 91 9 Under any condition there must be at least three windings of wire rope left on the hoisting drum Figure 3 92 10 When a load is suspended in the air the operator is not al...

Page 110: ...kily and carry out switchover operation abruptly Figure 3 94 12 When actual load reaches 90 of the rated one the load moment limiter will sound an alarm to which high attention should be given Figure...

Page 111: ...ations to the crane without permission Otherwise you should take the consequences Figure 3 97 c Stop the crane operation if one of the conditions occurs 1 The crane is overloaded or the weight of load...

Page 112: ...nd wire rope Figure 3 100 4 In case of poor visibility or darkness it is difficult to identify the load or signal Figure 3 101 5 There is defect or damage of structure or components which will impair...

Page 113: ...ping the crane otherwise persons nearby may be hurt by crane counterweight due to narrow distance between counterweight and surrounding building Figure 3 104 8 Keep the windows of crane operator s cab...

Page 114: ...uring traveling Figure 3 107 11 It is more dangerous that two cranes carry out lifting operations together Therefore a careful calculation must be made before commencing the work and the following imp...

Page 115: ...e load from the hook and set it down on the ground If necessary lower the boom frame 2 Apply slewing brake or lock slewing mechanism 3 Apply parking brake 4 Lock travel gear 5 Cut off power supply or...

Page 116: ...bolts nuts and pins lost and the components are cracked or damaged e Ensure that no modification has been made to the crane without permission e g increase or decrease in counterweight plate and impr...

Page 117: ...vehicle at once d The load capacities as given in the lifting capacity charts must be adhered to The loads given in the lifting capacity charts must not be exceeded Driving or slewing too fast with a...

Page 118: ...lfill its function as a safety device n Examine if the 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 cre...

Page 119: ...me 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 eli...

Page 120: ...ht arm stretched out over the head the palm facing forwards Tap fist on the safety helmet then give further hand signals Illustration Ser No 3 4 Signal Use auxiliary hook Hoist Description Bend the le...

Page 121: ...out right arm The palm faces upwards Wave the hand up repeatedly Illustration Ser No 7 Signal Rotate Description Turn left With right forearm vertical the palm of the hand facing outwards lower the fo...

Page 122: ...fingers to point at the position where the load should fall on Illustration Ser No 10 Signal Rotate slowly Description Turn left With right forearm vertical the palm of the hand facing outwards move f...

Page 123: ...forearm up With arm stretched sideways horizontally thumb pointing downwards the remaining fingers closed wave forearm down Illustration Ser No 13 14 Signal Raise boom slowly Lower boom slowly Descrip...

Page 124: ...e arm horizontally The palm faces downwards Swing the arm to one side of the body Stretch out both arms horizontally The palms face downwards Swing the arms to both sides of the body Illustration Ser...

Page 125: ...hand signal or interphone Vigilance is needed no matter which method is used to avoid misunderstanding DANGER 1 We recommend using the hand signals illustrated above However users can decide on their...

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Page 127: ...Chapter 4 Crane Operation Operator s Manual for Crawler Crane...

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Page 129: ...Manual for Crawler Crane Chapter 4 Crane Operation 4 1 Operating and control instruments 4 1 1 Operator s cab overview Figure 4 1 Operator s cab overview 3KG 3KG 5 5 7 1 2 4 6 8 9 10 11 12 13 14 15 3...

Page 130: ...seat It is adjustable 7 Fan At the rear right side of operator s cab internal It is used to cool the cab down 8 Right control lever Control the movements of hoisting winch 1 H1 main boom derricking w...

Page 131: ...22 High speed switch Control the high speed of hoisting winch 2 slewing gear and left travel gear For details please refer to section 4 5 4 23 Swing free running switch For details please refer to sec...

Page 132: ...er returning the control lever to neutral position the operator must press deadman s button first and then move the control lever Otherwise the operation of control lever is invalid 3 In normal condit...

Page 133: ...ards 39 Symbol right crawler backwards 40 Symbol spool up E W1 E refers to main boom derricking winch and W1 refers to luffing jib derricking winch Luffing jib derricking winch is not available 41 Sym...

Page 134: ...ighting switch 45 Working floodlight switch Control all the working floodlights on the crane 46 Oil cooling fan switch Pressing this switch can cool down the hydraulic oil 47 SET UP switch For details...

Page 135: ...ster lighting switch on the 2 nd position before switching on the working floodlight switch 2 After putting master lighting switch on the 1 st position the LED on the rocker switches of control panel...

Page 136: ...Right control panel Reeve SYNC In Mast ESYNC SpeedSet MidSp ReeveWinch Out HiSp Up Up Mast Down Cabin Down Assembly OverrollBypass DerrickBypass Off OverlowerBypass On Manual Throttle Throttle Auto 2...

Page 137: ...g variety of control lever The bigger the opening of control lever is the higher the engine speed is and vice versa 56 Hoisting bypass switch For details please refer to section 4 4 57 Lowering bypass...

Page 138: ...lease refer to section 4 5 2 2 2 For detailed description of Assembly please refer to section 4 5 7 2 66 Speed set switch Turn the switch right to high speed position the winches H1 H2 slewing mechani...

Page 139: ...display system Figure 4 6 Instruction for digital display system Table 4 6 Digital display system No Description Function 68 Load moment limiter Display the information about crane 69 LCD screen of pa...

Page 140: ...f parameter monitor The main screen is subdivided into six main areas Engine information Alarm functions Monitored additional functions Pressure and slewing angle Firewall anti collision function Func...

Page 141: ...play of water temperature 72 Display of engine oil pressure 73 Display of fuel level 74 Display of engine load 75 Control light Engine fault 76 Engine fault code The fuel level 73 and engine load 74 a...

Page 142: ...sh 79 Icon Oil return pipe clog If the oil return pipe is clogged the icon will flash 80 Icon Crane overload When crane is overloaded the icon will flash 81 Icon Angle between main boom and luffing ji...

Page 143: ...con Lower limit switch on H2 When there are only three windings of wire rope left on H2 the icon will flash 88 Icon Main boom 87 When main boom is raised to 87 position the icon will flash 89 Icon Til...

Page 144: ...ce up and down Otherwise they will stand still NO 1 is PLC2024 and NO 2 is PLC2023 4 2 2 4 Display of pressure and slewing angle Figure 4 11 Display of pressure and slewing angle Table 4 10 Display of...

Page 145: ...page 101 Display of upper angle limit of main boom 102 Display of lower angle limit of luffing jib When firewall setting is required the luffing jib angle can be set in the setting page 103 Display o...

Page 146: ...arameter adjustment This key is used to adjust relevant parameters of main motions and firewall function 109 Language The language can shift among Chinese English and Russian via this key 110 Key work...

Page 147: ...rane operator s seat 4 3 1 1 Vertical adjustment of headrest Figure 4 13 Vertical adjustment of headrest The height of headrest can be adjusted manually with proper strength 4 3 1 2 Adjustment of armr...

Page 148: ...ase the lever 4 3 1 4 Adjustment of the seat height There are two levers to adjust the seat height The front lever adjusts the height of front part of the seat and the rear lever adjusts the height of...

Page 149: ...on Operator s Manual for Crawler Crane 4 3 1 5 Adjustment of backrest Figure 4 17 Adjustment of backrest Pull the horizontal adjustment lever upwards pull the backrest to proper position and release t...

Page 150: ...lfilled 1 The crane is horizontally aligned 2 The gear of 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 c...

Page 151: ...moment limiter otherwise operation is not permitted to be carried out 2 Low engine oil pressure will impair the working efficiency of engine 3 Add diesel oil in time if the oil level is too low 4 If a...

Page 152: ...re switching on the working floodlight switch put the master lighting switch on the 2 nd position 2 Windshield wiper and washer Turn on front windshield wiper and roof windshield wiper by pressing the...

Page 153: ...temperature 10 C to start the engine you need to start the engine cold starting device first Place the controller power if any in the Stop state the ignition start switch in the Power position the col...

Page 154: ...top 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 while a load is being lifted there may be a risk o...

