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Foreword

Thanks very much for trusting ZOOMLION brand and purchasing ZOOMLION truck
crane.

These operating instructions are intended to put you in a position to operate the crane
safely and correctly and utilize the reliable usage options that it provides. We should
adhere to the operating instructions during operation and maintenance.

The accidents occurring during the crane operation are mostly caused by ignoring the
precautionary measures and safety regulations. Therefore, do take enough steps in
earnest to avoid such accidents. Incorrect operation, service and maintenance are all
dangerous and might cause life-threatening hazards. Therefore, do read, understand
and master the precautionary measures and notes prior to operating the crane.
Operations, checks and maintenance must be carried out carefully. The operator’s
motto must always be Safety first!

Warning

a) Only operate or maintain the crane if you have read, understand and
mastered the operating instructions;
b) Incorrect operation, service and maintenance are all dangerous and might
cause life-threatening hazards;
c) Always keep these operating instructions handy in the operator's cab. The
operating instructions belong with the crane!

The contents concerning about safety are marked with " “.


The following terms that are used in these operating instructions "Danger", "Warning",
and "Caution" are intended to point out certain important rules of conduct to all persons
who work with the crane. The meanings of the terms are as follows:

Danger

The term "Danger" is used to provide a warning about life-threatening hazards, serious
damage to property.

Warning

The term "Warning" is used to provide a warning about potentially serious personal
injury or damage to property.

Caution

The term "Caution" is used to provide a warning about potential minor or medium
personal injury, or damage to machinery or parts.

In order to avoid any mechanical damage or personal injury, the user should operate the
I
crane carefully and read these operating instructions constantly until he fully understands
and masters them. If you adopt the methods not included in these operating instructions,
the necessary measures should be taken to ensure safety.

If you transfer the ownership of this crane, the operating instructions should be given to
the new users.

If there are any questions, please contact with sales department of our company.

If these operating instructions are lost or damaged, please contact with sales department
of our company.

Note

Our product and technical documents are subject to technical improvements and
changes without notice. Therefore, please acquaint yourself with our latest
technology information. These operating instructions have been translated to be
best of one’s knowledge. Zoomlion assumes no liability for translation errors.
The Chinese version of the operating instructions is solely applicable for factual
accuracy. If you find any errors or if any misunderstandings arise when reading
these operating instructions, please contact Zoomlion immediately.

II
QY30V532.4T/20Y

Contents

Foreword ............................................................................................................................ 1

Chapter 1 Description of crane

1.1 Model and name plate ............................................................................................ 01-1


1.2 Main components and configurations ..................................................................... 01-4
1.2.1 Main components ....................................................................................... 01-4
1.2.2 Product description ..................................................................................... 01-6
1.2.3 Boom .......................................................................................................... 01-8
1.3 Technical data ........................................................................................................ 01-9
1.3.1 Overall view ................................................................................................ 01-9
1.3.2 Technical data........................................................................................... 01-10
1.3.3 Noise vibration value ................................................................................... 01-12
1.3.4 Working parameters .................................................................................... 01-12
1.3.5 Hook............................................................................................................ 01-13
1.3.6 Rated lifting capacity tables......................................................................... 01-15
1.3.7 Lifting height chart .................................................................................... 01-22
1.3.8 Working areas .......................................................................................... 01-24

Chapter 2 Safety

2.1 Safety instructions and safety signs ....................................................................... 02-1


2.2 Crane operation planning ....................................................................................... 02-3
2.3 Break-in instructions ............................................................................................... 02-4
2.4 General safety technical guidelines ........................................................................ 02-5
2.4.1 Requirements for crane operator, rigger and signalman ............................. 02-5
2.4.2 Selecting an operating site ......................................................................... 02-7
2.4.3 Supporting the crane .................................................................................. 02-8
2.4.4 Working conditions ................................................................................... 02-10
2.4.5 Notes for safe operation ........................................................................... 02-11
2.5 Hand signals......................................................................................................... 02-14

Chapter 3 Operation – crane chassis

3.1 Driver’s cab ............................................................................................................ 03-1


3.1.1 Overview .................................................................................................... 03-1
3.1.2 Steering wheel assy. ................................................................................... 03-3
3.1.3 Instrument panel and display unit ............................................................... 03-6

I
QY30V532.4T/20Y

3.1.4 Air horn switch.......................................................................................... 03-13


3.1.5 Engine control pedal ................................................................................ 03-13
3.1.6 Service brake pedal ................................................................................. 03-13
3.1.7 Clutch pedal ............................................................................................. 03-14
3.1.8 Center console ......................................................................................... 03-14
3.1.9 Crane lighting ........................................................................................... 03-21
3.1.10 Door – driver’s cab ................................................................................. 03-22
3.1.11 Seats in driver’s cab ............................................................................... 03-23
3.1.12 Attachments ........................................................................................... 03-24
3.2 Before starting up the vehicle ............................................................................... 03-25
3.2.1 Prerequisites ............................................................................................ 03-25
3.2.2 General checks before setting off............................................................. 03-25
3.2.3 Checks before setting off ......................................................................... 03-26
3.3 Driving the crane .................................................................................................. 03-26
3.3.1 Starting and stopping the engine .............................................................. 03-26
3.3.2 Transmission and clutch operation ........................................................... 03-28
3.3.3 Steering operation .................................................................................... 03-30
3.3.4 Brake operation ........................................................................................ 03-31
3.3.5 PTO operation .......................................................................................... 03-33
3.3.6 Towing ...................................................................................................... 03-34
3.4 Points for attention ............................................................................................... 03-35
3.4.1 Normal driving .......................................................................................... 03-35
3.4.2 Off-road driving ........................................................................................ 03-36
3.4.3 Parking ..................................................................................................... 03-36
3.4.4 Points for attention when vehicle breaks down ........................................ 03-36

Chapter 4 Operation – crane superstructure

4.1 Operator’s cab ....................................................................................................... 04-1


4.1.1 Overview .................................................................................................... 04-1
4.1.2 Instrument console ..................................................................................... 04-2
4.1.3 Joysticks .................................................................................................. 04-10
4.1.4 Engine control pedal ................................................................................ 04-13
4.1.5 Operator’s seat ........................................................................................ 04-13
4.2 Computer system ................................................................................................. 04-14
4.3 Starting up the crane ............................................................................................ 04-16
4.3.1 Checks before starting up....................................................................... 04-16

II
QY30V532.4T/20Y

4.3.2 Starting and stopping the engine ............................................................ 04-17


4.4 Safety devices ...................................................................................................... 04-18
4.4.1 Level gauge ............................................................................................ 04-18
4.4.2 Angle indicator ........................................................................................ 04-18
4.4.3 Hoisting limit switch ................................................................................ 04-18
4.4.4 Lowering limit switch ............................................................................... 04-20
4.4.5 Hydraulic safety devices ......................................................................... 04-21
4.4.6 Emergency off switch .............................................................................. 04-23
4.5 Crane operation .................................................................................................... 04-23
4.5.1 Preparations for crane operation ............................................................ 04-23
4.5.2 Outrigger - operation............................................................................... 04-24
4.5.3 Derricking .............................................................................................. 04-31
4.5.4 Telescoping ............................................................................................. 04-32
4.5.5 Lifting / lowering ...................................................................................... 04-34
4.5.6 Slewing ................................................................................................... 04-40
4.5.7 Simultaneous crane movements ............................................................. 04-42
4.5.8 Rope reeving .......................................................................................... 04-49

Chapter 5 Equipment

5.1 Safety technical guidelines ..................................................................................... 05-1


5.2 Jib ........................................................................................................................... 05-2
5.2.1 General ....................................................................................................... 05-2
5.2.2 Assembly .................................................................................................... 05-2
5.2.3 Angle settings ............................................................................................. 05-5
5.2.4 Removing ................................................................................................... 05-7
5.2.5 Reeving in the auxiliary hoist rope .............................................................. 05-7
5.2.6 Connection of hoisting limit switch .............................................................. 05-7
5.3 Rooster sheave ...................................................................................................... 05-8
5.3.1 Assembly ...................................................................................................... 05-8
5.3.2 Removing ..................................................................................................... 05-9

Chapter 6 Additional equipment

6.1 Air conditioning in driver’s cab ................................................................................ 06-1


6.1.1 Operating methods ....................................................................................... 06-1
6.2 Air conditioning in operator’s cab ........................................................................... 06-4
6.2.1 Air conditioning ............................................................................................. 06-4

III
QY30V532.4T/20Y

Chapter 7 Maintenance and service

7.1 After-sale service and maintenance ....................................................................... 07-1


7.2 Cleaning and service of the crane .......................................................................... 07-1
7.3 Oil and lubrication .................................................................................................. 07-2
7.3.1 Fuel and coolant selection ........................................................................ 07-2
7.3.2 Hydraulic oil .............................................................................................. 07-2
7.3.3 Gear oil ..................................................................................................... 07-5
7.3.4 Engine oil ................................................................................................. 07-7
7.3.5 Lubricating grease .................................................................................... 07-8
7.3.6 Lubricating points ..................................................................................... 07-8
7.4 Adjusting, cleaning and replacing parts ................................................................ 07-14
7.4.1 Tables for regular adjusting, cleaning and replacing parts ...................... 07-14
7.4.2 Wire rope ................................................................................................ 07-16
7.4.3 Replacing the hook................................................................................. 07-23
7.4.4 Replacing the oil return line filter cartridge ............................................. 07-23
7.4.5 Cleaning the diesel oil filter .................................................................... 07-25
7.4.6 Cleaning the air filter .............................................................................. 07-26
7.4.7 Cleaning the cooling system................................................................... 07-27
7.4.8 Deaerate air from clutch brake fluid........................................................ 07-28
7.4.9 Battery maintenance and service ........................................................... 07-28
7.4.10 Tires / wheels ....................................................................................... 07-29

Chapter 8 Crane inspections

8.1 Inspection of a new crane ...................................................................................... 08-1


8.2 Re-inspections ....................................................................................................... 08-3
8.2.1 General .................................................................................................... 08-3
8.2.2 Inspection of steel bearing structures ....................................................... 08-4
8.3 Inspection during break-in period ........................................................................... 08-6
8.4 Periodic crane inspections ..................................................................................... 08-7
8.4.1 Inspecting the rim ..................................................................................... 08-7
8.4.2 Inspecting the brake system ..................................................................... 08-7
8.4.3 Inspecting the hoist and slewing mechanisms ......................................... 08-9
8.4.4 Inspecting the hook ................................................................................. 08-11
8.4.5 Inspecting the wire rope pulley ................................................................ 08-11
8.4.6 Inspecting the wire rope .......................................................................... 08-11
8.4.7 Inspecting the mounting of the load bearing parts .................................. 08-12

IV
QY30V532.4T/20Y

8.4.8 Inspecting the oil and fuel reservoirs ...................................................... 08-12


8.4.9 Inspecting the hydraulic system .............................................................. 08-12
8.4.10 Inspecting the electrical system ............................................................ 08-13
8.4.11 Inspecting the safety devices ................................................................ 08-15
8.5 Inspection interval ................................................................................................ 08-17
8.5.1 Inspection interval - chassis ................................................................... 08-17
8.5.2 Inspection interval - superstructure......................................................... 08-23

Chapter 9 Diagnostics

9.1 Diagnosis and troubleshooting ............................................................................... 09-1


9.2 Chassis, troubleshooting ........................................................................................ 09-1
9.2.1 Clutch ....................................................................................................... 09-2
9.2.2 Transmission ............................................................................................ 09-4
9.2.3 Propeller shaft........................................................................................... 09-8
9.2.4 Intermediate and rear axles ...................................................................... 09-9
9.2.5 Steering system ...................................................................................... 09-10
9.2.6 Brake system .......................................................................................... 09-14
9.2.7 Electrical system ..................................................................................... 09-15
9.2.8 PTO ........................................................................................................ 09-17
9.2.9 Tires ........................................................................................................ 09-18
9.3 Superstructure, troubleshooting ........................................................................... 09-20
9.3.1 Electrical system ..................................................................................... 09-20
9.3.2 Hydraulic pump ....................................................................................... 09-22
9.3.3 Outrigger ................................................................................................. 09-23
9.3.4 Slewing mechanism ................................................................................ 09-24
9.3.5 Derricking mechanism ............................................................................ 09-25
9.3.6 Telescoping mechanism ......................................................................... 09-26
9.3.7 Hoisting mechanism ............................................................................... 09-27

Chapter 10 Transportation and storage

10.1 Transportation and points for attention ................................................................. 10-1


10.2 Requirements for storage and relevant notes....................................................... 10-2

V
OPERATING INSTRUCTIONS FORR ZOOMLION ® TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 1 Description of crane


Description of crane

1.1 Model and name plate

1.1.1 Model

Model in engineering industry: QY30V

Chassis model: ZLJ5325

1.1.2 Name plate

For name plate of the crane, please refer to Fig. 01-01.

Fig. 01-01
For name plate of the chassis, please refer to Fig. 01-02.

Fig. 01-02

01-1
Description of crane

1.1.3 Name plate installation location

The name plates of crane and chassis are respectively installed on the left side of
operator’s cab and the right longitudinal beam of chassis frame. For their exact
installation locations, please refer to Fig. 01 – 03 and Fig. 01 – 04 respectively.

Crane name plate


Fig. 01-03

Chassis name plate VIN

Fig. 01-04

1.1.4 Vehicle identification number (VIN) and its location

The VIN of QY30V truck crane is L5E5H3D3××A××××××, and is stamped in the crane
name plate, chassis name plate and right longitudinal beam of chassis frame. For the
details, please refer to Fig. 01 – 04.

1.1.5 Engine model and its manufacturer

Engine model: QSC 260

Manufacturer: Cummins Co. Ltd.

1.1.6 Engine name plate and its locations

The engine name plate is installed on the left part of engine. The exact location is
shown in Fig. 01-05.
01-2
Description of crane

Note

The above details must always be presented when the user needs our service
work.

Engine name plate

Fig. 01-05

01-3
Description of crane

1.2 Main components and configurations

1.2.1 Main components

— Illustration of crane chassis

10

11
12

13

14

15

9 16
8
7
17
6

Fig. 01 – 06
1. Rear fixed outrigger 2. Toolbox 3. Rear axle

4. Intermediate axle 5. Front fixed outrigger 6. Guard rail

7. Front axle 8. Exhaust system 9. Clutch

10. Driver’s cab 11. Guard board 12. Engine hood

13. Air intake system 14. Platform 15. Propeller shaft

16. Chassis frame assy. 17. Spare tire

01-4
Description of crane

— Illustration of complete vehicle

6
5

1 7

10

11

12

13
15
14

Fig. 01 – 07

1. Jib 2. Main boom 3. Length sensor

4. Angle indicator 5. Auxiliary winch 6. Main winch

7. Fixed counterweight 8. Sliding beam 9. Operator’s cab

10. Slewing mechanism 11. Derricking mechanism 12. Auxiliary hook

13. The 5th outrigger 14. Special purpose chassis 15. Main hook

01-5
Description of crane

1.2.2 Product description

– Crane chassis

Driver's cab Low-mounted full-width cab made of steel, with instrument console
installed in the front, adjustable steering wheel, and hydraulic cushion
seat with upper backrest, hand-operated windows on the both sides, air
conditioning, heater and sun visor installed inside to provide comfortable
working environment for a driver.

Chassis Distortion-resistant and load-bearing box-shaped structure made of


frame high-strength steel.

Engine High-pressure common-rail electron jet diesel engine special for


construction machinery.

Clutch Dry pull type single-plate clutch.

Transmission 8-speed mechanical transmission with contrate gear output. Main and
auxiliary gearboxes are with a synchronizer.

Suspension Front axle with longitudinal leaf spring suspension; rear axle with leaf
spring + equalizer beam + thrust rod suspension, Bogie balance
suspension is applied.

Wheel Special wheel rim and inflated tires.

Steering Including integral circulating ball-type power steering gear, steering


system pump and steering drive mechanism.

Brake It consists of service brake (driving brake), parking brake (emergency


system brake) and auxiliary brake.

Service brake: dual-circuit compressed air brake acting on all wheel


hubs.

Parking brake: spring-loaded brake acting on wheel hubs for


intermediate and rear axles.

Auxiliary brake: engine exhaust brake.

Propeller
Styre Series propeller shaft assy., open drive, contrate gear connected.
shaft

01-6
Description of crane

– Crane superstructure

Operator’s Cab made of steel with adjustable seat with headrest, with instrument
cab console installed in the front, pilot control levers, windshield wiper and
washing system.

Main boom It consists of 1 basic boom and 4 telescopic sections made of low-alloy
and high-strength steel, providing the boom with good bending-resistance
telescoping capability. Built-in sliding block and sliding block compensation technology
mechanism applied improve the guidance capability and lifting capacity. The boom is
telescoped via two telescopic cylinders and simultaneous telescoping
mechanism.

Derricking 1 front-mounted derricking cylinder with balance valve.


mechanism

Hoist Consisting of hydraulic motor, winch reducer, hoisting limit switch, lowering
mechanism limit switch and hoist rope.

Slewing Consisting of hydraulic motor, slewing reducer and slewing ring.


mechanism

Hydraulic Open-type hydraulic proportional pilot control, proportional


system speed-regulating system. It is driven by quadruple gear pump.

Load Including mentor, pressure sensor, length sensor and angle sensor.
moment
limiter

01-7
Description of crane

1.2.3 Boom

Including main boom and jib.

Main boom includes 1 basic boom and 4 telescopic boom sections.

Main boom length: 10.6m - 40m

Jib length: 8 m

When the fully extended main boom is fitted with jib (3 offsets: 5°, 17°, 30°), the boom
length is 48 m (40m+8m)

Jib length: 8m

Max. main boom


length: 40m
Max. main boom
length: 40m

Min. main
boom length:
10.6m

Fig. 01 – 08

01-8
Description of crane

1.3 Technical data

1.3.1 Overall view (Unit: Metric mm)

Fig. 01-9-1

Fig. 01-9-2

Fig. 01-9-3
01-9
Description of crane

1.3.2 Technical parameters

Item Value Remarks

Max. rated lifting capacity kg 30000


Max. load moment of
kN.m 1132
basic boom
Max. load moment of
kN.m 588
Max. length main boom
Max. lifting height of basic
m 11.1
boom
Max. lifting height of Max. These parameters
m 40.5
length boom do not include
deflection of boom
Working Max. lifting height of jib m 48.5 and jib.
performance Max. hoist rope speed
m/min 120 Drum 4th layer
(main winch)
Max. hoist rope speed
m/min 100 Drum 2nd layer
(auxiliary winch)
Boom derricking up time s 40
Boom telescoping out
s 80
time
Slewing speed r/min 0 - 2.2

Operating grade A1 ISO4301-2

Max. driving speed km/h 72

Max. gradeability % 40

Min. turning diameter m ≤22

Min. ground clearance mm 220


Limits for exhaust Conform to related
Driving EU stageⅢ
pollutants and smoke standard
Oil consumption per
L 50
hundred kilometers
Approach / departure
° 20/13
angle

Braking distance m ≤10 Initial speed


30km/h
Deadweight in driving
kg 32000
condition
Complete vehicle kerb
kg 31870
Weight mass
Front axle load kg 7500

Rear axle load kg 24500

01-10
Description of crane

Item Value Remarks


Overall dimensions
mm 13000×2500×3810
(L×W×H)
Longitudinal distance
m 5.36
between outriggers
Completely extended:
Transversal distance 6.1 m;
m
between outriggers Intermediately
extended: 4.2 m
Main boom length m 10.6 - 40

Main boom angle ° -2 - 80

Dimensions Jib length m 8

Offset ° 5, 17, 30

Front / rear overhang mm 2355/2928

Number of axles 3

Wheel base mm 4525+1350

Front mm 2040
Treads
Rear mm 1830/1830

Tail slewing radius 3390

Model QSC 260


6-cylinder in line,
Type supercharging,
inter-cooling
Engine Fuel type Light diesel

Displacement ml 8300

Rated power / RPM kW/r/min 194/2200

Max. torque / RPM N.m/r/min 1180/1500

Model 8JS118TB-B
Mechanical stepped
Type
speed change
Mechanical manual
Operating method
operation
Transmission 8 forward and 1 reverse
Number of speeds
speeds
Forward speeds:
11.40/7.94/5.63/4.0
Speed ratio 6/2.81/1.96/1.39/1.0
0
Reverse speed: 11.35
01-11
Description of crane

Item Value Remarks

Steering type Steering wheel


Outer diameter of
mm 480
steering wheel
Steering column Universal coupling

Steering Model PY-ZJ120C-Z/Y


system Steering Integral circulating ball
gear Type hydraulic booster
steering gear
Model QC25/13-ISLE
Steering
pump Type Gear type

Driving type 6×4


Driving axle
Speed ratio 5.93

Number of leaf springs (front / rear) 12/10

Cab capacity 2

Fuel tank capacity L 250

Hydraulic tank capacity L 500

1.3.3 Noise vibration value

When the truck crane is in normal work condition, measured according to ISO2631-1,
the whole body vibration is A(1): 1.1m/s2, A(4): 0.5m/s2, A(8): 0.4m/s2

Measurement uncertainty: 0.5A

When measured according to EN 13000 Annex G and 2000/14/EC, the sound pressure
in the driver’s cab is 78dB(A), the sound power level is 107dB(A). Measured according
to ISO 7731, the sound pressure level of the warning device measured in the free field
at a distance of 1m from the sound source in the main direction of radiation is 96dB(A)

1.3.4 Working parameters

– Max. support strength per outrigger

When the crane is working within the rated lifting capacity, the max. support strength
per outrigger is 38 t.

01-12
Description of crane

– Rope specification and length


Standard
Specification Length (mm)
code
4V*39S+5FC-17.0-1870-
Main hoist rope GB8918-2006 175000
left-hand ordinary lay

Auxiliary hoist 4V*39S+5FC-17.0-1870-


GB 8918-2006 105000
rope left-hand ordinary lay

– Standard rope reevings for various boom lengths


Boom
10.6 - 14.3 14.3 - 18.0 18.0 - 29.0 29.0 - 40.0 40.0+8.0
length
Reeving 8 6 4 3 1

Caution

(1) If rope reevings are less than the value listed in the above tables during
lifting, load on single wire rope must be checked to make sure that it is no
more than the max. permissible lifting capacity of single wire rope.

(2) Max. permissible lifting capacity of single wire rope is 4000kg.

1.3.5 Hook

1.3.5.1 Main hook parameter

General information
Changsha Lanying Industry Co. Ltd,
Manufacturer
``Xuzhou Dachangshi Construction Machinery Co. Ltd
Ordering code QY30.30A
Form of hook Single hook
Boss for safety catch Yes
Lifting capacity, classification
Nominal lifting load LH = 30 [t]
Lifting load in acc. to (standard used) DIN 15400:1990
Strength class / grade P
Mechanism group (ISO 4301-1) M3
Dimensions
Standard of hook dimensions GB10051
Round screw thread
Type and standard of shank thread
GB10051.1-88
Information about manufacturing process and material
Manufacturing process Die forging
Material DG34CoMn
Miscellaneous
Marking (standard used) GB10051
Certificate (standard used) GB10051
Mass (weight) 340 [kg]

01-13
Description of crane

1.3.5.2 Auxiliary hook parameter

General information
Changsha Lanying Industry Co. Ltd,
Manufacturer
Xuzhou Dachangshi Construction Machinery Co. Ltd
Ordering code QY25.3Y
Form of hook Single hook
Boss for safety catch Yes
Lifting capacity, classification
Nominal lifting load LH = 3 [t]
Lifting load in acc. to (standard used) DIN 15400:1990
Strength class / grade P
Mechanism group (ISO 4301-1) M3
Dimensions
Standard of hook dimensions GB10051
Round screw thread
Type and standard of shank thread
GB10051.1-88
Information about manufacturing process and material
Manufacturing process Die forging
Material DG20Mn
Miscellaneous
Marking (standard used) GB10051
Certificate (standard used) GB10051
Mass (weight) 105 [kg]

01-14
Description of crane

1.3.6 Rated lifting capacity tables


Table 1 Unit: Metric kg

Main boom (m)


Working
radius Outriggers and telescopic cylinder I completely extended, over side and over
(m) rear
10.6 14.3 18.0 23.5 29.0 34.5 40.0
2.5 35000*
3.0 30000 27000 22000
3.5 30000 27000 22000
4.0 28000 26000 20000 16500
4.5 25000 24000 18500 15500
5.0 23000 22000 17000 14500
5.5 21000 20500 15600 13500 11500
6.0 18500 18500 14600 12500 10900
6.5 16500 16500 13700 11800 10300
7.0 14600 14400 12800 11000 9700 8200
7.5 13000 12800 11900 10400 9200 7900
8.0 11600 11400 11100 9700 8800 7600
9.0 9300 9100 8700 8000 7000 6300
10.0 7600 7450 7900 7200 6400 5600
11.0 6400 6250 6900 6600 5850 5200
12.0 5150 5850 6100 5400 4800
13.0 4300 4950 5350 5000 4500
14.0 3600 4250 4600 4600 4200
15.0 3650 4050 4300 4000
16.0 3100 3500 3700 3700
18.0 2300 2700 2950 2950
20.0 2050 2300 2300
22.0 1550 1800 1800
24.0 1150 1300 1400
26.0 900 1050
28.0 650 750
30.0 550
I 0 50% 100% 100% 100% 100% 100%
II 0 0 0 25% 50% 75% 100%
Reeving 8 6 6 4 4 3 3
Hook 30t hook

01-15
Description of crane

Table 2 Unit: Metric kg

Main boom (m)


Working
radius Outriggers completely and telescopic cylinder I intermediately extended,
(m) over side and over rear
10.6 14.3 19.8 24.8 30.2 35.6
2.5 35000*
3.0 30000 27000
3.5 30000 27000
4.0 28000 26000 16500
4.5 25000 24000 15500
5.0 23000 22000 14500 11500
5.5 21000 20500 14000 11500
6.0 18500 18500 13500 11500
6.5 16500 16500 12800 11500 8200
7.0 14600 14400 12000 11500 8200
7.5 13000 12800 11200 11500 8100
8.0 11600 11400 10700 11500 8000 6300
9.0 9300 9700 10000 7400 6300
10.0 7600 8500 8800 6700 5750
11.0 6400 7200 7500 6300 5300
12.0 6200 6300 5700 4900
13.0 5200 5600 5400 4600
14.0 4600 4900 5000 4250
15.0 3900 4250 4600 4000
16.0 3400 3700 4000 3700
18.0 2900 3000 3100
20.0 2200 2350 2500
22.0 1700 1800 1900
24.0 1400 1450
26.0 1050 1150
28.0 750 900
30.0 650
I 0 50% 50% 50% 50% 50%
II 0 0 25% 50% 75% 100%
Reeving 8 6 4 4 3 3
Hook 30t hook

01-16
Description of crane

Table 3 Unit: Metric kg

Main boom (m)


Working
radius Outriggers completely extended and telescopic cylinder I completely
(m) retracted, over side and over rear
10.6 16.1 21.6 27.1 32.0
2.5 35000*
3.0 30000 16500
3.5 30000 16500
4.0 28000 16500 11500
4.5 25000 16500 11500
5.0 23000 16500 11500
5.5 21000 16000 11500 8200
6.0 18500 15800 11500 8200
6.5 16500 15300 11500 8200
7.0 14600 15000 11500 7500
7.5 13000 13500 10800 7300 6300
8.0 11600 12000 10000 7000 6300
9.0 10000 9000 6300 5700
10.0 8500 8500 5800 5100
11.0 7200 7500 5200 4700
12.0 5200 6300 4900 4250
13.0 4600 5600 4500 4000
14.0 4900 4100 3700
15.0 4250 3800 3200
16.0 3700 3600 3000
18.0 2900 3100 2600
20.0 2500 2300
22.0 2000 2000
24.0 1600 1700
26.0 1300
28.0 1100
30.0
I 0 0 0 0 0
II 0 25% 50% 75% 100%
Reeving 8 6 4 3 3
Hook 30t hook

01-17
Description of crane

Table 4 Unit: Metric kg

Main boom (m)


Working
radius Outriggers intermediately and telescopic cylinder I completely extended, over
(m) side and over rear
10.6 14.3 18.0 23.5 29.0 34.5 40.0
3.0 30000 27000 21000
3.5 26000 26000 19000
4.0 23000 22000 18000 15000
4.5 18000 18000 16000 14000
5.0 16000 16000 15000 13000
5.5 13000 13000 12500 12000 10500
6.0 11000 11000 10500 11000 10000
6.5 9500 9000 9000 9500 9200
7.0 8200 8000 7500 8500 8600 8000
7.5 6800 6600 6500 7200 7500 7300
8.0 6200 4500 5500 6500 7000 7000
9.0 3500 4500 5000 5500 6000 6000
10.0 2800 3500 4000 4500 4800 5000
11.0 2500 3200 3600 4000 4200
12.0 2000 2500 3000 3300 3500
13.0 1500 2000 2500 2600 3000
14.0 1100 1700 2000 2300 2500
15.0 1300 1600 1800 2100
16.0 1000 1300 1600 1800
18.0 800 1100 1200
20.0 700 900
22.0 600
I 0 50% 100% 100% 100% 100% 100%
II 0 0 0 25% 50% 75% 100%
Reeving 8 6 6 4 4 3 3
Hook 30t hook

01-18
Description of crane

Table 5 Unit: Metric kg

Main boom (m)


Working
radius Outriggers and telescopic cylinder I intermediately extended, over side and
(m) over rear
10.6 14.3 19.8 25.3 30.8 36.3
3.0 30000 27000
3.5 26000 26000
4.0 23000 22000 16500
4.5 18000 18000 15500
5.0 16000 16000 14500 11500
5.5 13000 13000 13500 11500
6.0 11000 11000 11500 11500
6.5 9500 9000 10000 10500 8200
7.0 8200 8000 8500 9200 8200
7.5 6800 6600 7200 7600 7800
8.0 6200 4500 6500 7100 7400 6300
9.0 3500 5200 5700 6000 6000
10.0 2800 4200 4500 5000 5200
11.0 3500 3800 4100 4400
12.0 2700 3100 3500 3700
13.0 2300 2700 2900 3100
14.0 1900 2100 2500 2700
15.0 1500 1800 2100 2300
16.0 1200 1500 1800 1900
18.0 1000 1200 1400
20.0 700 850 1000
22.0 700
I 0 50% 50% 50% 50% 50%
II 0 0 25% 50% 75% 100%
Reeving 8 6 4 4 3 3
Hook 30t hook

01-19
Description of crane

Table 6 Unit: Metric kg

Main boom (m)


Working
radius Outriggers intermediately extended and telescopic cylinder I completely
(m) retracted, over side and over rear
10.6 16.1 21.6 27.1 32.6
3.0 30000 16500
3.5 26000 16500
4.0 23000 16500 11500
4.5 18000 16500 11500
5.0 16000 16500 11500
5.5 13000 13800 11500 8200
6.0 11000 11300 11500 8200
6.5 9500 10000 10300 8000
7.0 8200 8300 9000 7400
7.5 6800 7400 7800 7000 6300
8.0 6200 6500 6800 6700 6100
9.0 5000 5500 6000 5300
10.0 4000 4500 5000 4800
11.0 3600 3800 4200 4500
12.0 3000 3000 3500 3800
13.0 2500 2500 3000 3200
14.0 2200 2500 2800
15.0 1900 2100 2300
16.0 1600 1800 2000
18.0 1000 400 1500
20.0 900 1100
22.0 700 800
I 0 0 0 0 0
II 0 25% 50% 75% 100%
Reeving 8 6 4 3 3
Hook 30t hook

01-20
Description of crane

Table 7 Unit: Metric kg

Main boom (m) + jib (m)


Outriggers completely extended
Main
boom 39.2+8.0
angle
(°) 5° 17° 30°
over side and over over side and over
over side and over rear
rear rear
80 3000 2200 1600
78 2900 2150 1600
76 2800 2100 1500
74 2650 2000 1450
72 2450 1850 1400
70 2250 1750 1350
68 2100 1600 1300
66 1900 1500 1250
64 1650 1400 1200
62 1450 1250 1050
60 1200 1100 950
58 1000 900 800
56 850 750 650
54 700 600 500
52 570 520 470
50 430 410 400
Reeving 1
Hook 3t hook

Note

This crane is provided with several rated lifting capacity tables. The operator
should select proper rated lifting load referring to resp. lifting capacity tables
according to actual working conditions.

01-21
Description of crane

1.3.7 Lifting height chart

01-22
Description of crane

Caution
(1) All the working conditions referred above are with outriggers completely or
intermediately extended. It is forbidden to lift a load without outriggers
extended;

(2) Extend the 5th outrigger. The values given in the lifting capacity tables are
suitable for full range operation. Fully extend the outriggers (except the 5th
outrigger) according to table 4, 5, and 6 when the crane is working over front.

(3) The lifting capacity table indicates the maximum load which can be lifted by
this crane in different working conditions and with specified requirements,
namely the rated lifting capacity. The values as given in the tables include the
mass of the hook (main hook of 340 kg and auxiliary of 105 kg) and slings.

The actual lifting Mass of hook and slings


capacity of the +
Rated lifting capacity =
crane

(4) The working radius in the rated lifting capacity table refers to the level
distance from hook center to slewing center when crane lifts a load;

(5) If the actual boom length and working radius are between two adjacent
values given in the rated lifting capacity table, the bigger one should be
referred to;

For example:

If the crane is working with 16m long main boom and under 4.8m working
radius, the lifting capacity found out in the rated lifting capacity table of
bigger values – 18m long main boom and 5.0m working radius - should be
referred to. That is to say, the rated lifting capacity 17000kg should be
referred to.

(6) When the main boom is used with jib assembled, the mass of slings and
900kg should be subtracted from the rated lifting capacity.

(7) The maximum lifting capacity for the rooster sheave is 3000kg. If the rated

01-23
Description of crane

lifting capacity found out in the rated lifting capacity table is less than 3000kg
according to the actual working conditions, the lifting capacity found out in
the table should be referred to.

For example:

The rated lifting capacity is 3000kg only when the crane is working with 18m
long main boom and under 6.5m working radius;

The rated lifting capacity is 2050kg if the crane is working with 29m long main
boom and under 20m working radius;

(8) It is forbidden to lift a load with main hook and auxiliary hook together during
crane operation.

(9) All the working radius and lifting height in lifting height charts do not include
the deflection of main boom and jib.
(10) Mark * indicated in rated lifting capacity tables are the working condition,
namely, over rear with rope reeving 8, and special equipment should be
used.

Warning

If the main boom length is more than 30m, derrick the main boom according to
the lifting height chart, even if the crane is without load. Otherwise, the crane may
topple.

1.3.8 Working areas

Over front Over side and


over rear

01-24
OPERATING INSTRUCTIONS FORR ZOOMLION ® TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 2 Safety
Safety

2.1 Safety instructions and safety signs

2.1.1 Safety instructions

a) When driving the crane on road, all national and regional traffic regulations must be
observed;

b) No person is allowed to stay in operator’s cab during driving;

c) The crane must be made to comply with the relevant local traffic regulations, before
it is driven on public streets, roads and other places. The weights, axle loads and
dimensions specified in the permits must be maintained;

d) The relevant persons should be trained to ensure safety operation. Initial


commissioning and starting must only be undertaken by a competent person who
has read and fully understands the information provided in the operating
instructions;

e) Comply with the safety signs on the crane to avoid serious injuries or casualties;

f) All the assembly, commissioning, operation, maintenance and service of crane


should only be carried out by special personnel.

Danger

Do not allow the hook block to impair the driver’s field of vision when driving the
crane on public roads!

2.1.2 Safety signs

a) The locations of safety signs are as shown in Fig. 02-01;


b) Points for attention:

1) The signs for all the potential danger referred in the operating instructions
have been stuck on specified positions. Do not move the signs without
permission!

2) The safety signs on the potentially dangerous parts should be maintained


regularly. Once there is any fading or damage, modify or replace them
immediately to ensure the signs are clean, complete, correct and legible;

02-1
Caution:

02-2
First-aid Caution: Prohibited: Risk of Prohibited:
box Noise! No entry! falling. No entry! CE marking

Fire CE Speed No access for Prohibited: No Danger: Warning: Caution: Speed Danger:
extinguisher marking limit: unauthorized Naked access Crushing/ Swinging Noise! limit: Crushing/
75km/h personnel! flame! for this collision load. 75km/h collision
Safety

area.

Fig. 02-01
Safety

2.2 Planning crane operation

In addition to a perfectly working crane and a well-trained crew, crane operation


planning is an important principle of safe crane operation.

The crane operator must obtain or receive the necessary information in a timely fashion
before driving to the work site. In particular:

a) Natural environment of work site;

b) Work site and travel distance;

c) Route;

d) Height and width clearance measurements;

e) Electric transmission lines (including voltage);

f) Space restrictions at the work site;

g) Movement restrictions caused by buildings;

h) Weight and dimensions of the loads to be lifted and the required hoisting height
and boom projection;

i) Ground bearing capacity at the work site.

Based on the above information, the crane operator must assemble the equipment
required to operate the crane:

1) Load hook/hook block;

2) Load handling device;

3) Jib;

4) Underlay materials for outrigger pads.

Warning

Crane operation may not be possible or improvisation can result if a crane


operator does not have all the required data.

02-3
Safety

2.3 Break-in instructions

The purpose of breaking-in is to adjust and improve the adaptability to environment of


vehicle. The break-in at the initial stage of use will make important effect on the service
life, working reliability and energy-saving performance. Pay attention to the following
items during the break-in period:

a) During the first 100h, the working load should not be too great and working speed
should not be too high, the maximum lifting capacity should not exceed 80% of the
rated one and it is not permitted to work at maximum speed;

b) Within the first 600km mileage, it is forbidden to drive the vehicle at the highest
speed and ensure the driving speed should not exceed 55km/h and the engine
RPM doesn’t exceed 1800rpm. Drive the vehicle on even road;

c) When the vehicle is driving for the first 600 – 1500km mileage, replace the engine
oil;

d) Within the first 600 – 2000km mileage, increase the driving speed or the engine
RPM gradually;

e) Do start and stop the vehicle slowly and gently. Shift the transmission frequently to
break in it at every gear position;

f) Breaking in the brake linings:

To achieve optimum braking performance, all new brake linings must be broken in
by activating the brakes. Activate the brakes by pumping them at low to high speed.
Hard braking is not permitted. In general, the break-in distance depends on the
type of vehicle, but a minimum of 500km is recommended. During this phase, the
maximum brake drum or braking lining temperature may not exceed 2000C.

Danger

Hard braking and continuous braking are not permitted!

2.4 General safety technical guidelines

2.4.1 Requirements of the crane operator, rigger and signalman

The primary responsibility of crane operator, rigger and signalman is to control, operate,
adjust the crane and conduct the operation in a manner that is safe for both themselves
and others. The main operating errors, which are made again and again while operating
or driving a crane, are as follows:

a) Slewing too quickly;

b) Quick braking of the load;

c) Diagonal pulling when the load is still on the ground;

d) Loose wire rope formation;

e) Overloading;
02-4
Safety

f) Crashing into bridges, roofs or high voltage wiring due to insufficient vertical
clearance;

g) Unsuitable operation when lift a load with several cranes at the same time.

About 20% of accidents are caused by improper maintenance:

a) Insufficient lubricating oil, lubricating grease or antifreeze;

b) Broken wire rope, worn parts;

c) Limit switch or load moment limiter not operating properly;


d) Brake or transmission failure;

e) Hydraulic defects (for example: cracked hoses);

f) Loose bolts.

Danger

In the interest of both yourself and others, make sure you understand how your
crane operates and familiarize yourself with all the risks associated with the work
to be done.

— General qualifications for operator


a) The person who has been trained with the safety knowledge about the crane
operation;

b) Healthy and agile;

c) Eyesight (remedied eyesight included) is above 0.7, no color blindness;

d) Hearing is qualified;

e) Know about the possible fatalness existing in the working area;

f) The ability to estimate and monitor load is enough;

g) Be able to estimate and monitor the distance, height, clearance and load correctly;

h) The operator must be familiar with the operating instructions for the crane, and
know the working principle, structural performance and the safety devices’ function
and adjusting method, as well as master the operation essentials and maintenance
skills;

i) Crane operator and signalman should be familiar with safety rules, safety signals
and symbols;

j) Be qualified with the work in hearing, eyesight and reaction ability; have the
requisite physical to operate the crane safely;

k) Know how to administer first aid and know how to use a fire extinguisher; know
how to survive in an emergency.
Make sure that only the personnel who are qualified and authorized are allowed to
operate the crane.
02-5
Safety

Danger

(1) Operator should check brakes, hook block, wire rope and safety devices
before operation. Any irregularities detected during inspection should be
removed immediately;

(2) The operator must focus his attention on his work during operation and is
forbidden to chat with others. Generally speaking, operator can only follow
the signal sent out by appointed persons. However, for a stop signal, the
operator should obey it at all times, no matter who send it out. He should
refuse to follow signal which violates operation regulations. Stop the crane
immediately if somebody is found climbing the crane;

(3) Operator who is in low spirits or poor health is not allowed to operate the
crane. Prohibit drinking and driving.
— General qualifications for rigger
During operation of the machine, the rigger is responsible for ensuring that the load is
slung or released safely and carefully and decides which hook and load handling device
to be used in accordance with work plan. Rigger is also responsible for the safety of the
crane.