Page 155: ...acity chart Only this way can it be able to fulfill its protective task If the crane operator does not observe this safety regulation there is a great danger of toppling or destroying the crane despit...

Page 156: ...ovements spool up hoisting winch 1 or 2 spool up derricking winch and reel off derricking winch are limited The tricolor light sends out red warning and the buzzer sounds continuously When the control...

Page 157: ...he engine stops 4 Safety bypass works if turn it for the first time Turn it again the engine stops or the working time is more than 30 minutes it will be invalid 5 The movement will be slower after th...

Page 158: ...dicator is fitted on the lower rear end of main boom pivot section i e on the right side of the crane operator s cab In this way the operator even in crane operator s cab can clearly read boom angle s...

Page 159: ...boom 4 4 5 3 Crane operation with main boom and luffing jib 1 When the main boom is raised to 80 position the main boom derrick speed will reduce to half of the original 2 When the main boom is raised...

Page 160: ...ition less than 60 In other words lower the luffing jib below 60 by the pulling force of load 4 4 6 Lowering limiter Figure 4 23 Lowering limiter In order to prevent wire rope from being wound in the...

Page 161: ...rator can get the permission to operate towards dangerous direction temporarily via this switch but it doesn t mean that the lowering limit situation is removed 2 The bypass of lowering limiter must b...

Page 162: ...k comes into contact with the hoisting limit switch weight during its upward movement the hoisting limit switch is triggered the buzzer sounds and the crane movement Spool up hoisting winches 1 and 2...

Page 163: ...ice When the high pressure oil pipe which is connected to support cylinder is damaged the bidirectional hydraulic lock fitted in oil circuit can prevent pressure oil in the two chambers of support cyl...

Page 164: ...sons in the danger zone 3 Before every crane operation at least an acoustic signal should be given Before engine startup ensure that the following icons on the screen will not flash 1 Icon Engine oil...

Page 165: ...nd changing forces The overloading condition should be recognized early and the crane movement should be slowed down accordingly 2 Checks during crane operation During crane operation daily activate a...

Page 166: ...0 which is described in the above grid The valid movement range for A B C D areas is 50 4 Setting configuration For the specific methods to set configuration please refer to load moment limiter instru...

Page 167: ...nge hoisting winch 1 hoisting winch 2 and derricking winch Rotating switch Normal speed The middle position of the switch means the automatic working speed of the system Middle speed When the hoisting...

Page 168: ...avel gear 4 5 1 2 Operation of travel gear The traveling movements are controlled by left and right control levers The movements left crawler forwards and left crawler backwards are controlled by left...

Page 169: ...control lever Otherwise the operation is invalid 3 The crane movements can still be carried out before the control lever is returned to neutral position with deadman s button released However to perf...

Page 170: ...d gear Differential steering Figure 4 32 Differential steering Steering to right Push left control lever heavily and push right control lever slightly to make the speed of left crawler higher than tha...

Page 171: ...forwards with boom located straight ahead and the traveling reducer is behind the slewing table 4 5 1 2 2 Traveling on slope Make crawler crane travel forwards and place slewing control lever in neutr...

Page 172: ...deviates forwards the crane should be stopped to adjust the center of gravity 2 When crawler crane is traveling on a slope with rated gradient it is impossible to obtain a special mass parameter acco...

Page 173: ...ng direction d Jerky crane movements must be avoided e The suspended load must be lashed to prevent it from swinging f Steering of crawler is forbidden 4 5 1 3 High speed travelling Figure 4 35 Operat...

Page 174: ...traveling switch 4 5 2 1 Hoisting winch 4 5 2 1 1 Components of hoisting winch Hoisting winch consists of hydraulic motor winch reducer brake lowering limiter hoisting limiter and wire rope as well a...

Page 175: ...wards Spool up hoisting winch 1 to lift Return to neutral position Hoisting winch 1 stops working 2 Operation of hoisting winch 2 Push left control lever backwards spool up hoisting winch 2 Push left...

Page 176: ...ctions of winch 1 and 2 they are determined by selected boom configuration 2 When spooling up or reeling off hoisting rope keep watching the winch to make sure that there is no slack wire rope on the...

Page 177: ...height of crane will increase accordingly which will therefore make the wire rope not long enough Such a problem can be solved by changing the rope reeving of wire rope Before changing the rope reevi...

Page 178: ...For crane operation with main boom crane operation with fixed jib Main boom angle can be adjusted by changing the length of wire rope reeved between derricking blocks which consist of derricking crow...

Page 179: ...r luffing jib 1 The operator must first choose boom configuration on the load moment limiter according to actual situation The functions of derricking mechanism are determined by selected boom configu...

Page 180: ...ions a S SL boom configurations The main boom angle can vary from 0 to 83 and the boom can be raised or lowered via main boom derricking winch Figure 4 41 S SL boom configuration Figure 4 42 Operation...

Page 181: ...l off main boom derricking winch to lower main boom Return it to neutral position Main boom derricking winch stops working b SF boom configuration The fixed jib can be mounted in the angle of either 1...

Page 182: ...nch to raise main boom Move it to right Reel off main boom derricking winch to lower main boom Return it to neutral position Main boom derricking winch stops working c SW boom configuration For this b...

Page 183: ...on 1 Use main boom derricking winch to derrick main boom 2 Use hoisting winch 1 to derrick luffing jib 1 Derrick the main boom Figure 4 46 Operation of main boom derricking winch CAUTION Right control...

Page 184: ...e luffing jib via hoisting winch 1 Figure 4 47 Raise lower luffing jib via hoisting winch 1 When hoisting winch 1 is used to raise or lower luffing jib push right control lever forwards and backwards...

Page 185: ...aveling switch prior to operating winches 2 Only when controlling the luffing jib alone can the high speed function for luffing jib be used 1 The derricking operation must be carried out stably Otherw...

Page 186: ...synchronization switch on the right control panel to Mast A frame E sync position as described below b Turn A frame erecting lowering switch to left Erecting up position as described below c Then the...

Page 187: ...in reverse direction with hoisting rope between the rope pulleys in the boom head and the hook block Turn the reeving winch switch to the right reel off reeving winch Figure 4 50 Operation of reeving...

Page 188: ...ing winch 1 as working winch a Turn synchronization switch to the Reeve SYNC position which is described as below b Push right control lever forwards and backwards the reeving winch and hoisting winch...

Page 189: ...Operation of slewing mechanism 4 5 4 1 Components of slewing mechanism The slewing mechanism consists of hydraulic motor planetary gear reducer brake drive gear and slewing ring etc The slewing speed...

Page 190: ...ing movement an acoustic signal should be given Table 4 21 Operation of slewing mechanism Control lever Operation Movement Left control lever Move it to left Slew the superstructure to left Move it to...

Page 191: ...ying 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 Before...

Page 192: ...ucture may still slew because it is not a positioning lock 9 Activating slewing brake switch to lock slewing mechanism abruptly should be avoided since it may cause damage to the superstructure 4 5 5...

Page 193: ...slew to right b Simultaneous operation of hoisting winch 1 and derricking mechanism Since both hoisting winch 1 and derricking mechanism are controlled by right control lever this simultaneous moveme...

Page 194: ...ement will not be achieved See above figure The simultaneous movements in following four ranges are A Reel off winch 1 lower load hook and spool up main boom derricking winch raise main boom B Reel of...

Page 195: ...rricking winch lower main boom Move to right Slew to right and spool up main boom derricking winch raise main boom Slew to right Slew to right and reel off main boom derricking winch lower main boom d...

Page 196: ...to right Left control lever Move forwards Reel off winch 2 lower load hook and slew to left Reel off winch 2 lower load hook Reel off winch 2 lower load hook and slew to right Return to neutral posit...

Page 197: ...se four areas is 30 b Simultaneous operation of hoisting winch 2 and derricking mechanism Operate the left and right control levers at the same time Figure 4 62 Simultaneous operation of hoisting winc...

Page 198: ...aneous operation of hoisting winch 2 and slewing mechanism Operate the left and right control levers at the same time For detailed operation see Section 4 5 5 1 e Simultaneous operation of hoisting wi...