Qualifications for rigger:

a) With crane operation certificate;

b) Be qualified with the work in hearing, eyesight and reaction ability;

c) Be able to estimate and monitor the distance, height, clearance and load correctly;

d) Have been trained in the skill of handling load;

e) Be able to choose the proper hook and load handling device according to
conditions of the load;

f) Have been trained in hand signals for operation and is familiar to use them;

g) Be able to safely use audio equipment (such as interphone) to send out oral order
exactly and clearly;

h) Make sure that only authorized personnel are allowed to carry out work.

— General qualifications for signalman

The signalman is to transfer signal from the rigger to operator. He can substitute for the
rigger to do conducting and hanging work, but such work can only be done by one
person at any time.

Qualifications for signalman:

a) Be qualified with the work in hearing, eyesight and reaction ability;

b) Be able to estimate the distance, height and clearance correctly;

c) Have been trained in hand signals for operating and is familiar to use them;

02-6
Safety

d) Be able to safely use audio equipment (such as interphone) to send out oral order
exactly and clearly;

e) Make sure that only authorized personnel are allowed to carry out work.

2.4.2 Selecting an operating site

It is very important to choose an appropriate location for crane operation in order to


minimize safety risks. When selecting the placement location of the crane, observe the
following:

a) The operation of the crane can be carried out within the necessary radius (working
radius and counterweight slewing radius);

b) Support the crane and other things only on ground with sufficient load bearing
capacity;
c) The ground pressure should comply with the permitted and expected value under
the crane with a required lifting load.

— Slopes and ditches


The crane may not be set up too close to slopes or ditches. Maintain adequate safety
clearances in accordance with the type of soil. The formula for calculating the safety
clearance is as follows:

For non-cohesive and soft cohesive A2


ground: A1
A2=2T
T
For stiff or semi-solid cohesive ground:
A1=T
T refers to the depth of ditch.

Danger

If the safety distance can not be maintained, fill and level up the slope and ditch.
Otherwise the crane can topple over!

— Permissible ground pressure of outrigger


When the crane is supported with a load, the outriggers transmit significant forces to the
ground. In certain cases, a single outrigger has to transmit almost the entire weight of
the crane, plus the load weight, to the ground. The ground must be able to safely
absorb this pressure every time. If the outrigger pad area is inadequate, then it must be
supported from below according to the load bearing capacity of the ground. The
calculation of required support area is as follows:

Support area = crane support force / load bearing capacity of the ground.

02-7
Safety

Load bearing capacity


Soil type
(kg/cm2)

A Back-filled, naturally compacted ground 0-1

Natural, clearly undisturbed ground:

1. Mud, peat, marshy soil 0

2. Non-cohesive ground, sufficient compactly layered


soil
1.5
Fine to medium grained sand
2.0
Coarse-grained sand to gravel

3. Cohesive ground:
B
Sludgy 0
Soft 0.4
Firm 1.0
Semi-compact 2.0
Hard 4.0

4. Rock with few fissures, in healthy, unweathered


condition and in a favorable location:
15
In cohesive layer order
30
In massive or column-style shape
Artificially compacted ground:

1. Asphalt 5-15
C
2. Concrete
50-250
Concrete group B I
350-550
Concrete group B II

If there is any doubt about the load bearing capacity of the ground at the placement site,
soil tests should be carried out, for example with a penetrometer.

Caution

Only strong materials may be used for the outrigger pad bases such as properly
dimensioned wooden timbers. In order to ensure that pressure is evenly
distributed over the base surface, the outrigger pads must be positioned in the
center of the support base.

2.4.3 Supporting

a) Before operation, all the wheels must be away from the ground;

b) Before extending the vertical outriggers, extend the sliding beams to the specified
positions;

c) All the sliding beams must be extended according to the data in the rated lifting
capacity table and secured by pins;

d) Before operation, the crane must be leveled. Under any working conditions, the

02-8
Safety

inclination angle α of the crane can not be more than 0.6°. Refer to Fig. 02 – 02.

Fig. 02 – 02

Danger

If the crane is positioned at an incline, and if the boom is turned towards the
slope, then the radius is increased as a result. It is possible that the crane can
topple over in extreme cases.

After the crane is supported, check the following safety measures:

a) The placement location has been selected in such a way that the crane can be
operated with the least possible radius;

b) The load bearing capacity of the ground is adequate;

c) There is sufficient distance to ditches and slopes;

d) All outriggers have been extended to the specified position;

e) The outriggers are secured with pins;

f) The outrigger pads are secured;

g) The crane has been leveled;

02-9
Safety

h) All tires do not touch the ground;

i) It has been ensured that there are no live electrical wires within the working range
of the crane;

j) There are no obstacles which will hinder the required crane movements.

2.4.4 Working conditions

a) Pay attention to the ambient temperature in the work site. The suitable temperature
range is -20℃ – +40℃;

b) If wind speeds are expected which are larger than the maximum permissible wind
speeds (grade 6) for the crane operation or thunderbolt bursts, the boom must be
retracted and taken down.

Danger

Operate the crane according to the above instructions, otherwise accidents may
occur!

With the following table, the wind force and wind speed can be estimated correctly:

Wind force Wind speed


Effect of the wind on the land
Beaufort Description m/s km/h

0 Calm 0 - 0.2 0 - 0.7 No wind, smoke rises vertically


Wind direction shown by smoke drift
1 Light air 0.4 - 1.4 1-5
but not by wind vanes
Wind felt on face, leaves rustle, vanes
2 Light breeze 1.6 - 3 6 - 11
moved by wind
Gentle Leaves and small twigs in constant
3 3.4 - 5.3 12 - 19
breeze motion, wind extends light flag
Moderate Raise dust, loose paper, small
4 5.5 - 7.8 20 - 28
breeze branches moved
Fresh Small trees in leaf begin to sway,
5 8 - 10.6 29 - 38
breeze crested wavelets on inland water
Large branches in motion; difficult to
6 Strong wind 10.8 - 13.7 39 - 49 use umbrellas, whistling heard in
telegraph wires
Whole trees in motion, difficult to walk
7 Near gale 13.9 - 17 50 - 61
against the wind
Breaks twigs off trees, impedes
8 Gale 17.2 - 20.6 62 - 74
progress
Slight structural damage (roof tiles
9 Strong gale 20.8 - 24.5 75 - 88
and chimney covers, etc. blown off)
Trees uprooted, considerable
10 Storm 24.7 - 28.3 89 - 102
damage occurs
c) Strong electromagnetic fields are likely to be present if the construction site is close
to a transmitter. Under this condition, be sure to consult a high frequency specialist
or contact with the local franchiser or the manufacturer.

02-10
Safety

Danger

Electromagnetic field can pose direct or indirect danger to persons,


equipment and objects, for example, effect on human organs due to radiation
and make spark or electric arc occur.

2.4.5 Points for attention for safe operation

a) No person is allowed to stand b) No person is allowed to stand on


under the boom during slewing table;
operation;

c) Never carry people on the load d) Never allow people to stand


or on lifting equipment; beneath swaying loads;

e) Prohibit lifting a load without f) Prohibit overloading;


outriggers extended;

g) The inclination angle α of the h) Do not pull load at an angle and


crane can not be more than 0.6° it is forbidden to lift staggered
during operation; load;

02-11
Safety

i) Prohibit lifting load buried in j) The operator is not permitted to


ground or frozen on the ground; leave the operator’s cab when
the load is suspended in the air;

k) It is forbidden to telescope the l) It is forbidden to drive with a


boom with a load; load;

m) When working in the vicinity of


power cables, a sufficient safety
clearance must be maintained if
the power is not cut off or the
hazardous area is not covered or
fenced off;

n) No standing within slewing radius;

02-12
Safety

o) Stop the crane in an emergency;

p) Never adjust the brake of hoist mechanism during lifting a load;

q) Under any conditions, wire rope on the winding drum is not allowed to be less than
3 windings;

r) Before crane operation, adjust the slings (rope or chain) to make the hook block on
the upright position of load gravity center;

s) Prevent the load or lifting equipment from collision with crane;

t) If it is thundering and lightening during operation, crane operation must be ceased.


Telescope the boom in and bring it into a safe condition. Take thunder protection
measures to ensure safety;

u) When starting and stopping the crane operation, ensure the movable parts and
movable load in danger zone will not interrupt any persons and objects;

v) When the actual lifting load reaches 90% of the rated one, the warning light will
light up and the buzzer will sound the alarm. At the time, much attention should be
paid to the operation;

w) The operation should be stable and gentle. Do not carry out any jerky movements
with the joysticks; avoid any sudden acceleration or braking or conversion
operation.

Danger

Stop working if one of the following instances occurs:

(1) The crane is overloaded or the load weight is uncertain;

(2) The load may fall off because it is secured or hanged loosely or unevenly;

(3) There is no lining pad between the edges of load and wire rope;

(4) The lighting in the work site is dim and the load or the signal can not be seen
very clear;

(5) There is defect or damage of structure and components which will impair the
safety of the crane, such as failure of brake and safety devices or damage of
wire rope.

02-13
Safety

2.5 Hand signals

a) Start b) Use main winch


Hold the right arm stretched Tap fist on head; then use
vertically upwards. The palm regular signal.
faces forwards.

c) Use auxiliary winch d) Lift the load

Tap elbow with one hand; then With forearm vertical, extended
use regular signal. fingers pointing up, move hand
in small horizontal circle.

e) Lower the load f) Lift the load slowly


With arm extended downward With forearm vertical, palm of the
with a 30° angle to the body, hand facing upwards, wave hand
forefinger pointing down, move up repeatedly.
hand in small horizontal circle.

02-14
Safety

g) Rotate

Turn left: With right forearm vertical, the palm of the hand facing outwards, lower
the forearm sideways horizontally, fingers pointing in the direction of rotation.
Turn right: With left forearm vertical, the palm of the hand facing outwards, lower
the forearm sideways horizontally, fingers pointing in the direction of rotation.

h) Lower the load slowly

With arm extended downwards with a 30° angle to the body, palm of the hand
facing downwards, wave hand down repeatedly.

02-15
Safety

i) Rotate slowly

Turn left: With right forearm vertical, the palm of the hand facing outwards, move
forearm horizontally and repeatedly, fingers pointing in the direction of rotation.

Turn right: With left forearm vertical, the palm of the hand facing outwards, move
forearm horizontally and repeatedly, fingers pointing in the direction of rotation.

j) Indicate load lowering position k) Raise boom

Extend the fingers to point at the Arm extended, finger closed,


position the load should fall on. thumb pointing upward.

l) Lower boom m) Raise boom slowly

Arm extended, finger closed, Forearm extends in front of body


thumb pointing downward. with palm facing downwards,
another hand moves up and
down with thumb pointing
upwards.

02-16
Safety

n) Lower boom slowly o) Extend boom


Forearm extends in front of body Both fists in front of body with
with palm facing upwards, thumbs pointing outwards.
another hand moves up and
down with thumb pointing
downwards.

p) Retract boom q) Stop

Both fists in front of body with Arm extended, palm down, and
thumbs pointing toward each move the arm back and forth
other. horizontally.

02-17
Safety

r) Emergency stop s) End a movement


Both arms extended, palms Cross your hands in front of your
down, move arms back and forth forehead.
horizontally.

02-18
中联
OPERATING INSTRUCTIONS FORR ZOOMLION
汽车起重机使用说明书
® TRUCK CRANE

Chapter 3 Operation – crane chassis


Operation – crane chassis

3.1 Driver’s cab

3.1.1 Overview

Fig. 03-01

1. Rotating beacon(optional)

2. Wire rope holder

3. Handrail

4. Key hole

5. Door handle

6. Mirrors (R)
7. Side turn signal

8. Front fog light

9. High/low beam

10. Front windshield wiper

11. Mirrors (L)

12. Corner marker light

Note
The rotating beacon is optional.

03-1
Operation – crane chassis

Fig. 03-02

1. Instrument console

2. Clutch oil reservoir

3. Steering wheel assembly

4. Air horn switch

5. Clutch pedal

6. Pedal – service brake


7. Pedal – engine control

8. Driver’s seat

9. Centre console

10. Co-driver’s seat

11. Fuse box

12. Tool box

13. Sun visor

03-2
Operation – crane chassis

3.1.2 Steering wheel assembly

Steering wheel assembly is composed of steering wheel, steering wheel adjustment


handle, left-hand and right-hand steering column switches, electric horn button and
ignition starter switch. See Fig.03-03.

Fig. 03-03
1. Ignition starter switch

2. Steering wheel adjustment handle

3. Steering wheel

4. Left-hand steering column switch

5. Electric horn button


6. Right-hand steering column switch
a) Steering wheel adjustment handle

The angle and height of the steering wheel can be adjusted to suit the driver.

Pull the adjustment handle upwards to adjust the height and angle of the steering
wheel.

Caution

(1) Risk of fatal injury if adjust the steering wheel while driving!

(2) Pull the handle downwards to lock the steering wheel after adjusting it.

b) Left-hand steering column switch


See Fig.03-04.

03-3
Operation – crane chassis

1
3
2

Fig.03-04

1) Activation of turn signal (left / right)

Jog steering column switch forwards (in direction 1): turn signal (right) is
activated;

Jog steering column switch backwards (in direction 2): turn signal (left) is
activated.

2) Switch between low beam and high beam and operate headlamp flasher

If there is a need to pass over the other vehicles, jog the switch upwards (in
direction 3), the high beam of the headlamp will light up simultaneously.

Jog the switch upwards and downwards continuously to operate headlamp


flasher.

Once the headlamp flasher is on, the headlamp will light up no matter what
working conditions the other lamps are in.

3) Activation of illumination

Rotate the end of the steering column switch to the position to activate
the front width lamp, rear width lamp, corner marker light, license plate lamp,
operating instrument lamp and low beam.
Rotate the end of the steering column switch to the position to activate
the high beam.
c) Right-hand steering column switch
See Fig.03-05.

03-4
Operation – crane chassis

1
4
3
2

Fig. 03 – 05

1) Activate windshield wiper

Rotate the end of this steering column switch to activate the windshield wiper.
The windshield wiper has 4 stages:

INT: Intermittent

LOW: Low speed

HI: High speed

OFF: Off

2) Activate windshield wiper washer system

Press the button (in position 4) on the end of this steering column switch. The
washer and wiper begin to work. They will not stop working until the button is
released.

Caution

If the washer continues working for 15 seconds or the liquid container is


empty, the wiper will stop its work. In sunny days, the wiper should be
used together with washer to avoid windshield being scraped. In cold
days, precautions should be taken to prevent the wiper from being
frozen on the windshield.

3) Activate exhaust brake

Jog the switch backwards (in direction 2) to activate exhaust brake; jog it
forwards (in direction 1) to deactivate the exhaust brake.

Caution

Depress the engine control pedal or clutch pedal can deactivate the
exhaust brake temporarily when exhaust brake is activated. However, the
exhaust brake will be activated automatically after releasing the engine
control pedal or clutch pedal. When the engine RPM is below 1200 rpm,
the exhaust brake will be deactivated automatically.

03-5
Operation – crane chassis

4) Activate parking signal

Jog the switch upwards (in direction 3) to activate the left and right turn signals
simultaneously, thus the parking signal is given. Repeat the operation again,
the switch will return to neutral position.

d) Electric horn button


It is in the central area of the steering wheel. Press either of the two buttons on the
left or right side of the central area to activate the electric horn.

e) Ignition starter switch

No electricity is supplied to the entire electrical system. The key can be


LOCK
plugged in and pulled out.

The battery begins to supply electricity and some of power consumers


ACC
can be switched on.

ON The entire electrical system is electrified.

The engine starts. When the key is released, it automatically returns to


S
position ON.

Caution

If the key is not in the position LOCK, it cannot be pulled out.

3.1.3 Instrument panel and display unit

- Dashboard assy.

Fig. 03-06

03-6
Operation – crane chassis

1. Tachometer

2. Coolant temperature gauge

3. Odometer

4. Axle pressure indicator


5. Engine oil pressure gauge
6. Fuel gauge

7. Voltmeter

- Instruments

a) Tachometer: b) Engine oil pressure gauge


Displays engine speed (RPM) Displays the engine oil
and its actual running time. pressure when the engine is
running.

c) Coolant temperature gauge d) Odometer:


Displays the coolant temperature Displays the vehicle speed and
of the engine. the total driving distance of the
vehicle.

e) Voltmeter f) Fuel gauge


Displays the voltage of generator Displays the fuel reserves.
during engine running and
displays the voltage of battery

03-7
Operation – crane chassis

without engine running.

g) Axle pressure indicator

The two pointers resp. display


the air pressure of air reservoirs
for front axles and intermediate /
rear axles.

- Display unit

Fig. 03 – 07
03-8
Operation – crane chassis

1 Control light Vehicle direction of travel left

2 Warning light Brake pressure too low

3 Warning light Charging monitoring

4 Warning light Engine coolant temperature too high

5 Control light High beam

6 Warning light Engine oil pressure too low

7 Control light Parking brake closed

8 Control light Longitudinal differential lock

9 Control light Transversal differential lock

10 Control light PTO activated

11 Warning light Door not closed well

12 Control light Exhaust brake

13 Control light Rear fog light

14 Control light Emergency steering (optional)

15 Control light Vehicle direction of travel right

16 Control light The 5th outrigger retracting completely (optional)

1 Control light 2 Warning light


Vehicle direction of turning left Brake pressure too low

Illuminates: Illuminates:

Vehicle is to turn left. Brake pressure is too low.

Extinguishes:

Brake pressure increases to


the specified value.

Caution

Do not drive the vehicle if


the warning light
illuminates!

03-9
Operation – crane chassis

3 Warning light Charging 4 Warning light


monitoring
Engine coolant temperature
Illuminates: too high
Ignition starter switch is in ON Illuminates:
position.
Engine coolant temperature is
Extinguishes after engine too high.
starts:
Check the coolant temperature
Engine begins to charge gauge and stop the vehicle to
battery. check the engine cooling
system.
Caution
Warning
If the warning light does not
extinguishes during engine Under this condition, do not
running, the generator stop the engine at once. Run
defects. Stop and check at the engine at idle speed for
once! several minutes. Otherwise,
the engine oil will be clung
to the engine inside because
the coolant temperature
suddenly decreases.

5 Control light High beam 6 Warning light


Illuminates: Engine oil pressure too low
High beam or headlamp flasher Illuminates:
is activated.
Ignition starter switch is in ON
position under normal

03-10
Operation – crane chassis

condition.

Extinguishes:

Engine starts.

Caution

If the warning light


illuminates during engine
running, the engine oil
pressure is too low or the
engine oil filter cartridge is
soiled. Immediately bring the
crane to a standstill and
rectify! Otherwise the engine
will be damaged seriously!

7 Control light Parking brake 8 Control light


closed
Longitudinal differential lock
Illuminates:
Illuminates:
Parking brake is active.
The transversal / longitudinal
Do not start the vehicle until the differential lock switch is
parking brake is released and switched on and the
the control light extinguishes. longitudinal differential is
locked.

9 Control light 10 Control light PTO activated

Transversal differential lock Illuminates:

03-11
Operation – crane chassis

Illuminates: The PTO is activated.


The transversal / longitudinal
differential lock switch is
switched on and the
transversal differential is
locked.

11 Warning light Door not closed 12 Control light


well
Illuminates:
Illuminates:
Exhaust brake active:
The door is not closed well.
Engine exhaust brake is ready
Warning for work or it is active.

Do not drive the vehicle


when the warning light
illuminates!

13 Control light Rear fog light 14 Control light Emergency


steering
Illuminates:
It serves as an option.
Rear fog light is on.
Illuminates:

The ignition starter switch is in


ON position.

Extinguishes:

The vehicle driving speed is

03-12
Operation – crane chassis

above 15 km/h.

Note

If the vehicle is not equipped


with emergency steering
system, the control light will
never illuminate.

15 Control light
Vehicle direction of turning right

Illuminates:

Vehicle is to turn right.

3.1.4 Air horn switch

It is located on the outside of clutch pedal and on the left side of driver.

Depressed: Air horn alarms.

Released: Air horn stops alarming

3.1.5 Engine control pedal

It is an electron pedal.

Depressed: the vehicle accelerates;

Released: the vehicle decelerates.

3.1.6 Foot pedal (M): Service brake

Depress the service brake to decelerate and stop the vehicle.