Page 199: ...osition Reel off winch 1 lower luffing jib Stop working Spool up winch 1 raise luffing jib Move backwards Spool up winch 2 lift load hook and reel off winch 1 lower luffing jib Spool up winch 2 lift l...

Page 200: ...ate the left and right control levers at the same time For detailed operation see Section 4 5 5 1 a Use luffing jib derricking winch to raise lower luffing jib When crane is fitted with luffing jib de...

Page 201: ...reel off winch 1 lower load hook 2 Spool up luffing jib derricking winch raise luffing jib Spool up luffing jib derricking winch raise luffing jib and spool up winch 1 lift load hook 2 Return to neutr...

Page 202: ...nch lower luffing jib C Spool up winch 1 lift load hook 2 and spool up luffing jib derricking winch raise luffing jib D Spool up winch 1 lift load hook 2 and reel off luffing jib derricking winch lowe...

Page 203: ...off luffing jib derricking winch lower luffing jib Return to neutral position Spool up luffing jib derricking winch raise luffing jib Stop working Reel off luffing jib derricking winch lower luffing j...

Page 204: ...derricking winch raise luffing jib Slew to left Slew to left and reel off luffing jib derricking winch lower luffing jib Return to neutral position Spool up luffing jib derricking winch raise luffing...

Page 205: ...ng winch 2 and main boom derricking winch Left control lever forwards and backwards right control lever left and right 6 Hoisting winch 2 and Hoisting winch 1 for luffing jib Left control lever forwar...

Page 206: ...rking condition the cab cannot be swiveled out but can tilt forwards and or backwards Only when the crane transfers from transport position to working position can the cab be swiveled out Figure 4 68...

Page 207: ...cab 4 Take off the working floodlight on the roof of cab before swiveling the operator s cab so as to prevent them from colliding with tilting back support of main boom 2 Tilting the operator s cab f...

Page 208: ...ting operator s cab forwards When operator s cab is tilted backwards turn the tilt cab forwards backwards switch to the right then the cab will tilt forwards After it tilts to proper position turn the...

Page 209: ...33 Instructions for switches on the auxiliary remote control box No Name of switch Operation Function 1 Left counterweight control switch Push up Extend left counterweight cylinder Push down Retract l...

Page 210: ...ct bolting cylinder 8 Reeving winch switch Push up Spool up reeving winch Push down Reel off reeving winch Its function is the same as that of reeving winch switch on the right control panel As soon a...

Page 211: ...carrier bolting cylinder is selected b When one of the selector levers is pushed down the support cylinder in corresponding position is selected e g when FR selector lever is pushed down the FR suppo...

Page 212: ...mechanism Requirements 1 Turn on the undercarriage control switch on auxiliary remote control box 2 Level the crane by operating crane support cylinder control levers 3 Erect A frame and tilt it forwa...

Page 213: ...tes the crane to erect A frame b Operation of self assembly dismantling mechanism 1 Turn W1 Winch Assembly switch on the right control panel to right 2 Push right control lever forwards the mounting c...

Page 214: ...Crane Operation Operator s Manual for Crawler Crane During self assembly dismantling operation turn W1 Winch Assembly switch on the right control panel to right CAUTION 4 86...

Page 215: ...rope reeving in accordance with operational planning and different boom configurations Table 4 34 Load hook and rope reeving Type of load hook Number of rope pulleys Maximum rope reeving Weight of lo...

Page 216: ...ne Operation Operator s Manual for Crawler Crane 4 6 1 Heavy duty boom S 4 6 1 1 Hoisting rope guidance and reeving 260 t load hook Figure 4 79 Hoisting rope guidance and reeving for 260 t load hook 4...

Page 217: ...Crane Operation Operator s Manual for Crawler Crane 160 100 t load hook Figure 4 80 Hoisting rope guidance and reeving for 160 100 t load hook 4 89...

Page 218: ...ne Operation Operator s Manual for Crawler Crane 50 t load hook Figure 4 81 Hoisting rope guidance and reeving for 50 t load hook Figure 4 82 Hoisting rope guidance and reeving for other load hooks 4...

Page 219: ...Figure 4 83 Hoisting rope guidance and reeving for main boom with tip boom 4 6 2 Light duty boom SL 4 6 2 1 Hoisting rope guidance and reeving Figure 4 84 Hoisting rope guidance and reeving for main...

Page 220: ...om on light duty boom Figure 4 85 Hoisting rope guidance and reeving for tip boom on light duty boom 4 6 3 Fixed jib on heavy duty boom SF Figure 4 86 Hoisting rope guidance and reeving for main boom...

Page 221: ...dance and reeving Figure 4 87 Hoisting rope guidance and reeving for main boom with luffing jib 6 5 4 4 3 2 1 30 t load hook 16 t load hook Winch 2 1 4 Winch 2 1 4 Winch 2 1 4 Winch 2 1 4 Winch 2 1 4...

Page 222: ...ane 4 6 4 2 Hoisting rope guidance for tip boom Figure 4 88 Hoisting rope guidance and reeving for tip boom on luffing jib 4 6 5 Derricking rope guidance and reeving Figure 4 89 Derricking rope guidan...

Page 223: ...Crane Operation Operator s Manual for Crawler Crane 4 6 6 Luffing rope guidance and reeving Figure 4 90 Luffing rope guidance and reeving 4 95...

Page 224: ......

Page 225: ...Chapter 5 Assembly and Dismantling Operator s Manual for Crawler Crane...

Page 226: ......

Page 227: ...he maximum permissible boom length and the wire rope should be installed strictly according to the hoisting rope reevings h Each dismantled part should not only satisfy the requirement of load bearing...

Page 228: ...o that the crane movements can be performed within maximum and minimum working radius f Check whether there are obstacles which will hinder required crane operations g Check whether the ground provide...

Page 229: ...oad hook a Check the hook for distortions e g at the hook jaw b Inspect all bolts and screws and ensure all cotter pins are complete c Check that the rotary connection of hook can move easily and the...

Page 230: ...ther using the hand tightened nut c Turn the hand tightened nut over the O ring until a firm and tight fit is attained d The hydraulic couplings may only be tightened or unscrewed by hand rather than...

Page 231: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 5 Incorrectly fitted or faulty limit switches and falling parts pins retaining pins ice etc can cause injury CAUTION...

Page 232: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 6 5 2 A frame Figure 5 1 A frame Slewing table A frame A frame erection cylinder...

Page 233: ...ylinder on A frame In the process of self assembly dismantling the A frame erecting mechanism serves as a mounting crane whose maximum lifting capacity is 25t in 5m working range b Serving as a compon...

Page 234: ...nd disconnect hydraulic lines with quick release couplings switch off the engine and wait for about 5 minutes 2 Assemble coupling components male and female ends and tighten them by nut 3 Turn the nut...

Page 235: ...thereby causing accidents 5 2 2 Operation of A frame 5 2 2 1 A frame movement control A frame can be erected or lowered by operating the A frame erecting lowering switch 58 in the operator s cab Figu...

Page 236: ...should be performed by two persons One worker gives guidance watch the A frame erection cylinder and rope guiding condition on the derricking winch while the other worker operates 5 2 2 2 Erecting A f...

Page 237: ...d that on slewing table and placed well in the derricking pulley block Figure 5 7 Main boom derricking winch operation c When A frame tilts forwards under its own weight to 165 limit position return r...

Page 238: ...p main boom derricking winch Then the erection cylinder as well as the A frame will be retracted c When the erection cylinder and A frame return to original or required position return the switch 58 i...

Page 239: ...ing procedure and safety regulations and clear about their areas of responsibility before operation c Checks before operation Check the basic machine before operation 5 3 1 2 Unloading the basic machi...

Page 240: ...to 110 position Figure 5 10 Erect A frame d Support the basic machine Swivel the folding brackets out into the support position Pull out the fixing screw for support plates on the undercarriage centr...

Page 241: ...nd the support cylinder by operating the cylinder telescoping control lever Note in the assembling process the maximum force the support cylinder can bear is 29 t Figure 5 12 Support plate 1 In no cir...