03-13
Operation – crane chassis

3.1.7 Foot pedal (L): Clutch

Depress the clutch pedal to disengage the clutch.

3.1.8 Center console

Fig. 03 – 08

1 Switches and warning lights

2 Media player

3 Control panel– A/C and heater

4 Range selector

5 Parking brake control lever

03-14
Operation – crane chassis

- Media player

Fig. 03 – 09

1 Display

2 Rotary switch for volume and functions adjustment

3 SD card slot

4 USB port

a) Button Power source b) Button

Changeover radio / SD / USB

POWER MODE

c) Button Band control d) Button Sound effect


selection

BND SEL

e) Button MUTE f) Button Time set

Press and release:

The time will be displayed;

Keep it pressed for 3s:

Buttons ▲ or ▼ can be used


to set time.

03-15
Operation – crane chassis

MUT DSP

g) Button h) Button

High-frequency scan (receive) / Low-frequency scan (receive) /


Skip next Skip previous

i) Preset button 1 (receive) j) Preset button 2 (receive)

Press and release: Press and release:

Play the first song; Play the second song.

Keep it pressed for a long


time:

Pause.

1 2 SCAN
k) Preset button 3 (receive) l) Preset button 4 (receive)

Press and release: Press and release:

Play the third song; Play the fourth song;

Keep it pressed for a long Press it pressed for a long


time: time:

Select the next file. Play at random.

3D 4 RDM
m) Preset button 5 (receive) n) Preset button 6 (receive)

Press and release: Press and release:

Play the fifth song; Play the sixth song;

Keep it pressed for a long Keep it pressed for a long


time: time:

Repeat. Select the next file.

5 RPT 6D

03-16
Operation – crane chassis

Note

Turn the ignition starter switch to "ACC" when using the player without
engine running.

- Range selector

The range selector is installed on the right-hand side of the driver.

Jog the selector leftwards, rightwards, forwards and backwards to select and
changeover the gear.

- Parking brake control lever

Always apply the parking brake when parking the vehicle.

If the service brake fails to operate owing to insufficient air pressure, the parking
brake can be used as an emergency brake.

Jog it backwards to activate the parking brake and emergency brake.

03-17
Operation – crane chassis

Switches and warning lights

Fig. 03 – 10

1 Button Engine off

2 Button Longitudinal and transversal differential locks

3 Button Front fog light

4 Button Rear fog light

5 Button Engine fault diagnosis

6 Warning light ABS error

7 Warning light Engine error code displayed

8 Warning light Engine coolant level too low

9 Warning light Engine defects

10 Control light Diesel engine preheating system

03-18
Operation – crane chassis

1 Button Engine off 2 Button

Keep it pressed for 2 – 3 Longitudinal and transversal


seconds: differential locks

The engine stops running. Pressed:

The longitudinal and


transversal differential locks
are activated.

Caution

Only when the vehicle is


stationary, can this button
be pressed.

3 Button Front fog light 4 Button Rear fog light

Pressed: Pressed:

The front fog light illuminates. The rear fog light lights up.

Note

Only when the high beam,


low beam or front fog light
lights up, can this button be
pressed.

5 Button Engine fault 6 Warning light ABS error

03-19
Operation – crane chassis

diagnosis

Pressed and released:

The “Warning light – engine


error code displayed” flashes
and error code of engine is
displayed if it illuminates all the
time.

7 Warning light 8 Warning light

Engine error code displayed Engine coolant level too low

Illuminates: Illuminates:

Engine defects. Rectify it right Engine coolant level in


away. expansion water tank is too
low.

Warning

Under this condition, add


coolant after it cools down.
Otherwise, the engine oil will
be clung to the engine inside
because the coolant
temperature suddenly
decreases.

9 Warning light Engine defects 10 Control light

The function of engine defect Diesel engine preheating


03-20
Operation – crane chassis

warning is not available, system


therefore the light always
Illuminates:
extinguishes.
Preheat the engine

3.1.9 Crane lighting

a) Front combination signals

Take the lights on the left as an example, the right lights are the same as the left
ones. For the details, refer to Fig. 03 – 11.

Fig. 03 – 11

1 Front low beam

2 Front turn signal

3 Front high beam

4 Front fog lamp

5 Front width lamp

6 Side turn signal

b) Interior illumination

03-21
Operation – crane chassis

The interior illumination is located


at the roof of the driver's cab,
including small lamp & its button
and door lamp & its button. The
direction of small lamp can be
adjusted by pressing its edge; the
small lamp button is a 2-handed
button.

The door lamp button is a


3-handed button:

Center position: off

Left and right positions: on


The door lamp will light up if any
door is open. If the doors are
closed well, the door lamp will go
out. In addition, the door lamp can
also be controlled manually.

3.1.10 Door – driver’s cab

a) Open the door from outside

Hold the handle and pull it


outwards.

b) Close the door

The door will be locked


automatically when the door is
closed.

Caution

Do not drive the vehicle if the doors are not properly closed and locked!

03-22
Operation – crane chassis

c) Open the door from inside

Pull the inside door switch


upwards and hold the handle to
push the door outwards.

d) Lock the door from inside

The locking knob is on the lower


edge of door window.

Press down the locking knob to


lock the door from inside.

Pull the locking knob upwards


before opening the door

Note

If the door is not closed well,


the locking knob cannot be
pressed down.

e) Lock the door from outside

Insert vehicle key into the key


hole. Turn it clockwise to lock the
door;
Turn it counterclockwise to unlock
the door.

3.1.11 Seats in driver's cab

a) Seat adjustment

03-23
Operation – crane chassis

This crane is equipped with


suspension seats, which can be
adjusted to suit any driver height
or size before setting off.

When adjusting the stiffness of the


seat, please set the red pointer
within the range from 40 kg to 130
kg.
1
1 Switch, adjust backrest
2
setting
3
2 Handle, adjust seat cushion 4
angle (rear section) 5
3 Handle, adjust seat cushion
angle (front section)

4 Rotary switch, adjust stiffness

5 Switch, adjust horizontal


setting

b) Seat belt adjustment

Adjust and fasten the three-point seat belt to suitable position before setting off.

Insert tongue piece into belt lacer to fasten the belt.

Press the button to unfasten the belt.

Caution

Risk of fatal injury if seat belt is not worn!

All occupants must be belted in before setting off in the crane and during
driving.

Wearing seat belts

- The belt must be tight against the body and not be distorted.

- With a three-point type belt, the shoulder section must be across centre of the
shoulder, not against the neck. The pelvis section should be as low as possible
across the pelvis, not across the abdomen.

- Seat belts only work properly when correctly tensioned.

3.1.12 Attachments

a) Sun visor

The sun visor is located above front windshield inside driver's cab.

03-24
Operation – crane chassis

Pull the sun visor downwards to shut out the sunlight.

Push the sun visor upwards to roll it up.

b) Toolbox

The toolbox is in the instrument console of the driver's cab, in which there are two
tool boxes. One is big and the other is small.

Press the switch to open the toolbox; press the cover to close it.

c) Cigarette lighter

Press the cigarette lighter and hold it in the position for 3 to 5 seconds, it will be
pulled out automatically. At this time, it can be used to light a cigarette. After using,
return it to the cigarette lighter hole.

Note

If the cigarette lighter needs to be used without engine running, you can turn
the ignition starter switch to ACC position.

3.2 Before starting up the vehicle

3.2.1 Prerequisites

a) If the crane is used for the first time, ensure there is no damage and abnormity;

b) The used light diesel oil and diesel oil should be suitable for the lowest ambient
temperature at working site. For the details, please refer to the Maintenance and
Service Manual for the QSC Series Diesel Engine.

3.2.2 General checks before setting off

a) Check the coolant level. Top up with coolant if required. Check fuel reserve at fuel
gauge in driver cab.

b) Check the parts in steering and brake systems for flexibility, safety and reliability.
Check the power steering fluid level and the clutch fluid level.

c) Check the following parts, such as the bolt for steering shaft universal joint, leaf
spring bolt, saddle clamp bolt and wheel bolt, for proper seating. And check the leaf
spring for crack;

d) Check the tire pressure (do not forget the spare wheel). Tires must be inflated to
the pressure specified for the tires mounted on the crane. The tire pressure should
be checked and corrected while the tires are cold. Check the tires, door locks,
windows and operating mechanisms for functional work;

e) Check the fittings of oil pipes, air pipes and water pipes for leakage and check
whether there is water in air reservoir;

f) Check the terminal post of battery for tight fit and check whether the electrolyte
level adheres to specified requirements;

03-25
Operation – crane chassis

g) Check the control light of air filter. If it is red, clean or replace the filter cartridge;

h) Place the ignition starter switch to position ON. Check the instruments, switches,
lighting, control lights and wipers for functional work and check the outside mirrors
for proper positions.

3.2.3 Checks before setting off

a) Check the following instruments for functions:

1) Engine oil pressure displayed in the pressure gauge should be above 0.1 MPa
when the engine is running at idle speed; it should be within 0.35 – 0.55 MPa
when the engine RPM is 1200 rpm;

2) The value shown in the axle pressure indicator should be above 0.55 MPa and
the warning light “Brake pressure too low” should be off. Otherwise, the air line
system cannot work normally, and thus affect driving safety;

3) The value displayed in the coolant temperature gauge should be above 60C
and the pointer should be within the green area.

b) Check whether PTO is disengaged;

c) Check whether the parking brake is released;

d) Start vehicle slowly with low gear. Never engage the clutch when engine is running
at excessively high speed (above 1600 rpm).

3.3 Driving the crane

3.3.1 Starting and stopping the engine

- Starting the engine

a) Checks:

1) Check engine oil level and check engine oil for clean;

2) Check the coolant level;

3) Check the fuel reserve.

b) Before starting the engine, ensure the following prerequisites are met:

1) Check whether range selector of the transmission is in neutral “N” position


and the parking brake has been applied;

2) Insert the ignition starter key into the key hole and turn it to stage 1;

3) Check whether the PTO switch is disengaged (at this time, the control
light “PTO activated” extinguishes);

4) In winter, the engine will preheat automatically, and at the same time, the
control light for diesel engine preheating system lights up;

5) After the control light for diesel engine preheating system extinguishes,

03-26
Operation – crane chassis

depress the engine control pedal softly and turn the ignition starter switch
to position S to start the engine.

Caution

(1) Turn the ignition starter switch to position S within 30 sec. after the
control light for diesel engine preheating system extinguishes;

(2) Never run the motor for more than 15 sec. continuously. The interval
between two attempts of starting must be at least 30 sec. to avoid
motor breaking down. If the engine can not be started for three
consecutive times, fix it right away.

Warning

In order to avoid inadvertently starting the vehicle, depress the clutch


pedal when starting the engine.
c) Preheat the engine and check instruments for functions:
Release the engine control pedal slowly and run the engine at idle speed for
several minutes to warm up the engine. At this time, check the instruments
and control lights for functions.

Caution

(1) In order to make the engine oil effectively distributed to each part of
engine and raise up water temperature to burn the fuel normally, it is
necessary to warm up the engine before starting.

(2) Avoid running the engine at high speed without a load during
warming up. Otherwise, the engine may be damaged and its service
life may be shortened;

(3) Do not run the engine at idle speed for a long time, which may
weaken engine performance;

(4) It is forbidden to run the engine at high speed with a heavy load
when the coolant temperature is below 60 ℃;

(5) The engine oil pressure should not be lower than 0.1MPa when the
engine runs at idle speed. With the engine being warmed up, the oil
pressure is going to be stable gradually.

Warning

Do not run the engine in a place where the combustible gas exists. The
gas may be inhaled into the engine through the air intake system to
make the engine speed up or overspeed, which may cause fire,
explosion and heavy wealth losses.

- Stopping the engine

03-27
Operation – crane chassis

a) Depress the service brake pedal slightly to decelerate the vehicle, at the same
time, shift down the transmission to gear 1;

b) When the engine decelerates to the low speed, depress the clutch pedal and
the service brake pedal at the same time to bring the vehicle to a standstill at
the specified location;

Caution

Except in an emergency, do not depress the service brake pedal jerkily!

c) Pull the parking brake control lever backwards to the locking position to park
the vehicle and then shift the transmission to neutral position;

d) Run the engine at idle speed for several minutes to cool down the engine;

e) Keep the engine off button pressed for 2 – 3 seconds until the engine stops
running;

f) Turn the ignition starter switch to position LOCK and pull the key out after the
engine is stopped about 30 sec.;

g) When the vehicle is stationary, the ignition starter switch cannot be set in
position ON or ACC for a long time, otherwise the battery will discharge;

h) When parking the vehicle on a slope, place wheel chocks before or behind the
wheels to avoid accident;

i) When parking the vehicle on the road at night, activate the hazard warning
light to avoid collision.

3.3.2 Transmission and clutch operation

- Transmission

a) Description

The crane is fitted with a main transmission and an auxiliary transmission. The
main transmission is mechanically controlled, and the auxiliary one is
pneumatically controlled.

The gearshift pressure should be more than 0.41 MPa.

For details, please refer to Fig. 03 – 12.

03-28
Operation – crane chassis

Fig. 03 – 12

b) Shifting gears

1) To avoid excessive and unnecessary clutch wear, always engage the first
gear when driving away. The high / low gear range changeover switch
should be changed into low gear range;

2) Always depress the clutch fully when shifting gears. And the range
selector should be shifted in position;

3) Both the high and low gear ranges have neutral position (i.e. gear 5 – 6 at
high gear range and gear 3 – 4 at low gear range).When parking the
vehicle, the range selector should be shifted in the neutral position of low
gear range;

4) When it is engaged into reverse gear, stop the vehicle firstly and then
change gear to avoid damaging the transmission. When engaging the
reverse gear, large force should be used to overcome resistance of the
reverse lock;

5) Do not skip gears when changing gears between low gear range and high
gear range. Otherwise, risk of serious damage to the synchronizer of
auxiliary transmission.

Warning

High / low gear range changeover switch must be used when


changing gear between gear 4 and 5.

6) When driving on a descending gradient, it is forbidden to shift gear


between high and low gear range;

7) When there is abnormal noise in the transmission or it is difficult to


operate the steering wheel, bring the vehicle to a standstill and rectify it at
once;

03-29
Operation – crane chassis

8) Inspect the lubricating grease level of transmission after stopping the


vehicle for several minutes.

Caution

The temperature of transmission should be between -40℃ – 120℃ during


continuous working.

When the temperature exceeds 120℃, the lubricating oil will be


decomposed and service life of transmission will be shortened.

c) Points for attention

Depress the clutch pedal when shifting gears. During downshifting, accelerate
at the neutral position to make the connecting parts have the same rotational
speed;

Warning

It is forbidden to slip when the range selector is in neutral position.

- Clutch operation
a) Description

In the drive system, clutch is a part directly connected with the engine. Its
function is to effectively engage or disengage its driving and driven parts under
driver’s operation.
b) Points for attention
1) During driving, never place the foot on clutch pedal if it is not used;

2) During downshifting, depress the service brake to decelerate the vehicle,


and then depress the clutch pedal properly to change into proper gear.

Caution

When shifting the gear during driving, depress the clutch pedal and
then release it rapidly, otherwise there is a risk of increasing clutch
abrasion.

3) Do not depress the clutch pedal as possible as you can except parking at
low speed.

Caution

Only when the compressed air pressure P is above 0.4 MPa, can the clutch
be completely disengaged.

3.3.3 Steering operation

Before steering, pay attention to the environment around and then decelerate the
vehicle:

03-30
Operation – crane chassis

a) The steering wheel can not be kept in its limit position for more than 5 seconds.
Otherwise, the steering gear may be damaged;

b) If the vehicle is steered insufficiently, do not jerkily depress the service brake pedal
or operate the steering wheel in the same direction continuously. The proper way is
to decelerate the vehicle gradually and adjust the steering wheel at the same time;

c) If the vehicle is steered too much, release the engine control pedal slowly or
depress the service brake pedal a little to decelerate the vehicle, and then adjust
the steering wheel in reverse direction as soon as possible;

Caution

In normal condition, the steering wheel should be adjusted gradually.

d) In sharp turning, decelerate the vehicle in time and shift into the low gear.

3.3.4 Brake operation

a) Description

The brake system consists of driving brake (service brake), exhaust brake and
emergency brake (parking brake). The emergency brake can also be selected to
park the vehicle in normal condition and on slopes.

b) Operation
1) Driving brake

There are several cases of braking. For details, please refer to the following
instructions:

- Normal brake during driving, release the engine control pedal ahead to
slow down the vehicle according to the actual road conditions (with regard
to the road surface, traffic, etc.), and then continuously or intermittently
depress the service brake to slow down stably or stop the vehicle.

- Slow brake after rapid brake: when there is an accident in front, depress
the service brake rapidly and then depress it again slowly. Release the
pedal slowly according to the distance away from the accident spot and
shift gear in accordance with the actual driving speed. At last, depress the
engine control pedal to drive at normal speed.

- Cadence brake: depress the service brake and release it. Repeat the
operation to decelerate the vehicle gradually. The operation should be
very gentle.

- Rapid brake: in a sudden emergency, release the engine control pedal


immediately and depress the service brake jerkily (sometimes apply the
parking brake at the same time) to bring the vehicle to a standstill as soon
as possible. As a result, the accident will be avoided.

03-31
Operation – crane chassis

Caution

If rapid brake is used frequently, the abrasion of tire, brake drum and
friction lining will be increased, and the service life of each part will
be shortened. Therefore, do not apply rapid brake except in an
emergency, especially in rainy days or on frozen road.

2) Exhaust brake

When vehicle is traveling on a long descending gradient, engine exhaust


brake is recommended. Under this condition, the vehicle decelerates via
engine instead of service brake. In this way, the driving safety can be improved,
and the braking performance decreasing and the brake failure, caused by
depressing service brake frequently to make brake drum overheat, can be
avoided.
Before applying exhaust brake, release the engine control pedal and jog the
right-hand steering column switch backwards, the exhaust brake is activated
and the control light for exhaust brake lights up.

Caution

Depressing the clutch pedal and engine control pedal at the same time
can deactivate the exhaust brake.

3) Emergency brake (parking brake)

If service brake fails or cannot be applied in time during driving, pull the
parking brake control lever backwards to the locking position to activate the
emergency brake. Push the control lever forwards to the unlocking position to
deactivate the emergency brake.

Caution

(1) Emergency brake (namely parking brake) can also be selected to


park the vehicle in normal condition and on slopes;

(2) Deactivate the emergency brake before driving.

c) Points for attention


1) After the engine control pedal is released during driving, do not step on the
brake pedal when there is no necessity to brake the vehicle;

2) Do not apply emergency brake when the vehicle is driving on the narrow,
frozen or muddy road or in a rainy / snowy day. Under the conditions, such as
crossing the railway, driving under the bridge, or driving on a road with pools of
water, or one side of the vehicle is driving on frozen or muddy road, avoid
applying the service brake as much as possible. Otherwise the vehicle may be
shut down suddenly;

3) After driving across a road with pools of water, depress the brake pedal for

03-32
Operation – crane chassis

several times to eliminate the water on the braking shoe so as to ensure the
brake performance;

4) Before driving on a long descending gradient, shift the range selector to


low-gear range. Under this condition, the driving speed is mainly controlled by
the traction resistance from the engine and with the assistance of exhaust
brake and service brake. Never make the vehicle roll away uncontrollably with
the transmission in neutral position;

5) When the parking brake is used as the auxiliary brake, never pull the hand
lever to its limit position. When parking the vehicle under any conditions, the
parking brake should be pulled back to the position, especially parking the
vehicle on a slope. Risk of fatal injury and accident!

3.3.5 PTO operation

- Engaging the PTO


See Fig. 03-13.

a) Open the shutoff gate valve of hydraulic reservoir to connect the hydraulic
reservoir and oil line;
b) Start the engine;

c) Check whether the value shown in pressure gauge is within the range of 0.6
MPa – 0.8 MPa after the engine runs stably;

d) Depress the clutch pedal;

e) Apply the parking brake and shift the range selector into the gear 4;

f) Pull up the PTO switch to engage the PTO, and then the PTO control light
lights up;

g) Release the clutch pedal slowly to make the crane ready to work.

a c d e f g

Fig. 03 – 13

- Disengaging the PTO

See Fig. 03-14.

a) Depress the clutch pedal;

b) Press the PTO switch to deactivate the PTO, and then the control light for PTO
extinguishes;

03-33
Operation – crane chassis

c) Shift the range selector into neutral position;

d) Release the clutch pedal slowly, and then the crane is in non-working state.

a b c d

Fig. 03 – 14
Caution

(1) Depress and release the clutch pedal slowly;

(2) If the PTO and the drive device for oil pump need repairing or replacing, put a
warning board on the ignition starter switch. Otherwise, risk of danger may
occur!