Page 242: ...2 Attaching the first crawler carrier a Tilt the A frame forwards according to the method in Section 5 2 Operation of A frame b Turn self assembly dismantling switch on the right control panel to righ...

Page 243: ...right control lever 30 backwards to retract the mounting cylinder to lift the first crawler carrier from the transport vehicle Slowly raise A frame and adjust the mounting cylinder to align the crawle...

Page 244: ...second crawler carrier can be attached The assembly sequence for the second crawler carrier is essentially the same as that for the first crawler carrier b After the second crawler carrier is attached...

Page 245: ...total led out from the left and right sides of undercarriage centre section which are respectively connected to the left and right crawler carriers Take the hydraulic connection to the left crawler c...

Page 246: ...Quick release coupling Plug the male end of quick release coupling to its female end Male end Female end 227 215 241 242 5 4 1 D P VB VA M3V260 160R Quick release coupling Left traveling motor Quick r...

Page 247: ...1 Depressurize hydraulic system before connecting and disconnecting Turn off engine and wait for 5 minutes 2 Coupling parts male end and female end are plugged into each other and screwed together usi...

Page 248: ...er the basic machine is fitted with the left and right crawler carriers lift the first counterweight plate from transport vehicle and lay it on the supports on the inside of crawler carriers after rot...

Page 249: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 23 Figure 5 23 Position of the central counterweight Central counterweight...

Page 250: ...both sides of superstructure tail end Figure 5 24 Counterweight base plate Procedure for mounting the rear counterweight Lift the counterweight base plate and lay it on a flat ground and then lift th...

Page 251: ...cedure for mounting the rear counterweight a Push up the counterweight left right lifting cylinder switches on the auxiliary remote control box the counterweight left and right cylinders will extend t...

Page 252: ...ntling of counterweight plates is carried out in the reverse order to assembly 1 When stacking the counterweight plate on top of one another align the upper counterweight plate over the circular promi...

Page 253: ...bly and Dismantling Operator s Manual for Crawler Crane 5 27 5 6 Available boom configurations for ZCC2600 crawler crane Figure 5 28 S boom configuration G10 G12 G15 G15 G15 G15 G15 G15 G14 G13 G11 G7...

Page 254: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 28 Figure 5 29 SL boom configuration G29 G25 G22 G15 G15 G15 G15 G15 G15 G14 G13 G11 G70 G17...

Page 255: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 29 Figure 5 30 SF boom configuration G70 G11 G13 G15 G15 G15 G15 G15 G15 G12 G31 G75 G74 G37 G32 G33 G17...

Page 256: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 30 Figure 5 31 SFV boom configuration G70 G17 G11 G13 G15 G15 G15 G15 G15 G15 G12 G37 G74 G75 G41...

Page 257: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 31 Figure 5 32 SW boom configuration G25B G25A G24 G24 G23 G21 G71 G73 G12 G15 G15 G15 G15 G14 G70 G17 G72 G28 G27 G22...

Page 258: ...1 G23 Luffing jib intermediate section 3 0 32 G24 Luffing jib intermediate section 6 0 59 G25B Luffing jib intermediate section 9 0 68 G25A Luffing jib intermediate section 9 0 82 G27 WA frame 1 1 74...

Page 259: ...oom configurations and anchoring rods combination that have not been stipulated in the operating manual are prohibited 2 When attaching boom sections make sure that the intermediate sections are assem...

Page 260: ...mber of main boom intermediate sections The basic boom is 20 m long including main boom pivot section G11 main boom head G12 and tip boom G10 There are three types of main boom intermediate section 3...

Page 261: ...35 Figure 5 34 Main boom pivot section Figure 5 35 Main boom head Figure 5 36 3 m main boom intermediate section Figure 5 37 6 m main boom intermediate section Figure 5 38 9 m main boom intermediate s...

Page 262: ...20 G11 G12 53 G11 G14 3 G15 G12 23 G11 G13 G12 56 G11 4 G15 G12 26 G11 G14 G12 59 G11 G13 4 G15 G12 29 G11 G15 G12 62 G11 G14 4 G15 G12 32 G11 G13 G15 G12 65 G11 5 G15 G12 35 G11 G14 G15 G12 68 G11 G1...

Page 263: ...Each kind of boom is assigned to anchoring rods of specific length and the anchoring rods should be connected strictly in accordance with the given method The connection method of anchoring rods of d...

Page 264: ...ble 5 3 Component parts of anchoring rods of heavy duty boom Part No Description Illustration 1 Pin spindle 2 Cotter pin GB T91 2000 8 60 3 Reducing piece 4 Pin spindle 5 Cotter pin GB T91 2000 10 95...

Page 265: ...for Crawler Crane 5 39 Part No Description Illustration 7 Pin spindle 8 Retaining pin 9 Double anchoring rod 10 Single anchoring rod 11 Single anchoring rod 12 Single anchoring rod 320 2 50 5 1250 65...

Page 266: ...of main boom 16 Pin spindle 17 Cotter pin GB T91 2000 8 95 The part number of anchoring rods of heavy duty boom given in Section combination of anchoring rods of heavy duty boom is consistent with tha...

Page 267: ...should be added accordingly The width of heavy duty boom anchoring rods is 65 mm and the diameter of pin spindle is 50 mm Combination of anchoring rods of heavy duty boom is shown in the following ta...

Page 268: ...of 3 m main boom intermedia te section mm Length of anchoring rods of 6 m main boom intermedia te section mm Length of anchoring rods of 9 m main boom intermedia te section mm Length of anchor ing ro...

Page 269: ...ections 4 m reducing section G29 and luffing jib sections And main boom sections consist of main boom pivot section G11 and an optional number of main boom intermediate sections 3 m G13 6 m G14 and 9...

Page 270: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 44 Figure 5 40 SL boom configuration G29 G25B G22 G15 G15 G15 G15 G15 G15 G14 G13 G11 G70 G17...

Page 271: ...ator s Manual for Crawler Crane 5 45 Figure 5 46 4 m reducing section Figure 5 47 Luffing jib pivot section Figure 5 48 Luffing jib head Figure 5 49 3 m luffing jib intermediate section 3090 1490 9445...

Page 272: ...9 G24 G22 89 G11 G13 G14 6 G15 G29 G23 G22 95 G11 G13 G14 6 G15 G29 G25B G22 5 7 2 2 Components of anchoring rods of light duty boom Anchoring rods of light duty boom consists of anchoring rods of hea...

Page 273: ...00 1250 300 320 A A 300 2 700 B B 300 57 00 6 A B 70630 Remarks For the connection method of anchoring rods please refer to the connection of anchoring rods of main boom For part number of anchoring r...

Page 274: ...er anchoring rod of reducing section of light duty boom Table 5 5 Components of anchoring rods of light duty boom Part No Description Illustration mm 1 Pin spindle 2 Retaining pin 3 Double anchoring r...

Page 275: ...ler Crane 5 49 Part No Description Illustration mm 4 Coupling link of light duty boom 5 Double anchoring rod 6 Cotter pin GB T91 2000 10 90 7 Coupling link of light duty boom 8 Double anchoring rod 30...

Page 276: ...1 Anchoring rod 12 Anchoring rod 13 Double anchoring rod The part numbers of anchoring rods given in Section light anchoring rods are consistent with those in the above table so the component parts of...

Page 277: ...y duty boom LA mm Reducing section 4000 mm Luffing jib intermediate section mm Luffing jib head 8750 mm Total length mm 86 70630 300 420 1 160 400 3 00 1420 300 1650 300 5700 300 500 83380 89 300 2700...

Page 278: ...e tensioners for 86 m long light duty boom Figure 5 53 Intermediate tensioners connection with 86 m light duty boom For the parts number of light anchoring rods given in the above table please refer t...

Page 279: ...er of light anchoring rods given in the above table please refer to Section light anchoring rods CAUTION 89000 Light duty boom 89 m Light anchoring rod 8 Double anchoring rod Intermediate tensioner Li...

Page 280: ...above table please refer to Section light anchoring rods CAUTION Connecting position of intermediate tensioner and light anchoring rods Light anchoring rod 8 Double anchoring rod Intermediate tensione...

Page 281: ...above table please refer to Section light anchoring rods CAUTION 95000 Light duty boom 95 m Light anchoring rod 8 Doble anchoring rod Intermediate tensioner Light anchoring rod 10 Anchoring rod To 4...

Page 282: ...follows Table 5 7 Component parts of intermediate tensioners anchoring rods Part No Description Illustration mm 1 Double anchoring rod 2 Pin spindle 3 Plate 5 520 50 2 45 84 6 270 50 4 45 Intermediate...

Page 283: ...od 7 Retaining pin Part number of intermediate tensioners given in Section intermediate tensioners on light duty boom is consistent with these in the above table Assemble the component parts of interm...

Page 284: ...an optional number of fixed jib intermediate section 6 m in length G34 The fixed jib can be assembled in the angle of 10 or 30 to main boom When different fixed jib length is required operator only ne...

Page 285: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 59 Figure 5 58 SF boom configuration G70 G11 G13 G15 G15 G15 G15 G15 G15 G12 G31 G75 G74 G37 G32 G33 G17...

Page 286: ...Manual for Crawler Crane 5 60 Figure 5 59 Fixed jib pivot section Figure 5 60 6 m fixed jib intermediate section Figure 5 61 Fixed jib head Figure 5 62 FA frame 7270 620 6430 1650 1060 1060 6060 6170...

Page 287: ...2 30 G31 3 G33 G32 5 7 3 2 Components of anchoring rods of SF boom The anchoring rods of SF boom comprises main boom anchoring rods fixed jib front anchoring rods and fixed jib rear anchoring rods For...

Page 288: ...65 Fixed jib front anchoring rods Table 5 9 Component parts of fixed jib front anchoring rods Part No Description Illustration mm 1 Double anchoring rod 2 Pin spindle 3 Retaining pin B C 30 A C B 7 6...

Page 289: ...nchoring rod 7 Double anchoring rod 8 Cotter pin GB T91 2000 10 90 9 Pin spindle The part numbers of anchoring rods given in Section Fixed jib front anchoring rods are consistent with these in the abo...

Page 290: ...Table 5 10 Combination of fixed jib front anchoring rods Fixed jib length m Length of fixed jib front anchoring rods mm Combination of fixed jib front anchoring rods between FA frame to fixed jib 12 1...

Page 291: ...can be mounted in the angle of either 10o or 30o to main boom the fixed jib rear anchoring rods can be combined in two ways The following figure shows the combination of rear anchoring rods when fixe...

Page 292: ...Components of fixed jib rear anchoring rods Part No Description Illustration mm 1 Sleeve 2 Cotter pin GB T91 2000 4 30 3 Nut GB T6170 2000 M20 8 4 Bolt GB T31 1 1988 M20 200 8 8 5 Anchoring rod 6 Sing...

Page 293: ...r Crawler Crane 5 67 Part No Description Illustration mm 8 Pin spindle 9 Retaining pin 10 Single anchoring rod 11 Coupling link 12 Double anchoring rod 13 Reducing piece 70 2 40 300 1 4 2555 45 4 40 4...

Page 294: ...in Section Fixed jib rear anchoring rods are consistent with these in the above table Assemble the component parts of anchoring rods according to the corresponding part numbers Table 5 12 Combination...

Page 295: ...of 14 or 20 to main boom When different main boom length is required the operator only needs to disconnect main boom pivot section from main boom head and then install main boom intermediate sections...

Page 296: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 70 Figure 5 69 Heavy fixed jib on heavy duty boom G70 G17 G11 G13 G15 G15 G15 G15 G15 G15 G12 G37 G74 G75 G41...

Page 297: ...omprises main boom anchoring rods heavy fixed jib front anchoring rods and heavy fixed jib rear anchoring rods For the combination of main boom anchoring rods see Section 5 7 1 2 Combination of anchor...

Page 298: ...ib front anchoring rods Table 5 13 Component parts of heavy fixed jib front anchoring rods Part No Description Illustration mm 1 Pin spindle 2 Retaining pin 3 Double anchoring rod B C C 1 2 3 4 5 6 7...

Page 299: ...ane 5 73 Part No Description Illustration mm 4 Single anchoring rod 5 Double anchoring rod 6 Reducing single anchoring rod 7 Pin spindle 8 Cotter pin GB T91 2000 10 90 9 Reducing double anchoring rod...

Page 300: ...h these in the above table Assemble the component parts of anchoring rods according to the corresponding part numbers b Heavy fixed jib rear anchoring rods The width of heavy fixed jib rear anchoring...

Page 301: ...Dismantling Operator s Manual for Crawler Crane 5 75 Figure 5 72 Heavy fixed jib rear anchoring rods C D B C D B 30 A view To boom frame 7 16 14 15 13 12 11 10 8 9 7 5 6 1 2 3 4 9 8 15 14 1 2 3 4 To F...

Page 302: ...nent parts of heavy fixed jib rear anchoring rods Part No Description Illustration mm 1 Sleeve 2 Cotter pin GB T91 2000 4 30 3 Nut GB T6170 2000 M20 8 4 Bolt GB T31 1 1988 M20 200 8 8 5 Anchoring rod...

Page 303: ...tor s Manual for Crawler Crane 5 77 Part No Description Illustration mm 8 Pin spindle 9 Retaining pin 10 Single anchoring rod 11 Coupling link 12 Double anchoring rod 1 4 2555 45 4 40 400 2 40 40 2200...

Page 304: ...ane 5 78 Part No Description Illustration mm 13 Reducing piece 14 Pin spindle 15 Cotter pin GB T91 2000 10 90 16 Reducing double anchoring rod 17 Single anchoring rod 18 Single anchoring rod 1 4 2420...

Page 305: ...the following table Table 5 15 Combination of heavy fixed jib rear anchoring rods Heavy fixed jib angle Length of heavy fixed jib rear anchoring rods mm Combination of heavy fixed jib rear anchoring r...

Page 306: ...5 7 5 1 Components of luffing jib The luffing jib whose length varies from 21 m to 60 m comprises luffing jib pivot section G21 luffing jib head G22 and an optional number of luffing jib intermediate...

Page 307: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 81 Figure 5 74 Combination of luffing jib sections G25B G25A G24 G24 G23 G21 G71 G73 G12 G15 G15 G15 G15 G14 G70 G17 G72 G28 G27 G22...

Page 308: ...ler Crane 5 82 Figure 5 75 Luffing jib pivot section Figure 5 76 Luffing jib head Figure 5 77 3 m luffing jib intermediate section Figure 5 78 6 m luffing jib intermediate section 9185 1490 1490 6090...

Page 309: ...jib intermediate section Figure 5 80 WA frame 2 Figure 5 81 Luffing jib tilting back support Figure 5 82 Rear tilting back support of luffing jib Figure 5 83 Rear tilting back support cylinder of luf...

Page 310: ...G21 G24 G25A G25B 2 G22 30 G21 G23 G25A G22 54 G21 G23 G24 G25A G25B 2 G22 33 G21 G24 G25A G22 57 G21 G24 2 G25A G25B 2 G22 36 G21 G25A G25B G22 60 G21 G23 G24 2 G25A 2 G25B G22 39 G21 G23 G25A G25B G...

Page 311: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 85 a Luffing jib front anchoring rods Figure 5 84 Luffing jib front anchoring rods connection...

Page 312: ...Table 5 17 Component parts of luffing jib front anchoring rods Part No Description Illustration mm 1 Cotter pin GB T91 2000 8 60 2 Pin spindle 3 Anchoring rod 4 Pin spindle 5 Coupling link 6 Cotter p...

Page 313: ...for Crawler Crane 5 87 Part No Description Illustration mm 7 Pin spindle 8 Double anchoring rod 9 Single reducing piece 10 Cotter pin GB T91 2000 10 120 11 Pin spindle 12 Double reducing piece 300 90...

Page 314: ...anual for Crawler Crane 5 88 Part No Description Illustration mm 13 Anchoring rod 14 Coupling link 15 Pin spindle 16 Retaining pin 17 Anchoring rod 18 Double anchoring rod 300 45 5 1940 51 2 45 182 45...