Warning

Do not place the range selector into other gears, meanwhile, apply the parking
brake when engaging the PTO.

3.3.6 Towing

There is a towing coupling at both the front and rear ends of the crane. The following
towing regulations must be adhered to:

a) Install strong towing rope onto the tow coupling at the front under the bumper. Start
slowly to avoid impact;

b) Engine of the towed vehicle must be started to ensure it can realize emergency
brake and steering operation. Otherwise it will be very dangerous;

Warning

If the engine does not work because of breakdown, it means the vehicle has
no braking force. At this time, the vehicle is not permitted to be towed.

c) Place the range selector in neutral position;

d) If the transmission breaks down, remove the propeller shaft;

e) If the differential gear or the rear axle is in malfunction, remove left and right half
shaft.

Caution

Exhaust brake system will be invalid if the propeller shaft or the half shaft is
removed.

03-34
Operation – crane chassis

3.4 Points for attention during operation

3.4.1 Points for attention during driving

a) Upshift or downshift gradually and do not skip shift;

b) During driving, if abnormal sound, smell, vibration or acceleration happens to the


vehicle, or the steering wheel and brake work abnormally, decelerate immediately
and stop the vehicle at a safe place for checks. If the cause of malfunction can not
be determined or the problem cannot be rectified, send the vehicle to the
specialized repair factory;

c) Once the warning lights light up, decelerate immediately and stop the vehicle at a
safe place for checks;

d) Pay attention to the display of instruments (including double-pointer barometer,


engine oil pressure gauge, water thermometer, etc.) to ensure they comply with the
requirements;

e) Before climbing an ascending gradient, downshift the transmission to reduce the


load on the engine and driving system;

f) Points for attention on descending gradient:

1) Check the brake system for functional work before driving on a descending
gradient;

2) When the vehicle is driven on a long descending gradient, engine exhaust


brake is recommended. Shift the range selector to the low-gear range to make
the exhaust brake work more efficiently;

3) Prevent the engine from overrunning. Overrunning of the engine refers to the
phenomenon that the engine driven by the wheel runs at the engine RPM
which exceeds its maximum permissible engine RPM.

Caution

(1) The engine is apt to be damaged due to overrunning;

(2) Downshift after decelerating. When downshifting from gear 4, the engine
RPM should be below 1500 rpm; when downshifting from gear 3, the
engine RPM should below 1200 rpm. Otherwise, overrunning may occur.

g) If oil shortage occurs during driving, air would enter into the fuel system. If the
engine still can not be started after adding the fuel, deaerate the fuel system.

Warning

It is forbidden to slip after engine shutdown.

03-35
Operation – crane chassis

3.4.2 Off-road driving

When it is difficult for the vehicle to drive in off-road condition or it falls into a quagmire,
the following measures should be taken:

a) Activate the transversal differential lock and longitudinal differential lock;

b) Shift the range selector to the low gear range and then engage the clutch slowly,
otherwise the service life of the crane will be shortened;

c) Run the engine at a RPM with maximum engine torque;

d) If the crane still cannot leave under this condition, tow it or place some rigid objects
such as woods or iron plates under the wheels.

3.4.3 Parking

a) When parking the vehicle on an ascending gradient or in a rainy / snowy day, keep
a long distance away from the front and rear vehicles;

b) After bringing the vehicle to a standstill, pull back the parking brake control lever to
locking position. If parking the vehicle on an ascending gradient, place wheel
chocks directly before and behind the wheels;

c) Shift the range selector to the neutral position of low gear range;

d) Gently depress the engine control pedal for 2 – 3 times before engine shutdown, so
as to ensure each part of engine can be lubricated completely. After that, run the
engine at idle speed for several minutes until the coolant temperature decreases.

Caution

When parking the vehicle on the road at night temporarily, activate the hazard
warning light.

3.4.4 Points for attention when vehicle breaks down

a) If the vehicle breaks down during driving, keep calm to make way for other vehicles
and decelerate gradually to park it in a safe area;

b) Activate the hazard warning light and place a triangle warning board behind the
vehicle to avoid collision;

c) If the brake is invalid due to failure of propeller shaft or rear axles, place wheel
chocks before and behind the wheels;

d) Pay attention to the road condition when rectifying the vehicle on the road in an
emergency.

If the operator can not repair the vehicle by himself, please contact the manufacturer or
specialized repair factory.

03-36
OPERATING INSTRUCTIONS FOR ZOOMLION
R
® TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 4 Operation – crane superstructure


Operation – crane superstructure

4.1 Operator’s cab

4.1.1 Overview

1 13

2
12

3 11

5 10

6
9
7
8

Fig. 04 – 01

1 Roof windshield wiper

2 Rated lifting capacity table

3 Right joystick

4 Right electrical control box

5 Front windshield wiper

6 Instrument console

7 Front air outlet


8 Deadman switch

9 Left electrical control box

10 Left joystick

11 Operator’s seat

12 Rear air outlet

13 Control panel for air conditioning and heater

04 - 1
Operation – crane superstructure

4.1.2 Instrument console

1 2 3 4

5 6 7

Fig. 04 – 02

1 Pilot pressure gauge

2 Pressure gauge, slewing hydraulic system

3 Load moment limiter

4 Cigarette lighter

5 Pressure gauge, main / auxiliary winch

6 Pressure gauge, derricking and telescoping hydraulic system

7 Control lights and switches

04-2
Operation – crane superstructure

2 4 14

1 15
3
5
13

7 12 16

6
18
9 10

17
8 11

Fig. 04 – 03

1 Control light Power source

2 Warning light The 5th outrigger pressure too high

3 Warning light Main / auxiliary winch approaching lower limit

4 Control light Telescopic cylinder I

5 Control light Telescopic cylinder II

6 Switch Working lights

7 Switch Set-up

8 Switch Engine off

9 Switch Working lights on boom head

10 Switch Oil cooler

11 Switch Front windshield wiper

12 Switch Front windshield washer system

13 Switch Pre-selection of telescope / auxiliary winch

14 Switch Bypassing “derrick up"

15 Switch Pre-selection of telescopic cylinder I / telescopic cylinder II

16 Cigarette lighter

17 Switch Emergency off

18 Ignition starter switch

04 - 3
Operation – crane superstructure

1 Control light Power source 2 Warning light


Illuminates: The 5th outrigger pressure too
high
The ignition starter switch is
turned to position I. Illuminates:

Pressure of the 5th outrigger


exceeds the maximum
permissible value.

3 Warning light 4 Control light


Main / auxiliary winch Telescopic cylinder I
approaching lower limit
Illuminates:
Illuminates:
Pre-selection of telescopic
Main / auxiliary winch cylinder I / telescopic cylinder II
approaches lower limit. switch is turned to position
.

5 Control light 6 Switch Working lights


Telescopic cylinder I Position 1:
Illuminates: Switch background lighting on;
Pre-selection of telescopic Position 2:
cylinder I / telescopic cylinder II
Switch background lighting,
switch is turned to position .
working lights on slewing table
and boom on.

04-4
Operation – crane superstructure

7 Switch Set-up

The switch can only be activated during assembling attachments or


maintenance.

Before activating the working mode “Set-up” under the working condition of
main boom, rooster sheave or jib and with the lifting capacity provided, the
following prerequisites must be fulfilled:

① The switch is pressed once;

② The joysticks are placed in Neutral position;

③ Load moment limiter sensor works normally;


④ 90% ≤ moment percentage < 110%;

⑤ Bypass switch for load moment limiter is not activated;

If 90% ≤ moment percentage ≤100%, all the movements output with delay. If
100% < moment percentage ≤ 110%, all the movements output with delay
(except the movement “derrick up”).

One of the following prerequisites must be met when deactivating set-up


working mode:

① Moment percentage > 110%;

② The joysticks return to Neutral position more than10 seconds;

③ The engine stops more than 10 seconds;

④ The sensor works abnormally;

⑤ The switch is pressed twice.

Before activating the working mode “Set-up” under the working condition of

04 - 5
Operation – crane superstructure

main boom or rooster sheave and no rated lifting capacity provided (when the
crane changeovers from on-road driving mode to operating mode or vice versa),
the following prerequisites must be met:

① The switch is pressed once;

② The joysticks are placed in Neutral position;

③ The load moment limiter sensor works normally;

④ Bypass switch for load moment limiter is not activated;

⑤ Main boom length ≤ 14 m;

⑥ Load calculated from the load moment limiter ≤ 1.0 ton.

When the set-up switch is activated, an icon "set-up" will be displayed on load
moment limiter, all the crane movements are at full speed.
When the set-up switch is deactivated, the following prerequisites must be met:

① The joysticks return to Neutral position for more than 10 seconds;

② The engine stops for more than 10 seconds;

③ The sensor works abnormally;

④ The switch is pressed twice;

⑤ Main boom length > 14 m;

⑥ Load calculated from the load moment limiter > 1.0 ton.

Before activating the working mode “Set-up” under the working conditions of jib
and no rated lifting capacity provided (for jib assembly and dismantling), the
following prerequisites must be fulfilled:

① Main boom length ≤ 11 m;

② The switch is pressed once;

③ The joysticks are placed in Neutral position;

④ The sensor works normally.

When the set-up switch is activated, an icon "set-up" will be displayed on load
moment limiter, all the crane movements are at full speed.

When the set-up switch is deactivated, the following prerequisites must be met:

① The joysticks return to Neutral position for more than 10 seconds;

② The engine stops for more than 10 seconds;

③ The sensor works abnormally;

④ The switch is pressed twice;

⑤ Main boom length > 11 m;

04-6
Operation – crane superstructure

⑥ The rated lifting capacities are provided;

⑦ The “Jib” working condition exits from the load moment limiter.

Warning

Never activate the switch during normal operation!

Otherwise, there will be life-threatening hazards or serious damages to


property.

8 Switch Engine off 9 Switch


Pressed on bottom for 1 to 2 Working lights on boom head
seconds:
Pressed on bottom:
Engine stops.
Working lights on boom head
Note are on.

This switch is invalid when


deadman switch is on.

10 Switch Oil cooler 11 Switch


Pressed on bottom: Front windshield wiper
The fan of oil cooler begins to Pressed on bottom:
work.
The front windshield wiper
begins to work.

04 - 7
Operation – crane superstructure

12 Switch 13 Switch Pre-selection of


telescope / auxiliary winch
Front windshield washer
system Left position:
Pressed on bottom: Telescope the boom.
Switch on the front windshield Right position:
washer system.
Spool up / reel off auxiliary
winch.

Warning

Never turn the switch to the


left or right position during
telescoping or when using
the auxiliary winch.

14 Switch Bypassing “derrick up"

If the “derrick up” crane movement is disabled, turn the switch to release the
limitation.

The following prerequisites must be met to ensure the switch is activated:

① Main boom angle ≤80°;

② Rated lifting capacity is provided;

③ 100%< moment percentage≤110%;

When the switch is activated, an icon "bypassing derrick up" will be displayed on
load moment limiter.

Note

04-8
Operation – crane superstructure

The switch would be invalid when one of the above prerequisites is not
met.

15 Switch 16 Cigarette lighter


Pre-selection of telescopic Press it for several seconds
cylinder I / telescopic cylinder II and pull it out to light a
cigarette.
Left position:

Telescope the telescopic boom


section 1 via telescopic
cylinder I.

Right position:

Telescope the telescopic boom


sections 2, 3 and 4 via
telescopic cylinder II.

17 Switch Emergency off

Pressed:

All superstructure movements


are cut off.

18 Ignition starter switch

With five switch positions, in clockwise direction

Positions P and O:

The ignition starter switch can be plugged in or plugged out.

Position I:

04 - 9
Operation – crane superstructure

Superstructure control system is energized.

Position II:

Standby.

Position III:

Engine starts.

After the engine has been started, release the key to let it return to the position I
automatically. Return key to position P or position O first if you want to restart
the engine.

Caution

The ignition starter switch can only be plugged out in position P or


position O.
O
P Ⅰ

4.1.3 Joysticks

Left joystick:

Spool auxiliary winch up, reel auxiliary winch off, telescope telescopic boom out,
telescope telescopic boom in, slew to the left and slew to the right.

Right joystick:

Spool main winch up, reel main winch off, derrick main boom up and derrick main boom
down.

For details, please refer to Fig. 04-04.

04-10
Operation – crane superstructure

Free swing button Free swing button

Left joystick Right joystick


Deadman
switch
Left control Right
box panel control box
assy. panel assy.

Left control box Right control box

Fig. 04 – 04

Both the left and right joysticks are fitted with free swing button and deadman switch,
see Fig. 04 – 04. Slewing table may slew unintentionally once the free swing button is
activated.

Left control box is installed with the following two switches:

1 Switch Bypassing “hoist 2 Switch Bypassing “hoist


up” down”
If the “hoist up” crane If the “hoist down” crane
movement is disabled, turn the movement is disabled, turn the
switch to release the limitation. switch to release the limitation.

The following prerequisites The following prerequisites


must be met when activating must be met when activating
the switch: the switch:
① Hoisting limit switch is ① Rated lifting capacity is not
triggered; provided;
② Set-up switch is activated; ② Set-up switch is activated;
③ Rated lifting capacity is not When the switch is activated,
provided; an icon "bypassing hoist down"
will be displayed on load
When the switch is activated,

04 - 11
Operation – crane superstructure

an icon "bypassing hoist up" moment limiter.


will be displayed on load
The switch is deactivated
moment limiter.
when one of the above
When the switch is prerequisites are not met.
deactivated, the following
prerequisites must be met:

① The switch returns to initial


position;

② Deacticate the set-up


switch;

③ Rated lifting capacity is


provided;

Warning

Never activate these two switches during normal operation!

Otherwise, there will be life-threatening hazards or serious damages to


property.

3 Bypass switch Load moment limiter

When switches bypassing “derrick up”, “hoist up” and “hoist down” are invalid,
activate this bypass switch to release the limitation; at this time, all the
movements output with delay and icon is displayed in load moment limiter.

The load moment limiter bypass switch is located near the main valve bracket.

The following prerequisites must be met when activating the switch:

① The joysticks are placed in Neutral position;

② The switch is switched on;

When the switch is deactivated, any of the following prerequisites must be met:

① The switch is switched off;

② The mode activating time > 30 minutes;

③ The engine stops running.

04-12
Operation – crane superstructure

Warning

Activate the deadman switch to obtain the superstructure pilot pressure


during normal operation.

And also deactivate the deadman switch when the operation is done.

Otherwise, there will be life-threatening hazards or serious damages to


property.

Warning

Never activate the switch during normal operation!

Otherwise, there will be life-threatening hazards or serious damages to


property.

Warning

Never press the free swing button when the load is lifted away from the
ground during normal operation!

Otherwise, there will be life-threatening hazards or serious damages to


property.

4.1.4 Engine control pedal

Depress the engine control pedal to accelerate slewing, derricking, telescoping and
hoisting movements.

4.1.5 Operator's seat

Horizontal seat Backrest


adjustment angle
hand levers adjustment
switch

Fig. 04 – 06

04 - 13
Operation – crane superstructure

4.2 Computer system

The load moment limiter is a computer system for controlling and monitoring mobile
cranes.

The load moment limiter calculates data from the pressure sensor, length sensors,
angle sensors and other monitoring devices to judge whether the crane is in safe
working conditions, and displays the basic parameters, such as boom length, boom
angle, working radius, rated lifting capacity etc., on the LCD.

The warning light lights up and buzzer sends out fast acoustic warning and all
dangerous crane movements are switched off if possible losses or dangerous situations
are detected by the load moment limiter. The working condition of truck crane is divided
into five working conditions via load moment limiter: normal working condition, “set-up”
working condition, bypassing “derrick up” working condition, bypassing “hoist up”
working condition, bypassing “hoist down” working condition and load moment limiter
bypass working condition.

4.2.1 Normal working condition

In normal working condition, if the actual load reaches 90% – 100% of the rated one,
the warning light lights up and buzzer sends out slow acoustic warning. At this time, the
operator should pay much attention to the operation.

If the actual load reaches 100% of the rated one, the warning light lights up and buzzer
sends out fast acoustic warning and all dangerous crane movements are switched off.

No icon is displayed in load moment limiter during normal working condition.

4.2.2 Set-up working condition

The following icon is displayed in load moment limiter during set-up working condition.

4.2.3 Bypassing “derrick up” working condition

The following icon is displayed in load moment limiter during bypassing “derrick up”
working condition.

4.2.4 Bypassing “hoist up” working condition

The following icon is displayed in load moment limiter during bypassing “hoist up”
working condition.

04-14
Operation – crane superstructure

4.2.5 Bypassing “hoist down” working condition

The following icon is displayed in load moment limiter during bypassing “hoist down”
working condition.

4.2.6 Load moment limiter bypass working condition

The following icon is displayed in load moment limiter during load moment limiter
bypass working condition.

Load moment limiter bypass working condition is activated for 30 minutes. A countdown
icon is displayed in load moment limiter. As a high-level bypass working condition, it
also activate the bypassing “derrick up”, bypassing “hoist up” and bypassing “ hoist
down” working conditions at the same time. And icons of these working conditions are
simultaneously displayed in load moment limiter.

In addition, the following icon is displayed in load moment limiter when load moment
limiter outputs retarding control.

The following icon is displayed in load moment limiter when the rated lifting capacity is
not provided.

Caution

The load moment limiter can prevent crane from toppling or boom destructed
and personnel death and injures, thus ensures safe operation of the crane.
However, do not rely entirely on the load moment limiter. If the rated lifting load
displayed on the load moment limiter is different from the one shown in the lifting
capacity table, refer to the lifting capacity table.

Caution

Setting the operating mode correctly is the vital factor for ensuring correct using
of this system and crane. Only the operator who is skillful at operating this crane
and system can set the operating mode. In normal situations, the operating mode
must be set in accordance with actual operating mode.

Warning

The load moment limiter should only be commissioned by technical personnel!


For details, please refer to Load Moment Limiter Operating Manual attached to the
crane.

04 - 15
Operation – crane superstructure

4.3 Starting up the crane

4.3.1 Checks before starting up

Ensure that the following prerequisites are met before starting up:

a) Checking the engine oil level

1) The machine has been leveled;

2) Pull out the dipstick and wipe off it;

3) Re-insert it into oil and pull out again;

4) The oil level must be between the Min. and Max. marks on the oil dipstick.

Warning

Danger of damaging the engine!


If the oil level has dropped below the Minimum mark, top up engine oil
until the oil level is between the Minimum and Maximum marks.

Top up engine oil and check again.

b) Checking oil level in the hydraulic reservoir

The oil level must be between the Min. and Max. marks on the oil dipstick. Open
the shutoff gate valve of hydraulic reservoir to connect oil tank and oil line.

Position of the shutoff gate valve is shown in Fig. 04 – 07. Operate the lever for
shutoff gate valve of hydraulic reservoir to connect hydraulic reservoir and oil line.

Fig. 04 – 07

c) Checking the fuel reserve

Check fuel reserve at fuel gauge in driver cab. Add it timely once it is not sufficient.

Caution

Deaerate the fuel system before adding fuel.

04-16
Operation – crane superstructure

If the fuel tank has been run dry, always deaerate the whole fuel system
before adding fuel.

Do not run the fuel tank dry!

d) Checking the coolant level

Add it timely once the coolant level is too low.

e) Checking general conditions of crane

1) Check lubricating conditions of each moving part of the crane. Add lubricating
oil or grease timely to ensure lubricating effect;

2) Check that the crane is properly supported on a level load-bearing surface,


and has been set up horizontally;

3) Check that the toothed ring of the slewing ring connection is clean;

4) Check that the front and rear parts of oil cooler and A/C radiator have been
cleaned and are free of blockage;

5) Ensure that there are no people or objects in the crane danger zone;

6) Make sure that the cable / rope drums and sensors are free of snow and ice;

7) Make sure that there are no loose parts on the superstructure (specially on the
telescopic boom);

8) Ensure that both the left and right joysticks in operator’s cab are in their neutral
positions before engaging the PTO;

9) Ensure that all the outrigger control levers are in their neutral positions;

10) Make sure that parking brake is applied.

4.3.2 Starting and stopping the engine

For the starting and stopping the engine in driver’s cab, please refer to the operating
instructions in Chapter 3 "Operation – crane chassis”.

Starting and stopping the engine in operator’s cab should be carried out in accordance
with the following operating instructions.

a) Stopping the engine

Press and hold the switch “Engine off” on the instrument panel for 1 to 2 seconds to
switch off the engine.

Press the switch “Emergency off” to switch off the engine in an emergency.

b) Starting the engine

The ignition starter switch on the instrument panel can be used to switch on the
engine if the following prerequisites are met:

1) PTO has been engaged;

04 - 17
Operation – crane superstructure

2) The transmission is in the required position.


If the switch “Emergency off” is activated in an emergency, turn the switch
clockwise to remove the limitation. At this time, turn the ignition starter switch
to start the engine. Otherwise, the ignition starter switch is invalid.

4.4 Safety devices

4.4.1 Level gauge

The level gauge, which is located near outrigger control mechanism, is attached to each
side of the vehicle for operating the outriggers to ensure the vehicle is level before
operation. After adjustment, bubbles in the level gauge should be in the exact center
position of the level gauge.

Caution

Check the level gauge for proper work. If not, adjust the nuts beneath the level
gauge.

4.4.2 Angle indicator

The angle indicator is installed on the lower rear part of the basic boom (on the right
side of the operator’s cab), see Fig. 04 – 08. The operator can observe it clearly in the
cab. Angle indicator, which can indicate the included angle between the main boom and
the horizontal plane, should be used in combination with rated lifting capacity tables and
lifting height charts.

Fig. 04 – 08

4.4.3 Hoisting limit switch

The hoisting limit switch is intended to prevent the hook block from colliding with the

04-18
Operation – crane superstructure

rope pulley. When the distance detected between the hook block and the pulley is less
than the safety one, the hoisting limit switch is triggered and the dangerous crane
movements “Spool up winches”, “Derrick main boom down” and “Telescope boom out”
are switched off automatically and acoustic warning will be sent. At this time, only the
crane movements “Reel off winches”, “Derrick main boom up” and “Telescope boom in”
can be switched on. See Fig. 04 – 09.

Hoisting
Hoisting limit
limit switch
switch weight
weight
Hoisting
limit
switch
weight
Dangerous operation
(Be switched off)
Bypassed (Return
to safe operation)

Fig. 04 – 09

Press the bypassing “hoist up” switch on the left control box to bypass the switch-off.

Warning

Never use the bypassing “hoist up” switch in normal operation!

Connection and installation of hoisting limit switches on jib and rooster sheave are as
follows:
a) When the jib is used, remove the bypass aviation socket on the position “ ” of
the terminal box and install aviation socket which is connected to the hoisting limit
switch on the auxiliary winch into the terminal box. And then connect the plug on
the jib to the socket on the boom head. See Fig. 04 – 10.

04 - 19
Operation – crane superstructure

Fig. 04 – 10

b) When the rooster sheave is used, dismantle the hoisting limit switch on the jib and
connect the plug on the hoisting limit switch to the socket on the rooster sheave.
See the following Fig. After the hoisting limit switch on the rooster sheave is
installed, remove the bypass aviation socket on the position “ ” of terminal box
and connect the aviation socket on the hoisting limit switch on the auxiliary winch
into the terminal box. And then, connect the plug on the rooster sheave to the
socket on the main boom head. See Fig. 04 – 11.

Fig. 04 – 11

4.4.4 Lowering limit switch

In order to prevent the wire rope from being spooled reversely after being reeled off
completely, the lowering limit switches installed beside the winches will automatically
switch off the movement “Reel off winches” if there are only 3 rope windings remaining
on the winches.

04-20
Operation – crane superstructure

In this case, the acoustic sound will be sent out and only the crane movement “Spool up
winches” is permitted. During commissioning and maintenance, activate the bypass key
switch on the control console to release the limitation. See Fig. 04 – 12.

Warning

Never use the bypassing “hoist down” switch in normal operation!

Fig. 04 – 12

4.4.5 Hydraulic safety devices

- Relief valves in hydraulic system

The relief valves in hydraulic system can prevent the pressure in the circuit from
excessively rising, thus avoid hydraulic pump and hydraulic motor from being
damaged and hydraulic system from being overloaded.

- Outrigger locking device


If the high-pressure oil pipe which is connected to vertical cylinder is damaged, the
two-way hydraulic lock in the outrigger hydraulic circuit can stop the pressure oil in
the two chambers of outrigger cylinder to prevent the outrigger from retracting or
extending inadvertently, and thus ensure the safe operation of the crane.

- Locking device for crane movement “Derrick main boom up”


If the high-pressure oil pipe in the hydraulic circuit of derricking cylinder is damaged,
the balance valve in the hydraulic circuit can stop the hydraulic oil in the derricking
cylinder piston side immediately to prevent the boom from falling down
inadvertently, and thus ensure the safe operation of the crane.

- Locking device for crane movement “Telescope main boom out”


If the high-pressure oil pipe in the hydraulic circuit of telescopic cylinder is
damaged, the balance valve in the hydraulic circuit can stop the hydraulic oil in the
telescopic cylinder piston side immediately to prevent the telescopic boom sections
from retracting inadvertently, and thus ensure the safe operation of the crane.

04 - 21
Operation – crane superstructure

- The 5th outrigger overpressure warning system


In order to prevent the vehicle front from bending and deformation caused by
overpressure on the 5th outrigger, a pressure relay is installed in the 5th outrigger
cylinder. When lifting operation is carried out over front, once the pressure of
hydraulic system detected in the 5th outrigger exceeds the maximum permissible
value, warning light “The 5th outrigger pressure too high” lights up and buzzer
sounds.

Warning

Do not carry out lifting operation over front when the warning light “The 5th
outrigger pressure too high” lights up and buzzer sends out acoustic
warning.

- System pressure monitoring


There are four pressure gauges on the instrument panel in the operator’s cab, see
Fig. 04 – 13. Functions of the pressure gauges are as follows:

Pressure gauge 1: monitor the pressure of oil circuit in control system.

Pressure gauge 2: monitor the pressure of oil circuit in slewing mechanism.

Pressure gauge 3: monitor the pressure of oil circuits in main winch, auxiliary
winch.

Pressure gauge 4: monitoring the pressure of derricking and telescoping


mechanism.

Fig. 04 – 13

Pressure limits are as follows:

Pressure of spooling up oil circuit in main / auxiliary winch: ≤ 23 MPa, pressure of


reeling off oil circuit in main / auxiliary winch: 10 – 12 MPa;
04-22
Operation – crane superstructure

Pressure of derricking up oil circuit: ≤ 23 MPa, pressure of derricking down oil


circuit: 9 – 12 MPa;

Pressure of telescoping oil circuit: ≤ 14 MPa;

Pressure of slewing oil circuit: ≤ 12 MPa;

Pressure of control oil circuit: ≤ 4 MPa.

4.4.6 Emergency off switch

The “Emergency off switch” (See the Fig. on the left) is fitted on
the instrument console in operator’s cab. If it is operated in an
emergency, the engine and electrical crane control are switched
off. Every movement carried out will be immediately stopped. At
this time, the engine can not be started.

After emergency is removed, the switch-off can be bypassed by


turning it in the arrow direction.

Warning

Only use the “Emergency off switch” in the event of a clear emergency!

Use of the “Emergency off switch” for normal operation is not permitted!

4.5 Crane operation

4.5.1 Preparations for crane operation

Ensure that following checks are operated before operation:

a) Assess the load condition;

b) Check the crane location, ground condition and surface bearing condition;

c) Check wire ropes (including wire rope’s connections, winding drum and pulleys);

d) Check the liquid level and power source of the crane;

Note

(1) Fuel reserve of the fuel tank is more than 1/4 of the tank capacity (Check
the fuel gauge);

(2) The oil level in hydraulic reservoir should be between the Minimum and
Maximum marks in the driving condition.

e) Ensure that there are no obstacles in the crane working area and no persons in the
danger zone. Check the communication system of operator and conductor to
ensure that nothing will hinder the operation;

f) Check safety devices for functional work;

g) Remain the communication between the operator and the rigger.

04 - 23
Operation – crane superstructure

Warning

In order to protect the crane and reduce the danger of accidents, always operate
the joysticks slowly and sensitively.

Danger

Ensure that there are no obstacles in the crane working area and no persons in
danger zone. Give a short warning signal (horn) before starting a crane
movement.

4.5.2 Outrigger – operation

The outrigger control devices, consisting of accelerator control switch, outrigger control
levers and level gauge, are attached to both sides of chassis frame of the vehicle. You can
operate the control levers to extend or retract the outriggers simultaneously or
independently. See Fig. 04 – 14.

Fig. 04 – 14

Warning

Extend outriggers before crane operation. Select even and hard working sites. If the
working site is soft or uneven, put suitable materials and bases beneath the
outrigger pads.

– Outrigger control levers

Outrigger control levers are shown in Fig. 04 – 15.

a) Outrigger control direction illustrations and points for attention are printed in
the outrigger control label;

b) Control lever 1: extend or retract the horizontal or vertical cylinder;


04-24
Operation – crane superstructure

1) Move lever 1 upwards or downwards: extend or retract the horizontal or


vertical cylinder;

2) Move lever 1 upwards: retract horizontal / vertical cylinder;

3) Neutral position: stop the cylinder’s movement;

4) Move lever 1 downwards: extend horizontal / vertical cylinder;

c) Control lever 3: select left rear outrigger;

Control lever 4: select right rear outrigger;

Control lever 5: select left front outrigger;

Control lever 6: select right front outrigger;

Move levers 3, 4, 5 and 6 together with moving lever 1 to initiate


corresponding movements.

1) Move levers 3 – 6 upwards and move lever 1 upwards or downwards:


extend / retract horizontal cylinders;

2) Move levers 3 – 6 downwards and move lever 1 upwards or downwards:


extend / retract vertical cylinders;

d) Control lever 2: select the 5th outrigger


Move lever 2 downwards and move lever 1 upwards: retract the 5th outrigger;

Move lever 2 downwards and move lever 1 downwards: extend the 5th
outrigger.

Caution

During operation of outriggers, turn the accelerator control switch clockwise


to increase working speed of outriggers.

Warning

It is prohibited to extend or retract horizontal cylinders after outrigger pads


are in contact with the ground!

04 - 25
Operation – crane superstructure

1
2
3
4
5
6

Fig. 04 – 15

– Outrigger extension

a) Remove the pins of sliding beam.

b) As illustrated in Fig. 04 – 16:

1) Stand on the left (or right) side of the crane;

2) Move levers 3, 4, 5 and 6 upwards;

3) Move lever 1 downwards till the mark “ ” is completely exposed, that is


to say the outriggers are intermediately extended;

4) Continue moving lever 1 downwards to fully extend the sliding beams;

5) Move the levers to neutral positions after the sliding beams are fully
extended;

6) Walk to the other side of the crane to extend sliding beams on the other
side.

04-26
Operation – crane superstructure

1
3 2
6 54

Fig. 04 – 16

Warning

The marks “ ” on outriggers must completely exposed and the pins


must be secured if the crane is working with outriggers intermediately
extended. Otherwise, the crane may topple.
c) After all the vertical outriggers are extended completely, observe whether the
bubble of the level gauge is in the center to check the complete vehicle for
level conditions. If not, level it according to the following instructions:

How to level the vehicle:


If vehicle right side is higher than the left one (See Fig. 04 – 17)

1) Move levers 4 and 6 downwards slowly;

2) Move lever 1 upwards;

3) Observe the level gauge. Once the vehicle is leveled, move levers to
neutral positions.

1
2
43
65

Fig. 04 – 17

d) When the vehicle is leveled, move levers to their neutral positions;

e) When the crane is working over front with the same lifting capacities as over
side and over rear, the 5th outrigger should be used.

How to extend the 5th outrigger:

1) Move lever 2 downwards;

04 - 27
Operation – crane superstructure

2) Move lever 1 downwards until the 5th outrigger is 5 – 10 mm away from


the ground. See Fig. 04 – 18.

1
2
43
65

Fig. 04 – 18

f) When the vehicle is leveled, move levers to their neutral positions;

g) When the crane is working over front with the same lifting capacities as over
side and over rear, the 5th outrigger should be used.

How to extend the 5th outrigger:

3) Move lever 2 downwards;

4) Move lever 1 downwards until the 5th outrigger is 5 – 10 mm away from


the ground. See Fig. 04 – 19.

1
3 2
6 54

Fig. 04 – 19

h) Insert the pins of sliding beam. The crane is ready to work.

Caution

Lever 1 can return to neutral position automatically after being released,


while other levers should be returned manually.
– Outrigger retraction

Warning

After crane operation is finished, telescope in the boom fully and secure it on
the boom support. After that, retract the 5th outrigger before retracting all the
other outriggers.

04-28
Operation – crane superstructure

a) How to retract the 5th outrigger:


1) Move lever 2 downwards;
2) Move lever 1 upwards until the 5th outrigger is fully retracted. See Fig.
04-20.

1
3 2
6 54

Fig. 04 – 20

b) As illustrated in Fig. 04-21:

1) Stand on the left (or right) side of the crane;

2) Move levers 3, 4, 5 and 6 downwards;

3) Move lever 1 upwards to retract vertical cylinders completely;

4) Walk to the other side of the crane to retract vertical cylinders on the other
side.

Fig. 04 – 21

c) As illustrated in Fig. 04 – 22:

1) Stand on the left (or right) side of the crane;

2) Move levers 3, 4, 5 and 6 upwards;

3) Move lever 1 upwards to retract horizontal cylinders completely;

4) Walk to the other side of the crane to retract horizontal cylinders on the
other side.

04 - 29
Operation – crane superstructure

Fig. 04 – 22

d) Secure the pins for sliding beam after outriggers are fully retracted.

– Installing and removing the outrigger pads

Outrigger pad is shown in Fig. 04 – 23.

Fig. 04 – 23

a) Installing the outrigger pad

Before the outriggers are extended, withdraw the socket pin and pull outrigger
pad outwards until its center aligns with the vertical cylinder. Insert socket pins
and secure them.

Weight of outrigger pad: about 35 kg.

b) Removing the outrigger pad

After the outriggers are retracted, withdraw the socket pin and slide outrigger
pad inwards until it reaches the limit position. Insert socket pins and secure
them.

Caution

(1) Keep enough space when operating the outriggers so as to avoid


injuring persons or damaging the crane and other articles;
(2) Outrigger pads should be installed before outriggers are operated;
04-30
Operation – crane superstructure

(3) Ensure that all the outrigger pads (except the 5th outrigger pad) contact
with the ground;
(4) The 5th outrigger can only be extended to the position where its outrigger
pad is about 5 – 10mm above the ground. It is not permitted that the two
front outriggers are away from the ground due to excessive extending of
the 5th outrigger;
(5) All the tires should be lifted away from the ground before operation;

(6) Check the level gauge for proper work. If not, adjust the nuts beneath the
level gauge.

Warning

It is prohibited to operate the outrigger control levers during lifting operation.

4.5.3 Derricking

As it is illustrated in Fig. 04-24:

Derricking mechanism is controlled by the right joystick.

Deflect the joystick leftwards (direction ③): derrick main boom up;

Deflect the joystick rightwards (direction ④): derrick main boom down.

Neutral position: stop the derricking movements.

Fig. 04-24

Speed of crane derricking movement can be controlled by the deflection of the right
joystick and by applying the accelerator pedal. Depress the accelerator pedal or
increase the inclination angle of the right joystick to speed up the derricking movement.
(When deflection angle of the joystick is small, it is recommended not to apply the
accelerator pedal.) Do not change the derricking speed jerkily to ensure stable crane
operations.

An angle indicator and an angle detector are fitted on the main boom. The boom angle
can be read from the angle indicator. The angle detector is an electronic device which
can transmit information of the boom angle to the load moment limiter and display it on
the screen. See Fig. 04-25.

04 - 31
Operation – crane superstructure

Fig. 04-25
Warning

(1) Derricking operation should be carried out stably. Jerky operation is


prohibited!

(2) The derricking angle and working radius should be restricted according to
the lifting capacity tables.

4.5.4 Telescoping

The boom adopts 5 boom sections. The telescoping mechanism is composed of two
telescopic cylinders, boom extension ropes and boom retraction ropes, etc.

The movements “Telescope boom in / out” are controlled by the telescopic cylinders
and the boom extension / retraction ropes used together.

04-32
Operation – crane superstructure

Basic Telescopic Boom retraction Telescopic Telescopic Telescopic


boom boom section 1 rope I boom section boom boom
2 section 3 section 4

Telescopic Telescopic Boom extension Boom Boom


cylinder I cylinder II rope I retraction extension
rope II rope II

Fig. 04 – 26

a) As illustrated in Fig. 04-27:

Telescoping mechanism is controlled by the left joystick.

Deflect the joystick forwards (direction ①): telescope the telescopic boom sections
out;

Deflect the joystick backwards (direction ② ): telescope the telescopic boom


sections in.

Neutral position: stop the telescoping movements.

Fig. 04-27

Caution

(1) If the hook block contacts the weight of hoisting limit switches during its
upward movement, the buzzer sends out fast acoustic warning and the crane
movement “Telescope boom out” is cut off. Reel off the wire rope a little if

04 - 33
Operation – crane superstructure

the boom still needs to be telescoped out;


(2) Speed of crane movement “Telescoping” is controlled by the deflection of
right joystick and by the pedal of engine control. Depress the engine control
pedal or increase the deflection angle of the joystick to speed up the
telescoping movement. Do not change the telescoping speed jerkily to
ensure stable crane operations;
(3) Telescope the boom stably and at constant speed;
(4) Do not telescope the boom out immediately after the boom is telescoped in.
Initiate telescoping movement after 2 seconds;
(5) The bypass key switch can only be activated during commissioning and
maintenance. Never use the bypass key switch in normal operation!
(6) Operator should strictly carry out the telescoping operation according to
Lifting Capacity Tables. Otherwise, the crane may topple or be damaged.

Warning

Do not telescope the telescopic boom with a load. Otherwise:

(1) The telescopic cylinder and boom extension / retraction ropes may be
damaged;

(2) The crane may topple.

4.5.5 Lifting / lowering

– Preparations for lifting / lowering

Read Rated lifting capacity tables and Lifting height charts before lifting / lowering
operation. (Refer to Chapter 1).

How to look up rated lifting capacity in the Rated lifting capacity table (See
Fig. 04 – 28):

Look up the main boom length according to the lifting height and working radius in
lifting height chart;

Look up the rated lifting capacity according to the checked main boom length in
rated lifting table.

Note

If the jib is fitted, look up the rated lifting capacity according to the boom
angle in the table.

For example:

If outriggers are fully extended and the main boom is over side and over rear, look
up the rated lifting capacity according to the following figure:

The rated lifting capacity with working radius of R:

If the main boom length is L2 m, the rated lifting capacity is W2 kg.


04-34
Operation – crane superstructure

Caution

(1) Look up the corresponding rated lifting capacity according to actual


working conditions.
(2) Observe the notes shown below the rated lifting capacity table.

Supposed height above ground:


about H (m)
Supposed radius: about R (m)

Boom length: L (m)


Boom angle: About θ (°)

Fig. 04 – 28

Caution

The parameters shown in the lifting height chart do not include the deflection
of main boom.

Rated lifting capacities are changed with working radius.

04 - 35
Operation – crane superstructure

Fig. 04 – 29

RATED LIFTING CAPACITY TABLE


Main boom

WORKING Outriggers completely extended, over side and over Outriggers


RADIUS rear intermediately extended

L1 L2 L3 L4 L5 L6 10.6 14.3 18.0

30000 27000 21000

26000 26000 19000

R W2 23000 22000 18000

18000 18000 16000

Note

L2 refers to main boom length; W2 refers to rated lifting capacity.

Fig. 04 – 30

– Spooling up / reeling off main winch

a) Right joystick:

Spooling up / reeling off the main winch is controlled by the right joystick.
 Deflect the joystick in direction ① (forwards)

04-36
Operation – crane superstructure

Results:
– Main winch reels off and the load is lowered.
 Deflect the joystick in direction ② (backwards)

Results:

– Main winch spools up and the load is lifted.


 Deflect the joystick in neutral

Results:

The main winch stops working.

Fig. 04 – 31

b) Main winch mechanism is working.

Fig. 04 – 32
– Spooling up / reeling off auxiliary winch

a) Turn the pre-selection switch “Telescope / auxiliary winch” to the right,

04 - 37
Operation – crane superstructure

Fig. 04-33

b) Left joystick:

Spooling up / reeling off the auxiliary winch is controlled by the left joystick.
 Deflect the joystick in direction ① (forwards)

Results:
– Auxiliary winch reels off and the load is lowered.
 Deflect the joystick in direction ② (backwards)

Results:
– Auxiliary winch spools up and the load is lifted.
 Deflect the joystick in neutral

Results:

The auxiliary winch stops working.

Fig. 04 – 34

c) Auxiliary winch mechanism is working.

04-38
Operation – crane superstructure

Fig. 04 – 35
Return the joysticks to the neutral positions slowly and then the hoisting
mechanism stops working immediately.