Page 315: ...awler Crane 5 89 Part No Description Illustration mm 19 Anchoring rod 20 Anchoring rod 21 Double anchoring rod 22 Anchoring rod 23 Anchoring rod 24 Double anchoring rod 45 800 5 500 50 2 45 5 1650 50...

Page 316: ...ng rod 26 Double anchoring rod 27 Anchoring rod The part numbers of anchoring rods given in Section Luffing jib front anchoring rods are consistent with these in the above table Assemble the component...

Page 317: ...interme diate section mm Length of anchori ng rods of 9 m main boom interme diate section mm Length of anchorin g rods of luffing jib head 8750 mm Total length of anchori ng rods mm 21 500 300 340 30...

Page 318: ...ing Operator s Manual for Crawler Crane 5 92 b Luffing jib rear anchoring rods The combination of the luffing jib rear anchoring rods is shown in the following figure Figure 5 85 Luffing jib rear anch...

Page 319: ...e 5 93 Table 5 19 Component parts of luffing jib rear anchoring rods Part No Description Illustration mm 1 Retaining pin 2 Pin spindle 3 Double anchoring rod 4 Coupling link 5 Cotter pin GB T91 2000 1...

Page 320: ...s Manual for Crawler Crane 5 94 7 Double anchoring rod 8 Coupling link 9 Single anchoring rod 10 Single anchoring rod 11 Anchoring rod 12 Anchoring rod 5700 50 2 45 2700 50 2 45 1240 56 2 50 2100 56 2...

Page 321: ...ing rods of main boom head 4840 mm Length of anchoring rods of 3 m main boom intermedi ate section mm Length of anchoring rods of 6 m main boom intermedi ate section mm Length of anchoring rods of 9 m...

Page 322: ...2 For assembly work on the crane a safety assembly working platform must be used Improvisations are prohibited Otherwise there is a danger of falling down 3 Any other boom configurations and anchorin...

Page 323: ...unting cylinder on A frame with two lifting chains Figure 5 87 Pinning on main boom pivot section b Adjust A frame to proper position by moving right control lever 30 to left or right Turn self assemb...

Page 324: ...nder d Activate the pivot section bolting cylinder switch on auxiliary remote control box to extend the pivot section bolting cylinder and then fit the locking plate In this way the main boom pivot se...

Page 325: ...that the connection holes in one intermediate section are precisely aligned with those in the other intermediate section see the following figure Join them with double tapered pins 1 and secure on bo...

Page 326: ...ting parts of main boom section Part No Description Illustration mm 1 Double tapered pin 2 Retaining spring 3 Double tapered pin b Attaching the preassembled main boom to main boom pivot section Slowl...

Page 327: ...aining springs 2 Adjust the mounting cylinder on A frame until the lower connection holes in pivot section are aligned with those in adjacent main boom intermediate section Join the lower connecting h...

Page 328: ...ng pins The arrangement and combination of main boom anchoring rods are specified in Section 5 7 1 3 Figure 5 92 Assembling main boom anchoring rods b Reeving hoisting winch 2 in 1 Move right control...

Page 329: ...rope pulley and load hook After that stop operation on winch 2 and reeving winch detach the rope lock Finally spool up the reeve winch to wind the rope end point onto the reeving winch Figure 5 93 Ree...

Page 330: ...eeved in desired direction between the rope pulleys and load hook see the following figures Rope reeving plans the hoisting rope is led by rope of reeving winch 1 Working personnel who guides the wire...

Page 331: ...ctrics to main boom 5 8 3 1 Electrical line connections The following figure shows the connected electrical parts on main boom Before erecting the boom make sure that all electrical lines are connecte...

Page 332: ...209 Digital Hi Definition network ballhead camera On main boom head if safety monitoring system is used 210 Cable drum 3 On main boom head if luffing jib or fixed jib is used 211 Hoisting limit switc...

Page 333: ...in boom head has 10 input and output sockets in total marked with from 1 to 10 Each socket on this junction box is described below Table 5 24 Main boom junction box wiring Socket No Function 1 Connect...

Page 334: ...ter Rotate the vane of anemometer to check whether the wind velocity shown on the display in the operator s cab is normal c Check hoisting limit switch for H1 Support and hold the hoisting limit switc...

Page 335: ...and falling parts pins retaining pins ice etc can cause injury 5 8 4 2 Erecting main boom a Move right control lever 30 to the left to spool up main boom derricking winch E and the main boom anchoring...

Page 336: ...oom up will be switched off automatically along with acoustic warning being sent out but the main boom can still be derricked up by turning the bypass key switch to bypass position When main boom is r...

Page 337: ...the main boom head comes into contact with the ground Return right control lever 30 to neutral position 1 In the process of lowering main boom the hoisting winch 2 must be reeled off to avoid the hook...

Page 338: ...ter the operating mode is changed to assembly mode all safety devices built in the crane will be deactivated the assembly dismantling of the machine should therefore be carried out with utmost care 2...

Page 339: ...y crane and swing to main boom head Attach the luffing jib pivot section to the main boom head from above Continue lowering the luffing jib pivot section until it can be pinned to main boom head Pin t...

Page 340: ...f luffing jib pivot section Table 5 25 Connecting parts of luffing jib pivot section to main boom head Part No Description Illustration mm 17 Shaft end retaining plate 18 Bolt GB T5783 2000 M12 35 8 8...

Page 341: ...or Crawler Crane 5 115 Part No Description Illustration mm 19 Washer GB T93 1987 12 20 Pin spindle 21 Bolt GB T5783 2000 M16 55 8 8 22 Washer GB T93 1987 16 23 Retaining plate 24 Pin spindle 25 Retain...

Page 342: ...d pins 1 secured on both sides with retaining springs 2 see the following figure Figure 5 100 Connecting of luffing jib section Connecting parts of luffing jib section is shown as follows Table 5 26 C...

Page 343: ...ection with luffing jib d Assemble the tilting back support of luffing jib and tilting back support of WA frame 2 Firstly connect the tilting back support of luffing jib to main boom head with pin spi...

Page 344: ...ne 5 118 Figure 5 102 Assembly of the tilting back support of luffing jib Table 5 27 Connecting parts of luffing jib tilting back support Part No Description Illustration mm 1 Pin spindle 2 Cotter pin...

Page 345: ...e remote control box to unwind the rope of reeving winch 2 Reeve the rope of reeving winch in the reverse direction between the load hook and the rope pulley on luffing jib head and then pull it to th...

Page 346: ...s luffing jib derricking winch 2 Working personnel who guides the wire rope should take great care to prevent against falling down when walking on the boom frame otherwise serious accident may occur 3...

Page 347: ...order to prevent the WA frame 2 from tilting over 2 At Position 2 lift the WA frame 1 by an auxiliary crane 3 At Position 3 connect to the rope from winch H2 with an attachment chain 4 During the pro...

Page 348: ...nch H2 cannot be too large Otherwise the boom the jib as well as the A frame is liable to damage Meanwhile the luffing jib cannot lift off the ground Figure 5 106 Rear tilting back support of luffing...

Page 349: ...rope until the luffing jib rear anchoring rod is tensioned slightly Insert the pin spindle 2 in corresponding hole in the tilting back support of WA frame 2 and secure it with retaining pin 3 Figure 5...

Page 350: ...to wind luffing rope onto luffing winch so as to raise the WA frame 1 to proper position Select appropriate length of front anchoring rods according to luffing jib length and then connect the front a...

Page 351: ...tail end of main boom pivot section Return the switch 60 or the reeving winch on the remote control box to neutral position to stop unwinding rope Push left control lever 20 forwards to unwind the ho...

Page 352: ...ctrical lines are connected and safety measures are checked Figure 5 110 Layout of electrical pats on main boom pivot section Table 5 31 Electrical parts on main boom pivot section Part No Description...

Page 353: ...ad 207 Warning lamps two On main boom head 208 Junction box On main boom head 209 Control box for Load Moment Limiter on luffing jib On main boom head 210 Cable drum 3 On main boom head 211 Luffing ji...