Speed of crane movement “Spooling up / reeling off main / auxiliary winch” can
be controlled by the deflection of the right / left joystick and by the pedal of
engine control. Depress the engine control pedal or increase the deflection
angle of the joystick to speed up the hoisting movement. (When deflection
angle of the joystick is small, it is recommended not to apply the engine control
pedal.) Do not change the hoisting speed jerkily to ensure stable crane
operations.

If the hook block contacts the weight of hoisting limit switches during its
upward movement, the hook block contacts the lowering limit switch during its
downward movement or the maximum permissible load moment is exceeded,
the buzzer sends out fast acoustic warning and the crane movement “Spool up
/ reel off winches” is cut off. At this time, the crane can only work towards safe
directions till the dangerous operation is deactivated.

Caution

(1) Change the reeving numbers according to the Rated lifting capacity
tables when choosing different boom lengths. Before changing the
reeving numbers, fit the hoisting limit switch weights;

(2) Under any conditions, there must be at least three windings of wire
rope left on the winding drum;

(3) Lift the load vertically. Do not drag the load that is still on the ground.
It is prohibited to lift the load laterally;

(4) When a load is lifted away from the ground, it should first be
suspended in the air for a moment. Do not lift the load until the

04 - 39
Operation – crane superstructure

operator confirms that there is no safety hazard. Do not derrick up


and telescope out the boom to lift the load if the load does not leave
away from the ground;

(5) Do not change the joysticks between “Spool up” and “Reel off”
jerkily. The operator should return the joysticks to neutral positions
and ensure that the winding drum has stopped rotating before
changing between “Spool up” and “Reel off”. Otherwise, the
machine will be damaged;

(6) The slings must be of enough strength. The lifting capacity includes
the mass of the hook and slings.

(7) Do not stand on the load.

(8) If the hook rotates due to twisted rope, lay down the load on the
ground. Don’t lift the load until the rope is totally untangled.

4.5.6 Slewing

– Operation of left joystick for slewing


As it is illustrated in Fig. 04 – 36:

Slewing mechanism is controlled by the left joystick.


 Deflect the joystick in direction ③(leftwards)

Results:
– The crane superstructure slews to the left.
 Deflect the joystick in direction ④ (rightwards)

Results:
– The crane superstructure slews to the right.
 Deflect the joystick in neutral

Results:

The crane superstructure stops slewing.


Fig. 04 – 36

Speed of crane movement “Slewing” can be controlled by the deflection of the left
04-40
Operation – crane superstructure

joystick and by the pedal of the engine control. Depress the engine control pedal or
increase the deflection angle of the joystick to speed up the slewing movement.
(When deflection angle of the joystick is small, it is recommended not to apply the
engine control pedal.) Do not change the slewing speed jerkily to ensure stable
crane operations.

Caution

(1) Operator’s field of vision is greatly restricted over side and over rear
during slewing operation. Therefore, operate the crane with maximum
care.

(2) Ensure that there are no obstacles in the crane slewing area (within
slewing radius R) and no persons in the danger zone. Give a short
warning signal (horn) before starting a crane movement.

– Securing device for slewing operation


The securing device for slewing operation is installed in the front of the slewing
table. Ensure that the superstructure is unpinned before initiating the slewing
movement. Insert and secure the pin after finishing this operation. See Fig. 04 –
37.

Fig. 04 – 37

Caution

(1) Initiate the slewing movements smoothly. Jerky operation is prohibited;

(2) In order to ensure safe operation of a new crane, the user must check
bolts of slewing ring and tighten the bolts with 900N.m tightening torque
after initiating for 100 operating hours. Then check and tighten the bolts
after 500 operating hours. After that, do the checks every 1000 hours;

(3) The crane can slew with load. Do not laterally drag the load that is still on
the ground. Otherwise, it is very dangerous;

(4) Check whether the outriggers are extended intermediately / completely


before slewing operation;

04 - 41
Operation – crane superstructure

(5) Ensure there is enough space for the crane slewing operation;

(6) Lubricate the slewing ring at regular intervals.

4.5.7 Simultaneous crane movements

The simultaneous crane movements, which can greatly improve the working efficiency,
refer to that the crane can carry out 2 movements simultaneously. However, because
the simultaneous crane movements are towards two different directions, the operator
should take maximum care to avoid accidents. This crane has 9 simultaneous
movements.

Ensure that the following preconditions are met when initiating simultaneous crane
movements:

– Do depress engine control pedal;


– Do not deflect the joysticks to limit positions.

Warning

Simultaneous crane movements should only be carried out after the load being
lifted away from ground. It is prohibited to telescope the boom with load.

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a. Turn the Pre-selection


switch “Telescope /
auxiliary winch” to the left
position;
b. Operate left joystick and
right joystick at the same
① ①
time according to left Fig.
Main winch + to make main winch and
1
telescope ② ②
telescoping mechanism
work simultaneously;
c. Left joystick:
① Telescope telescopic
boom out;
② Telescope telescopic
boom in.
d. Right joystick:

04-42
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

① Reel main winch off;


② Spool main winch up

a. Turn the Pre-selection


switch “Telescope /
auxiliary winch” to the
right position;
b. Operate left joystick and
right joystick at the same
time according to left
① ①
Fig. to make main winch
Main winch + and auxiliary winch work
2
Auxiliary winch ② ②
simultaneously;
c. Left joystick:
① Reel auxiliary winch
off;
② Spool auxiliary winch
up.
d. Right joystick:
① Reel main winch off;
② Spool main winch up.

a. Turn the Pre-selection


switch “Telescope /
auxiliary winch” to the
① ④
left position;
Derricking
3 + b. Operate left joystick and
② ③
Telescoping right joystick at the same
time according to left
Fig. to make derricking
mechanism and
telescoping mechanism
04 - 43
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

work simultaneously;
c. Left joystick:
① Telescope telescopic
boom out;
② Telescope telescopic
boom in.
d. Right joystick:
③ Derrick main boom
up;
④ Derrick main boom
down.

a. Turn the Pre-selection


switch “Telescope /
auxiliary winch” to the
right position;
b. Operate left joystick and
right joystick at the same
time according to left
① ④ Fig. to make derricking
Derricking mechanism and auxiliary
4 +
② ③ winch work
auxiliary winch
simultaneously;
c. Left joystick:
① Reel auxiliary winch
off;
② Spool auxiliary winch
up.
d. Right joystick:
③ Derrick main boom
up;

04-44
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

④ Derrick main boom


down.

a. Operate left joystick and


right joystick at the same
time according to left
Fig. to make slewing
mechanism and

④ ④ derricking mechanism
Slewing work simultaneously;
5 +
③ ③ b. Left joystick:
Derricking
③ Slew to the right;
④ Slewing to the left.
c. Right joystick:
③ Derrick main boom
up;
④ Derrick main boom
down.

a. Operate left joystick and


right joystick at the same
time according to left
Fig. to make slewing

④ ①
mechanism and main
Slewing winch work
6 +
simultaneously;
③ ②
Main winch
b. Left joystick:
③ Slew to the right;
④ Slewing to the left.
c. Right joystick:
① Derrick main boom
down;
04 - 45
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

② Derrick main boom


up.

a. Deflect the right joystick


between any two
adjacent arrows with an
angle of 45° to make
derricking mechanism
and main winch initiate
relevant movements
(See left Fig.)
simultaneously;

⑤ b. Right joystick:
Derricking
7 + ⑥ ⑤ Derrick main boom

Main winch down / spool main
winch up;
⑥ Derrick main boom
up / reel main winch
off;
⑦ Derrick main boom
down / reel main
winch off;
⑧ Derrick main boom
up / spool main
winch up

a. Turn the Pre-selection



⑤ switch “Telescope /
Slewing
8 + ⑥ auxiliary winch” to the

Auxiliary winch right position;
b. Deflect the left joystick
between any two
04-46
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

adjacent arrows with an


angle of 45° to make
slewing mechanism and
auxiliary winch initiate
relevant movements
(See left Fig.)
simultaneously;
c. Left joystick:
⑤ Slew to the left /
spool auxiliary winch
up;
⑥ Slew to the right /
reel auxiliary winch
down;
⑦ Slew to the left / reel
auxiliary winch down;
⑧ Slew to the right /
spool auxiliary winch
up.

a. Turn the Pre-selection


switch “Telescope /
auxiliary winch” to the
⑦ left position;

Slewing b. Deflect the left joystick
9 + ⑥
between any two

telescoping
adjacent arrows with an
angle of 45° to make
slewing mechanism and
telescoping mechanism
initiate relevant

04 - 47
Operation – crane superstructure

Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

movements (See left


Fig.) simultaneously;
c. Left joystick:
⑤ Slew to the left /
telescope telescopic
boom in;
⑥ Slew to the right /
telescope telescopic
boom out;
⑦ Slew to the left /
telescope telescopic
boom out;
⑧ Slew to the right /
telescope telescopic
boom in.

4.5.8 Rope reeving

a b c d

See Fig. 04 – 38

04-48
Operation – crane superstructure

Ensure that the following preconditions are fulfilled:

– The outriggers have already been extended;

– The main boom has been fully telescoped in and turned to the side or rear working
area.

See Fig. 04 – 38.

a) Derrick boom down and place hook (a) on the ground;

b) Remove the rope securing tube (b);

c) Remove hoisting limit switch weight (c) from wire rope;

d) Remove the pouch socket;

e) When rope reeving is in odd reeving number, install the pouch socket onto the
hook;

f) Change rope reevings (d).

Note

(1) Install the hoisting limit switch weight according to rope reeving number.
When it is in even reeving number, attach the weight onto the branch with
pouch socket; when it is in odd reeving number, attach the weight onto the
branch adjacent to the branch with pouch socket. See Fig. 04 – 39.

a b

Fig. 04 – 39

(2) Spool the rope smoothly and orderly onto the drum.

(3) For methods of installing pouch socket and rope clamp, please refer to Fig.
04 – 40.

04 - 49
Operation – crane superstructure

Fig. 04 – 40

04-50
R
OPERATING INSTRUCTIONS 中联 汽车起重机使用说明书
FOR ZOOMLION ® TRUCK CRANE

Chapter 5 Equipment
Equipment

5.1 Safety technical guidelines

a) The hoist rope must be reeved between the rope pulley on the boom head and
hook pulley in accordance with the corresponding reevings specified in lifting
capacity table;

b) Counterweight plates must be fitted according to lifting capacity tables;

c) The jib which are not in contact with ground during assembly / disassembly must
be supported by appropriate and stable materials;

Danger

(1) All assembly work must be carried out using suitable aids (scaffolding or
lifting platforms, etc.)! If this is not observed, personnel could fall and
suffer life-threatening injures;
(2) Do not stand beneath the boom especially when the jib is being pinned
or unpinned.

d) Check whether the safety precautions comply with the requirements;

e) Before assembling and dismantling the jib, ensure that the following prerequisites
are met:

1) The crane is properly supported and level;

2) The telescopic boom is fully telescoped in;

3) Fit the jib according to the rated lifting capacity table;

4) All pinned connections have been secured;


5) All limit switches have been correctly fitted and are fully operational;

6) The hoist rope has been correctly placed in the rope pulleys with the rope
securing tubes to prevent it from jumping out;

7) There are no loose parts on the jib.

Danger

In winter, the telescopic boom, jib and associated components (limit


switches, cable drums, corner marker lights, wind speed sensor etc.) must
be kept free of snow and ice.

Incorrectly fitted or faulty limit switches and falling parts (pins, spring-loaded
safety pins, ice etc.) can cause injury!

05-1
Equipment

5.2 Jib

5.2.1 General

Jib is one of the important components of truck crane. It is auxiliary equipment used to
increase the crane lifting height. With the jib assembled, the load can be lifted to a
higher height and the working radius can be enlarged via changing offset.

The jib is 8 m long. During driving, the jib is secured under the main boom by pins.

Warning

Do not lift a load with the jib until the outriggers are extended!

5.2.2. Assembly

The jib can be assembled below an angle of 5, 17 or 30 to the telescopic boom
according to job requirements. Take out the auxiliary hook from the hook holder before
the jib is assembled.

Assemble the jib below an angle of 5 in the following steps:

a) Ensure there is 25m slewing range to the slewing center;

b) Extend the outriggers and level the crane with level gauge;

Fig. 05-01
c) Remove inserted pin I. Align with their pin holes I and II of U-type fork at the end of
jib, and secure with spring-loaded pins. See Fig.05-02;

05-2
Equipment

Inserted pin I

Inserted pin I

Fig. 05-02-01

Pin hole II Pin hole III

Pin hole I

Fig. 05-02-02
d) Spool up main winch till the main hook is near the pulley on the boom head. Run
auxiliary hoist rope over the pulley on the boom head, reeve in rooster sheave
(remove the rope guard tube of rooster sheave) and install the auxiliary hook;

e) Run 7.5m spare wire rope, and secure them in the rear bracket on the right side of
basic boom and the auxiliary hook. Adjust the wire rope length by the winches. The
rope should not be excessively loose or tight. See Fig.05-03;

05-3
Equipment

Fig. 05-03
f) Derrick up the boom about 60°, and then telescope out the boom a little. At this
time, the jib automatically falls off from the spring-loaded pin. Slowly reel off the
winch till the jib is plumb. See Fig.05-04;

Fig. 05-04

Caution

Operate slowly and stably.

g) Remove the spare wire rope end from the auxiliary hook. Reeve the auxiliary hoist
rope in rooster sheave and assemble the hoisting limit switch of auxiliary winch;

h) Stably operate the winch (or slowly telescope out the main boom) at low speed to
tighten the rope in order to let the auxiliary hook contact the jib head, meanwhile,
observe the condition of jib. When the angle between the jib and the main boom is
about 120°, slowly telescope out the main boom till the jib bracket is lifted. See
Fig.05-05;

05-4
Equipment

Fig. 05-05

Caution

Do not jerkily spool up the winches. Keep the jib away from the ground at
least 0.5m when derricking down the boom.

i) When the jib reaches the required position, remove the drag rod and pin II. Install
the drag rod on the head of telescopic boom section III, and secure them with
spring-loaded pin IV. And insert the pin I which is on the left side of jib into the pin
hole II. See Fig.05-06;

Fig.05-06
j) Derrick up the boom above 60°, the boom can be fully telescoped out;

k) Check the assembly and ensure all connections are reliable.

5.2.3 Angle settings

The way of changing the jib angle from 5 to 17° or 30:

a) Deflect the left joystick to reel off the auxiliary hoist rope for 2 m to 3 m at low
speed;
b) Change offset to 17° or 30°:

05-5
Equipment

1) Unpin the pin and spring-loaded pin at the adjusting plate of adapter at jib end;

2) Derrick the main boom up slowly until the long groove of adjusting plate is
supported.

As a result, the offset is set to 17° or 30°.See Fig.05-07.

Fig.05-07

05-6
Equipment

5.2.4 Dismantling

After jib operation, dismantle the jib in the reverse steps of assembly.

Caution

Pin the pins after the removal of jib.

5.2.5 Reeving in the auxiliary hoist rope

a) Reeve the auxiliary hoist rope through the hoist rope guide;

b) Reeve over rope guard device I and rope guard device II;

c) When the rope is reeved through the rope guard device II, remove rope guard and
spring-loaded pin;

d) Reeve the rope head over the wedge sleeve and connect with the auxiliary hook;
e) Install the rope guard device II;

f) For details, please refer to Fig. 05-08.

Rope guard device I


Rope guard device II

Fig. 05-08

5.2.6 Connection of hoisting limit switch

As for the connection of hoisting limit switch, please refer to Fig.05-09.

05-7
Equipment

Fig.05-09

Caution

Under the jib working condition, connect the cable bundle between the hoisting
limiting switch on the auxiliary winch and jib first in order to activate hoisting
limiting switch. Before dismantling the jib, disconnect the cable bundle between
the hoisting limiting switch on the auxiliary winch and jib first. Otherwise, the
cable bundle may be broken!

5.3 Rooster sheave

The rooster sheave is composed of bracket, rope pulley shaft, pulley and pins. When
the crane is not used or in driving condition, it is mounted on the outside the top boom
section head.

Rooster sheave is set up for rapid hoists over the boom nose to improve the working
efficiency when the loads are light.

5.3.1 Assembly

a) Derrick down the telescopic boom to the rear or to the side to its minimum angle
( -2);

b) Release the securing pin and turn the rooster sheave bracket until connecting pin
can be bolted. See Fig.05-10;

c) Reeve auxiliary hoist rope over the sheave, reeve in auxiliary hook and attach
hoisting limit switch. Check the assembly and ensure all connections are reliable.

05-8
Equipment

Connecting pin
Securing pin

Rooster sheave

Fig.05-10

5.3.2 Dismantling

Dismantle the rooster sheave in reverse step of assembly. Turn it to the outside of top
boom section and secure it.

05-9
R
中联 汽车起重机使用说明书
ZOOMLION ® OPERATING INSTRUCTIONS FOR TRUCK CRANE

Chapter 6 Additional equipment


Additional equipment

6.1 Air conditioning in driver's cab

6.1.1 Operating methods

The control panel is on the center console in the driver’s cab.

Fig. 06 – 01
a) The description of symbols on display screen are shown as follows:

set

Auto

Temperature

Outer air circulation

Interior air circulation

Footwell air supply


Front window supply

Defrosting air supply button

Refrigeration

Fan speed stage 1

Fan speed stage 2

Fan speed stage 3

Fan speed stage 4

Fan speed stage 5

Fan speed stage 6

Vehicle body

b) Operating instructions for push-buttons:

06 - 1
Additional equipment

1) Temperature adjustment button

Pressed: set the temperature

2) Fan speed button

Pressed: adjust the fan speed.

3) .OFF button

Pressed: air conditioning system is turned off.

4) AUTO button

Press AUTO: auto operating mode is activated.

Press AUTO twice, press A/C or defrosting air supply: exit auto operating mode。

5) A/C button

Pressed: A/C begins to refrigerate

6) Circulation button

Pressed: Changeover interior / outer air circulation

7) Defrosting air supply button

Pressed: enter defrosting mode.

06 - 2
Additional equipment

8) Mode button

Pressed: Changeover among different control modes

Warning

Never use the heater during driving if engine coolant temperature is below 70℃.

Caution

(1) Do not use air conditioning for a long time when the engine is stopped or is
running at idle speed; otherwise, it will cause excessive battery consumption
and thus affect normal driving;

(2) If the vehicle continuously drives at low speed, please downshift 1 gear to
increase the engine RPM. If the vehicle is started suddenly or it is climbing
long ascending gradients, please switch off the air conditioning to prevent
the engine from overheating;

(3) Run the air conditioning for several minutes once a month, which can not
only be good for the lubricating circulation, but also keep the system in good
state;

(4) Check refrigerant regularly. If there is no or not enough refrigerant, add it


timely;

(5) If there are abnormal vibration, noise or smell during operation, stop and
examine the machine immediately. Never run with faults;

(6) Clean the surface of condenser regularly. Do not clean it with steam. Clean it
with compressed air or cold water;

(7) Never dismantle the belt or pipeline of compressor after using the air
conditioning;

(8) In summer, close the shutoff gate valve on the hot-water pipe of heater at the
bottom of driver's cab; otherwise refrigeration effect may be affected. In
winter, open the shutoff gate valve to make hot water enter into the heater.

06 - 3
Additional equipment

6.2 Air conditioning in operator's cab

In order to provide a comfortable operating environment for the operator, operator’s cab
of our crane can be equipped with an air conditioning and heater according to
customer’s requirement. The control panel behind the operator’s seat is used to adjust
the room temperature.

Fig. 06 – 02

6.2.1 Air conditioning

The air conditioning control panel is on the housing of air conditioning interior machine
in operator’s cab. There are two rotary switches and a control light on the control panel.
See Fig. 06 – 03.

a) Temperature control switch

The rotary switch is used to control the temperature in the cab by adjusting the
temperature of air blew out.

b) Fan speed switch

This switch controls the speed of the evaporator fan to obtain proper fan speed.

c) Control light

The compressor is started and the cooling system is in working state when the control
light lights up.

06 - 4
Additional equipment

Fig. 06 – 03
– Operating methods
When the air conditioning is turned on, turn the fan speed switch to the “HIGH” position
and hold it in “high” position for 5 minutes. Then turn the temperature control switch to
the “COOL” position. At this time, the temperature in the cab starts to fall down. When
the required temperature is obtained, turn the temperature control switch anticlockwise
slowly until the control light goes out and the compressor stops working. At this moment,
the temperature in the cab is at its set value.

When the temperature in the cab is higher than the set value, the control light lights up,
the compressor starts automatically and the cooling system begins to work.
Adjusting the angle of the air outlet can change the direction of the cold wind; Different
kinds of air volume can be obtained by setting the fan speed switch respectively in
“HIGH”, “MIDDLE” or “LOW” position.