Page 354: ...jib head two lamps 218 Anemometer On luffing jib head 219 Hoisting limit switch Installed on luffing jib head and connected with hoisting limit switch weight two 220 Luffing jib junction box junction...

Page 355: ...ling Operator s Manual for Crawler Crane 5 129 d Establish electrical connection from socket 10 on main boom junction box junction box 5 installed on main boom head to junction box 6 installed on luff...

Page 356: ...jib head and then insert it into the socket on junction box 7 installed on luffing jib head a Establish electrical connection from associated switches to the junction box 6 b Establish electrical conn...

Page 357: ...or for left tiling back support cylinder of WA frame 1 2 Pressure sensor for right tiling back support cylinder of WA frame 1 3 Limit switch for left tiling back support cylinder of WA frame 1 4 Limit...

Page 358: ...ator s Manual for Crawler Crane 5 132 Figure 5 115 Diagram Electrical connection of junction box 6 Electrical connection of junction box 7 FXH 7 installed on luffing jib head Figure 5 116 Junction box...

Page 359: ...re that the switch is triggered and then check that the icon upper limit switch on H2 on the screen will flash and the buzzer will sound d Limit switch 214 211 The limit switch is a kind of metal indu...

Page 360: ...switch on the screen will flash 5 9 4 2 Requirements for erecting main boom with luffing jib a The crane is properly supported and level b The counterweight is properly installed c Select appropriate...

Page 361: ...When luffing jib is erected by hoisting winch 1 H1 Select luffing jib configuration on the LCD screen of load moment limiter Move right control lever 30 to the left to slowly raise main boom to a prop...

Page 362: ...Assembly and Dismantling Operator s Manual for Crawler Crane 5 136 Figure 5 119 Erect main boom with luffing jib...

Page 363: ...ame time move left control lever 20 forwards to unwind the hoisting rope which will be under the guidance of rope of reeving winch reeved between the rope pulleys on luffing jib head and load hook Fin...

Page 364: ...ected to required working position return the left and right control levers 20 30 to neutral position b Push left control lever 20 backwards to spool up hoisting winch 2 until the load hook is lifted...

Page 365: ...ise the luffing jib is liable to overturn Before the load is detached from the hook lower the luffing jib to a position less than 60 by the pulling force of load 5 9 4 4 Lowering main boom with luffin...

Page 366: ...n the process of lowering the boom make anchoring rods of luffing jib hang down a little 5 The winding of wire rope should be supervised by a person appointed and no person is standing within danger z...

Page 367: ...ing winch 1 slowly put WA frame 2 on the WA frame 1 with the help of auxiliary crane 1 At this time WA frame 2 is lowered down with the help of auxiliary crane rather than the hoisting rope 2 After WA...

Page 368: ...ction G29 The assembly sequence of boom sections for both parts of it and the arrangement and combination of anchoring rods as well as safety precautions have been detailed in Section 5 7 2 Light duty...

Page 369: ...3 socket at the front of slewing table Insert the cable plug of cable drum 2 into the corresponding socket on junction box installed on luffing jib head For electrical connections to other parts pleas...

Page 370: ...ng for the load to be lifted h Change the operating mode to assembly mode 1 After the operating mode is changed to assembly mode all safety device built in the crane will be deactivated the assembly d...

Page 371: ...FA frame with an auxiliary crane and swing to main boom head Attach the fixed jib pivot section to the main boom head from above Continue lowering the fixed jib pivot section until it can be pinned to...

Page 372: ...retaining plate 4 Washer GB T93 1987 16 5 Bolt GB T5783 2000 M16 55 8 8 c According to actual condition choose appropriate numbers of fixed jib intermediate sections 6 m G33 in length and then pin th...

Page 373: ...f anchoring rods of heavy duty boom Preassemble partial fixed jib rear anchoring rods to FA frame see the following A view for the part number appear in the following figure please refer to Section 5...

Page 374: ...G37 and secure them with cotter pin 1 Lift FA frame G37 with an auxiliary crane until the fixed jib front anchoring rods is tensioned slightly Attach the inner pipe of the other end of front tilting...

Page 375: ...Assembly of front tilting back support of fixed jib Table 5 38 Connecting parts Part No Description Illustration mm 1 Cotter pin GB T91 2000 8 60 2 Pin spindle 3 Cotter pin 112 40 Rear anchoring rod o...

Page 376: ...between rope pulleys on luffing jib head and load hook finally attach it to hoisting rope with rope lock Spool up the reeving winch The reeving winch can be spooled up by two operating methods Method...

Page 377: ...lever 30 to the left to spool up main boom derricking winch When main boom is raised to a proper position lift the inner pipe of rear titling back support of fixed jib G75 with an auxiliary crane and...

Page 378: ...1 Pin spindle 2 Cotter pin GB T91 2000 8 60 1 Make sure that hoisting rope on fixed jib head is not exposed to crushing force 2 Ensure that the fixed jib head is rolling forwards on the running wheel...

Page 379: ...o fixed jib 5 11 3 1 Electrical lines connection The following figure shows the connected electrical parts on main boom with fixed jib Before erecting the boom make sure that all electrical lines are...

Page 380: ...head 210 Warning lamp On fixed jib head 211 Junction box of fixed jib On fixed jib head 212 Hoisting limit switch weight Connected to hoisting rope on fixed jib head 213 Hoisting limit switch On fixed...

Page 381: ...junction box here installed on fixed jib head has 3 output sockets in total marked with from 1 to 3 Each socket on this junction box is described below Table 5 41 Fixed jib junction box wiring Socket...

Page 382: ...ed jib 5 11 4 1 Prerequisites a All electrical connections have been established b The limit switch control lever has been checked for smooth movement c Check the warning lamp on the boom head d Check...

Page 383: ...oad hook will not be dragged on the ground When main boom is raised to 30 position the assembly mode will be changed to operating mode automatically Return the left and right control levers to neutral...

Page 384: ...sition where the boom will be lowered To avoid load hook s colliding with the pulley head the load hook must not be lifted too high in the process of lowering main boom with fixed jib c Move right con...

Page 385: ...t The winding of wire rope should be supervised by a person appointed and no person is standing within danger zone during operation f Lift FA frame by an auxiliary crane and then dismantle the front a...

Page 386: ...boom 5 13 Assembly and dismantling of tip boom For the assembly of tip boom of ZCC2600 crawler crane please refer to the figure below Figure 5 133 Assembly of tip boom on main boom head Table 5 43 Co...

Page 387: ...5 161 5 14 Transport weights and dimensions of main components Figure 5 134 Basic machine 45 5 t 1 Figure 5 135 Counterweight base plate 11 t 1 Figure 5 136 Crawler carrier assy 24 5 t 2 8983 1400 120...

Page 388: ...d Dismantling Operator s Manual for Crawler Crane 5 162 Figure 5 137 Counterweight plate 7 1 t 10 Figure 5 139 Central counterweight 16 t 2 Figure 5 140 260 t load hook 4 2 t 1 1400 2530 Unit mm Unit...

Page 389: ...for Crawler Crane 5 163 Figure 5 141 160 100 t load hook 2 8 t 1 Figure 5 142 50 t load hook 1 7 t 1 Figure 5 143 30 t load hook 1 07 t 1 Figure 5 144 16 t load hook 0 8 t 1 1160 530 1630 470 612 196...

Page 390: ...t 1 Figure 5 146 Main boom head 3 38 t 1 Figure 5 147 3 m main boom intermediate section 0 72 t 1 Figure 5 148 6 m main boom intermediate section 1 2 t 1 Figure 5 149 9 m main boom intermediate secti...

Page 391: ...5 150 4m reducing section 0 82 t 1 Figure 5 151 Fixed jib pivot section 0 47 t 1 Figure 5 152 Fixed jib head 0 64 t 1 Figure 5 153 6 m fixed jib intermediate section 0 5 t 1 7270 620 1060 6060 6430 1...

Page 392: ...e 0 75 t 1 Figure 5 155 Luffing jib pivot section 1 05 t 1 Figure 5 156 Luffing jib head 1 1 t 1 Figure 5 157 3 m luffing jib intermediate section 0 32 t 1 Figure 5 158 6 m luffing jib intermediate se...

Page 393: ...g jib intermediate section A 0 82 t 1 Figure 5 160 9 m luffing jib intermediate section B 0 68 t 1 Figure 5 161 Heavy duty fixed jib 1 t 1 Figure 5 162 WA frame 2 1 74 t 1 Figure 5 163 WA frame 1 1 52...

Page 394: ...them from jostling and sliding c To understand the detailed transport means please consult our company If the crane is not used for more than 6 months take the following protective measures a Wipe of...

Page 395: ...Chapter 6 Appendix Operator s Manual for Crawler Crane...

Page 396: ......

Page 397: ...pter 6 Appendix 6 1 Description of special heavy fixed jib on heavy duty boom SFV D boom configuration is used to lifting and turning over the shield tunneling machine 6 1 1 Terminology 6 1 1 1 Boom c...

Page 398: ...xed jib on heavy duty boom S 20 m 29 m FV 6 m 6 1 1 2 Description of component parts and component of heavy fixed jib a Combination of heavy fixed jib 1 2 3 4 5 6 7 Figure 6 2 Boom system 1 Main boom...

Page 399: ...ined by main boom length Combination of rear anchoring rods for special heavy fixed jib is shown in the following figure Figure 6 3 Rear anchoring rods for special heavy fixed jib When the longest mai...

Page 400: ...00 2700 2700 300 300 2700 1000 1000 1000 25120 22120 19120 16120 29m 26m 23m 20m Figure 6 4 Rear anchoring rods for special heavy fixed jib CAUTION The numbers above the combination of anchoring rods...

Page 401: ...or s Manual for Crawler Crane Part No Description Illustration mm 3 Double anchoring rod 4 Coupling link 5 Pin spindle 6 Cotter pin GB T91 2000 10 90 7 Double anchoring rod 8 Coupling link 400 2 50 45...

Page 402: ...anchoring rods can be found by referring to the part numbers when assembling c Combination of front anchoring rods for special heavy fixed jib Combination of front anchoring rods for special heavy fix...

Page 403: ...ion of anchoring rods are projected lengths of component parts The component parts corresponding to part numbers are shown in the following table Table 6 3 Component parts of front anchoring rods for...

Page 404: ...g Operator s Manual for Crawler Crane Part No Description Illustration mm 7 Pin spindle 8 Double anchoring rod 9 Coupling link 10 Cotter pin GB T91 2000 10 90 11 Pin spindle 12 Double anchoring rod 2...

Page 405: ...fixed jib are consistent with those in the above table so the component parts of anchoring rods can be found by referring to the part numbers when assembling d Component of fixed jib tilting back supp...

Page 406: ...5 m long 0 64 t in weight and 1 piece unit 5000 2578 1400 Figure 6 6 FVA frame CAUTION Only when the crane is operated with heavy duty boom and special heavy fixed jib can the FVA frame G37 D be asse...

Page 407: ...rts for FVA frame Table 6 4 Component parts of tilting back support for FVA frame G75 D Part No Description Illustration mm 1 Outer pipe 2 Spring 3 Inner pipe 1200 36 40 89 253 60 1596 5 38 40 74 1200...

Page 408: ...ith those in above figure DANGER The tilting back support for special FVA frame G75 D is different from the tilting back support for general FV frame G75 It is prohibited to misuse 3 Tilting back supp...

Page 409: ...ner pipe 4 Pin spindle 5 Cotter pin GB T91 2000 8 60 CAUTION 1 Only when the crane is operated with heavy duty boom and special heavy fixed jib can the tilting back support for special heavy fixed jib...

Page 410: ...l safety device built in the crane will be deactivated the assembly dismantling of the machine should therefore be carried out with utmost care 2 Any assembly work on crane should be carried out on sa...

Page 411: ...n boom and main boom anchoring rods according to the required length described in Chapter 5 of ZCC2600 Operator s Manual b Raise the special heavy fixed jib G41 with an auxiliary crane attach it to th...

Page 412: ...for Crawler Crane Table 6 5 Connecting parts of special heavy fixed jib to main boom head Part No Description Illustration mm 1 Retaining spring 2 Pin spindle 3 Shaft end retaining plate 4 Washer GB T...

Page 413: ...of rear anchoring rods for special heavy fixed jib Figure 6 10 Assembly of rear anchoring rods to FVA frame d Preassemble partial front anchoring rods to FVA frame G37 D see the following B view for...

Page 414: ...jib G74 D to FVA frame G37 D 5 and secure them with cotter pin 3 Assemble the inner pipe end of tilting back support for FVA frame G75 D to main boom head Lift the FVA frame G37 D 5 with an auxiliary...

Page 415: ...A frame Table 6 6 Connecting parts of tilting back support system Part No Description Illustration mm 1 Tilting back support for FVA frame G75 D 2 Tilting back support for special heavy fixed jib G74...

Page 416: ...the main derricking rope lift up the main boom slightly and straighten the anchoring rod to make sure that the tilting back support system is installed in place h Reeve the main lifting rope of main...

Page 417: ...ad 6 2 4 Connect electrics to special heavy fixed jib Refer to Section 5 11 3 of ZCC2600 Operator s Manual 6 2 5 Erecting lowering and dismantling special heavy fixed jib heavy duty boom SFV D Refer t...

Page 418: ...danger the rear counterweight should be assembled correctly 6 3 1 Description of special heavy fixed jib for S boom The heavy duty boom with heavy fixed jib of 6 m is 20 m 29 m long And the special h...

Page 419: ...anual for Crawler Crane 6 3 2 Description of special heavy fixed jib for SFV D boom The heavy duty boom with 260 t main load hook weighting 4 2 t is 20 m 29 m long Only use auxiliary load hook Figure...

Page 420: ...nual for Crawler Crane 6 3 3 Description of special heavy fixed jib for SFV D boom used to turning over the shield tunneling machine Use main boom and fixed jib simultaneously Figure 6 16 Main load ho...

Page 421: ...120 70 80 9 146 13 4 68 11 2 112 67 67 10 132 14 6 67 12 3 100 64 47 11 115 15 9 65 13 4 89 61 16 12 102 17 1 62 14 6 80 54 14 14 82 19 6 53 16 8 67 46 35 16 68 22 1 45 19 0 55 37 22 18 56 24 4 40 21...

Page 422: ...1 2 70 9 4 117 77 69 8 164 11 8 69 9 9 107 75 40 9 142 13 0 68 11 0 98 73 09 10 128 14 2 67 12 1 92 70 74 11 112 15 5 65 13 2 85 68 35 12 101 16 7 62 14 3 78 63 43 14 80 19 1 53 16 5 64 58 27 16 66 21...

Page 423: ...of Moment Limiter for more details 6 5 How to turn over the shield tunneling machine The way of turning over the shield tunneling machine is shown in Figure 6 17 to Figure 6 21 Step 1 Make the crane i...

Page 424: ...Appendix A s s e m b l y a n d D i s m a n t l i n g Operator s Manual for Crawler Crane A0 B0 C0 B H G A L L1 L4 7 6 5 4 1 2 3 Figure 6 17 Turn over the shield tunneling machine 6 28...

Page 425: ...winch 2 main load hook 6 and auxiliary load hook 7 is lifted slowly at the same speed shield tunneling machine is lifted horizontally until the distance between the bottom of shield tunneling machine...

Page 426: ...l up hoisting winch 1 and reel off hoisting winch 2 main load hook 6 is lifted slowly and auxiliary load hook 7 is lowered slowly at the same speed The chain 4 of wire rope slides on the pulley 5 Keep...

Page 427: ...e shield tunneling machine Step 4 Stop the lifting motion of main load hook 6 lower the auxiliary load hook 7 slowly and make chain of wire rope slide in pulley 5 until the points A and B of shield tu...

Page 428: ...Appendix A s s e m b l y a n d D i s m a n t l i n g Operator s Manual for Crawler Crane A B C A C B 7 4 5 6 7 6 5 4 Figure 6 21 Turn over the shield tunneling machine 6 32...

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