When the air conditioning is used, do not turn the temperature control switch to the
“COOL” position otherwise the evaporator may get frost to impair the cooling effect.

Caution

(1) It is forbidden to dismantle the air conditioning system without


manufacturer’s permission.

(2) Check the tension of the compressor belt periodically and adjust it in time.

(3) Wash off the dirt on the surface of the radiating rib of the condenser to avoid
reducing the cooling effect of system.

(4) When changing the components of air conditioning system, add refrigerant
oil according to corresponding requirements. The oil brand of the new
refrigerant oil should be the same as that of refrigerant oil used in the
compressor.

(5) The brand and type of newly-added refrigerant should be the same as that
used in the system when the refrigerant is added or changed.
06 - 5
Additional equipment

(6) Evaporator lowers the temperature in the cab at its high gear position, and
keeps the temperature in cab at medium gear position or low gear position.

(7) When the components in the system break down, replace them with the
spare parts supplied or designated by the manufacturer in order to protect
the system against damage

(8) Under the condition of low temperature & high humidity, never make the
evaporator work at low gear position in order to prevent the evaporator from
freezing.

(9) When the air conditioning is not used in winter, run it for 10 minutes every
month to make the freezing oil soak the whole system to avoid refrigerant
leakage.

– Requirements for periodic maintenance of air conditioning system

Item Maintenance Repair interval

Condenser fan motor Check and repair 3-monthly

Evaporator fan motor Check and repair 3-monthly

Once a month or shorten


Check condenser for blockage. the maintenance interval
Condenser
If necessary, clean it. depending on actual
working condition.
3-monthly or short the
Check the evaporator for
maintenance interval
Evaporator functional work and abnormal
depending on actual
sound. Clean the air inlet.
working condition.

Check it for functional work,


Solenoid clutch 3-monthly
and clean it if necessary

Check that the wire connector


Connectors Once a month
is fitted tightly

Explanation:

a) Evaporator--- the square box in the driver’s cab from which the cold air is
blown out. There are several air vents on it.
b) Condenser---the device is used for the exchange of the hot air outside the
driver’s cab. In some vehicle, it is mounted between water tank and fan
(without the condenser fan motor) while in the others, it is on the side of
the vehicle (with the condenser fan motor).
c) Condenser fan motor---it is mounted with the condenser to help the hot air
exchange of the condenser.

06 - 6
Additional equipment

6.2.2 Heater

The heater control panel is on the housing of air conditioning interior machine in
operator’s cab. There is a rocker switch on the control panel. The rocker switch has two
control lights. One is a power control light, the other is a control light of the switch.

a) Rocker switch

The rotary switch is used to control the heater automatically.

b) Power control light

This control light is used to indicate whether the power is switched on.

c) Control light of the switch

This control light is used to indicate the working state of the heater and the error code.

Fig. 06 – 04
– Operating conditions
a) Ambient temperature≥ -40ºC, altitude≤ 3000 m.

b) It can not be immerged into water, and can’t wash it with water directly.

c) The heater should use the antifreeze fluid or the diesel oil that is suitable for the
ambient temperature,

Caution

It is forbidden to use the gasoline.

For the selection of the fuel type, please refer to the following table.

Ambient Above Above Above


Above 5ºC Above -5ºC
temperature -15ºC -30ºC -40ºC

Fuel 0# diesel oil 10# diesel oil 20# diesel oil 35# diesel oil 50# diesel oil

06 - 7
Additional equipment

For the selection of the antifreeze fluid, please refer to the following table.

Ambient temperature Above -25ºC Above -40ºC

Antifreeze fluid -25ºC antifreeze fluid -40ºC antifreeze fluid

– Operating methods
The rocker switch has two gear positions. When the switch is in the 1st gear position,
only the water pump works; when it is in the 2nd gear position, both the water pump and
heater work. At this time, the fan speed switch is turned on to blow out warm air.

通风 制冷
VENTILATE COOL

LOW低

MIDDLE中

HIGH高 COOL制冷
关 关
OFF OFF

Fig. 06 – 05

When the water outlet temperature reaches 80℃, the heater stops heating and the
control light of the switch goes out. When the water temperature is lower than 65℃, the
heater will work again. The above operations will repeat in cycles.

When the heater is used for the first time in cold seasons, first check the heater
condition to ensure there is no foreign matters blocked in the air passage, the heater
rotates freely, the combustion-supporting air inlet and the exhaust gas outlet are not
blocked with clay etc. and air intake & air exhaust are smooth.

When the heater does not need to be used, the switch should be turned off. Meanwhile,
the power control light goes out and the heater stops burning. But at this time, control
light of the switch doesn’t go out immediately and is off about 3 minutes

Caution

The vehicle power is forbidden to be switched off when the control lights are on,
otherwise heat inside the heater can’t be dispersed and the heater will fail.

06 - 8
Additional equipment

– Troubleshooting

Problem Cause Remedy


Fan speed switch on the air
No warm air Turn on fan speed switch on the
conditioning control panel isn’t
blows out. air conditioning control panel.
turned on.
The heater
does not stop
The solenoid valve is dirty or can not Clean oil pipe and check the
working within
be closed completely, or the flame connection, the control box and
60 seconds
detector is short-circuited. the flame detector.
after the oil was
cut off.
Check whether the power
The power line supply is stable (especially
The wave of power supply is big and
shakes when the stable pressure power
unstable.
abnormally. supply is applied), or replace
control panel.
The voltage of heater is higher than Check voltage. If the voltage is
32V for 5 seconds (for the heater too high, check voltage
The voltage is
whose rated voltage is 12V, it means regulator of the engine. If it is
too high.
that the voltage is higher than 16V not too high, replace the control
for 5 seconds). box.
The voltage of heater is lower than Dismantle engine and heater,
20V (for the heater whose rated and then check the generator
The voltage is
voltage is 12V, it means that the and line pressure. If the voltage
too low.
voltage is lower than 10V for 5 is not too low, replace control
seconds) panel.
The flame When the heater does not burn, the Check whether the line is
detector is flame detector still show burning short-circuited, replace flame
short-circuited. state. detector or control panel.
When the relay
of motor is
The contact point is connected, or
switched off, it Replace control panel.
the control switch fails.
is still
electrified.
The solenoid
valve relay is
still electrified
The contact point is connected or
when it is
the coil breaks off, or the control Replace control panel or its coil.
switched off or
panel fails.
the solenoid
valve coil
breaks off.
The fuse breaks off, the wire is Restore the fuse, check
The fuse
disconnected, or the control panel connection or replace control
breaks off.
fails. panel.
When the relay
of solenoid
valve is The control panel is damaged.
Replace control panel.
electrified, it
can not output
signals.

06 - 9
Additional equipment

Problem Cause Remedy


When the relay
of motor is
electrified, it The relay or control panel fails. Replace control panel.
can not output
signals.
Check motor connection. Pull
The main motor can not rotate after out plug to check motor, if it can
The motor can
it is electrified or the rotational speed not rotate or the rotational speed
not rotate.
is too low. is low, replace motor. Otherwise
replace the control panel.
The water
temperature There is water in sensor or the
Replace sensor or control box.
sensor is circuit board is wet.
short-circuited.
The water
The sensor line breaks off or the
temperature Replace sensor or control box.
circuit board fails.
sensor breaks.
The flame Check connection of flame
The flame detector does not output
detector can detector, replace the detector or
flame signal.
not be ignited. control panel.
If the oil tank is short of oil, add
Extinguish oil; If the oil pipe leaks, tighten
Extinguish flame during burning and
flame during or replace it; replace
can not burn again.
burning. short-circuited flame detector
and control box.
Strong Close other interference source,
Other interferences.
interference replace control panel.
The ignition The ignition plug burn out or the line Fasten connection, replace
plug breaks. looses. ignition plug.
The ignition
plug is It is short-circuited. Check it.
short-circuited.
The ignition
plug relay has
The relay or the control panel fails. Replace control panel.
no output
signal.

06 - 10
OPERATING INSTRUCTIONS FOR ZOOMLION
R ® TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 7 Maintenance and service


Maintenance and service

7.1 After-sale service and maintenance

The products and after-sale service team of ZOOMLION are most reliable for you!

ZOOMLION truck crane, with advanced technology, can work all the time under tough
environment and harsh conditions. It possesses excellent and stable operating
performance, convenient and economical operation and easy maintenance.

ZOOMLION truck crane, integrating the best globally-supported components and the
modern manufacturing methods, are of reliable quality and outstanding performance.

ZOOMLION’s service begins when the crane is handed over. We will offer profession
training on crane to your crane operators if it is needed.

We will provide excellent after-sale service for you all around the world in time.

Putting the demands of customer on the first place, we will fix the breakdown as soon
as possible through our after-sale consult service so as to guarantee the high efficiency
and excellent performance of customer’s crane. Our service technicians, the backbone
of our after-sale service team, having rich special knowledge and service experience,
can serve for you with a complete set of tools at any moment.

Caution

Customers claims for warranties and refunds!

Only original Zoomlion replacement parts have been tested for operational use in
cranes, and they can be installed without risking safety.

In the event that replacement parts are used that are not original ZOOMLION parts,
we disclaims all liability, both for system functionality and the replacement parts.

7.2 Cleaning and service of the crane

Clean the crane with water. The water temperature cannot be above 60℃.

Grease all the moving parts, e.g., universal propeller shaft and slewing ring of the crane,
after cleaning.

The steering wheel, control console, floor and ornaments in the driver’s cab should only
be cleaned with warm water mixed with a little washing liquid.

Do not use any scouring agents.

07-1
Maintenance and service

7.3 Oil and lubrication

Proper lubrication of the crane can reduce the friction resistance and mechanical
abrasion and avoid parts defects. Furthermore, service life of the crane can be
prolonged.

7.3.1 Fuel and coolant selection

a) Fuel

The brands of light diesel oil (complying with GB252-2000 standard) used in
different ambient temperature are listed in the following table:

Lowest ambient
≥4℃ ≥-5℃ <-5~-14℃ <-14~-29℃ <-29~-44℃
temperature
Diesel oil 0 -10 -20 -35 -50

Note

The lowest ambient temperature refers to the lowest working temperature


with a risk ratio of 10%.

b) Coolant
It is recommended to use long-life antifreeze fluid or similar long-life antifreeze fluid
whose functions such as boiling point, freezing point, PH value and minimum
adaptive temperature, are equal to the former.

Warning

It is forbidden to substitute coolant with ordinary water in the cooling


system.

7.3.2 Hydraulic oil

When crane is delivered to you from the factory ready for operation, it is supplied with
L-HM46 low-temperature wear-resisting hydraulic oil.

If there is any special requirement, we can supply other hydraulic oil according to the
ambient temperature of working environment. For details, please refer to the following
table:

07-2
Maintenance and service

Ambient Ambient Ambient


Ambient
temperature temperature temperature
Item temperature
within within below
above 40°C
-20°C – 40°C -30°C – -20°C -30°C

Reference standard GB11118.1-94 GB11118.1-94 GB11118.1-94 SH 0358-95

Aviation
Type of oil L-HM L-HM L-HS
hydraulic oil

Viscosity grade 68 46 32 10

Min. flash point (split) ℃ 180 180 140 92

Kinematic viscosity at 40℃ More than 10


61.2-74.8 41.4-50.6 19.8-24.2
mm²/s at 50℃

Max. temperature when


kinematic viscosity at 1500 -30 -50
mm²/s ℃

Min. viscosity index 95 95 130

Max. pour point ℃ -9 -9 -45

Caution

The quality, viscosity and cleanness of hydraulic oil are the most important
factors for normal operations of the crane.
Failure to replace hydraulic oil in time will cause various kinds of malfunctions
and greatly shorten the service life of the crane.

Our company will not take any responsibilities for any consequences caused by
customer’s failing to change and filter oil in accordance with the requests
stipulated in the operating instructions.

— Filtering / changing intervals

Vehicle Filter or Filter or


delivery change Every 6 months change
date After the first 2 months oil
oil

— Changing steps

a) Change hydraulic oil in the hydraulic tank

1) Drain out the hydraulic oil;

2) Remove the master oil return pipe;


07-3
Maintenance and service

3) Clean the tank and oil filter with chemical cleaning agent (solid particle
pollution grade ≤18/15) carefully;

4) After airing, wash them with new hydraulic oil (solid particle pollution
grade ≤ 18/15);

5) Drain out the washing oil;

6) Add new hydraulic oil.

b) Run the engine at low speed to start the pump and drive the mechanisms (to
drain out the original oil in every circuit of the system with new hydraulic oil);

Note

The original oil is not permitted to return to the oil tank.

Do not stop the oil pump until new oil flows out from the master oil
return pipe.

Add new oil continuously into hydraulic tank to prevent the oil pump
from inhaling air.

c) Connect master oil return pipe with oil tank;

d) Set each component to initial working state;

e) Add hydraulic oil to required level.

— Checking the oil level and oil temperature


During driving, check the oil level and oil temperature via liquid level gauge. For
details, please refer to Fig. 07 – 01.

Fig. 07 – 01
The highest working temperature of hydraulic oil is 80°C.

The mark 0°C is the minimum mark.

If the oil level has dropped below the minimum mark, top up the oil tank until the oil
level is between the minimum and maximum marks.

07-4
Maintenance and service

7.3.3 Gear oil

Before delivery, each moving part has been topped up with L-CKD150 industrial closed
gear oil in accordance with GB5903-1995 standard.

— Gear oil changing interval

Vehicle
delivery Every 12 months Change
After the first 2 months Change
date oil
oil

Caution

(1) Change gear oil if it is polluted seriously even though it has not reached
the oil change intervals;

(2) Often check oil level and add oil in time if it is lower than the minimum
mark;

(3) Gear oil of different brands cannot be mixed;

(4) Use the recommended gear oil according to ambient temperature,


otherwise, the reducer mechanism will be damaged due to unqualified
gear oil or gear oil with improper viscosity.

— The gear oil of following parts needs to be changed


a) Winch reducer

The gear oil required for winch reducer is about 1.5L.

If the ambient temperature is very low, preheat the crane first.

Fig. 07 – 02

07-5
Maintenance and service

b) Slewing reducer

Fill oil after removing the plug of oil filler aperture.

The gear oil required for slewing reducer is about 4.5L.

If the ambient temperature is very low, preheat the crane first.

Fig. 07 – 03

c) Transmission

When engine oil is still warm after running, remove the oil drain plug to drain
out the gear oil. Remove the impurities on the plug and then tighten the plug.
Fill gear oil from the inspection plug hole.
The gear oil required for transmission is about 13L.

Fig. 07 – 04
Warning

When driving the crane within the first 2000 – 5000 km, lubricating oil of
the new transmission should be replaced.
07-6
Maintenance and service

d) Intermediate and rear axles

Fig. 07 – 05
Caution

(1) When changing gear oil, drain out the used gear oil when it is still
warm;

(2) For the first replacement of the gear oil for the intermediate and rear
axles after the break-in period of a new crane:

– Add diluted engine oil into rear axle after draining out the
original oil.

– Support the crane rear wheels, start the engine and engage the
gear.

– After running for about 5 minutes, wash the rear axle, drain out
the engine oil and then add new gear oil.

(3) Add the lubricating grease to main reducer and hub reducer until the
grease overflows from the oil filler.

7.3.4 Engine oil

As details about engine oil, please refer to Service Manual for QSC Series Diesel
Engine.

Caution

Choose fuel of proper viscosity suitable for the ambient temperature; otherwise
the engine will be frozen when the ambient temperature is low.

The fuel tank must be topped up; otherwise solidification of air moisture inside
the fuel tank will make the tank freeze and rust, and thus cause engine hard to
start.

07-7
Maintenance and service

7.3.5 Lubricating grease

ZL-2 and ZG-3 lubricating grease is recommended for this crane.

Parameter

Work
Type Drop Max.
Wimble Filling
Appearance Point Moisture
Degree Method
(ºC) (%)
(1/10mm)
ZL-2 Smooth inunctum with the
Lubricating color from light yellow to 175 265~295 —— Grease or
grease brown fill with
ZG-3 Equal inunctum with the grease
Lubricating color from light yellow to 90 220~250 2.5 pump
grease dark brown

7.3.6 Lubricating points

Working oil and lubricating grease used in this vehicle can not only ensure normal
working of each mechanism, but also prolong their service life and bring their functions
into full play.

Therefore, lubricate the specified lubricating points with specified grease regularly in
accordance with the lubricating table.

— Lubricating table – chassis

Number of
Ser. Names of Lubricating Lubricating Lubricating
lubricating
No. lubricating points intervals method grease type
point
Change the L-HV32 hydraulic
1 Steering reservoir 1 10000km
grease oil
Inject with ZL-2 lithium
2 Water pump shaft 1 1500km
grease pump base grease
Inject with ZL-2 lithium
3 Steering knuckle 4 5000km
grease pump base grease
Inject with ZL-2 lithium
4 Tie-rod ball pin 2 5000km
grease pump base grease
Clutch release Inject with ZL-2 lithium
5 1 1500km
bearing grease pump base grease
Clutch release fork Inject with ZL-2 lithium
6 2 1500km
shaft grease pump base grease
Battery electrode Every Grease Industrial
7 4
post season Vaseline LF40
Universal-joint
Inject with ZL-2 lithium base
8 bearing for propeller 5 1000km
grease pump grease
shaft
9 Intermediate 1 1500km Inject with ZL-2 lithium

07-8
Maintenance and service

Number of
Ser. Names of Lubricating Lubricating Lubricating
lubricating
No. lubricating points intervals method grease type
point
bearing for propeller grease pump base grease
shaft
Sliding fork for Inject with ZL-2 lithium
10 2 5000km
propeller shaft grease pump base grease
Central reducer for 5000km Add grease
11 intermediate and 2 Change the GL-5 85W/90
rear axles 10000km grease
Pin spindle for front Inject with ZL-2lithium base
12 4 2000km
and rear leaf spring grease pump grease
ZG-Sgraphite
Front and rear leaf
13 4 10000km Grease calcium base
spring
grease
Hub reducer for 5000km Add grease
14 intermediate and 4 Change the GL-5 85W/90
rear axles 10000km grease
Balance beam for Inject with ZL-2lithium base
15 rear suspension 6 5000km
grease pump grease
Hub bearing for ZL-2lithium base
16 6 5000km Grease
axles grease
Brake cam shaft for Inject with ZL-2lithium base
17 6 2500km
axles grease pump grease
10000km Add grease
Transmission (with
18 1 Change the GL-5 85W/90
PTO) 50000km grease
5000km Add grease
L-ECD15W/40
19 Engine oil underpan 1 Change the
10000km Diesel oil
grease

Shock absorber Change the Synthetic stator


20 2 10000km
grease oil
Drag link for
Inject with ZL-2 lithium
21 steering pitman arm 2 5000km
grease pump base grease
shaft
Range selector seat
L-AN32
22 and universal joint 1 5000km Drip in
mechanical oil
yoke
Accelerator pedal L-AN32
23 1 5000km Drip in
shaft mechanical oil
Steering propeller L-AN32
24 1 5000km Drip in
shaft mechanical oil
L-AN32
25 Clutch pedal shaft 1 5000km Drip in
mechanical oil

07-9
Maintenance and service

Caution

(1) Determine the actual working time of engine via the tachometer and carry out
maintenance work in accordance with “Diesel engine maintenance
specifications” in Maintenance Manual for QSC Series Diesel Engine;

(2) The lubricating oil of PTO is supplied by the transmission, and its oil level is
determined by that of the transmission;

(3) After adding or changing lubricating grease, wipe off the grease around the
threaded plug and check for leaks;

(4) For the first replacement of the gear oil for the rear axle after the break-in
period of a new crane:

– Add diluted engine oil into rear axle after draining out the original oil.

– Support the crane rear wheels, start the engine and engage the gear.

– After running for about 5 minutes, wash the rear axle, drain out the
engine oil and then add new gear oil.

07-10
Maintenance and service

— Lubricating table – superstructure

Ser. Names of lubricating Lubricating Lubricating Lubricating


No. points interval method grease type

Upper pulley block (shaft) Inject with ZL-2 lubricating


1 Every 10 days
on main boom grease pump grease

Lower pulley block (shaft) Inject with ZL-2 lubricating


2 Every 10 days
on main boom grease pump grease

Sliding surfaces of main ZL-2 lubricating


3 Every 10 days Grease
boom grease

Upper articulated-point
Inject with ZL-2 lubricating
4 shaft and knuckle bearing Every month
grease pump grease
of derricking cylinder

ZG-3 lubricating
5 Wire rope Every 10 days Grease
grease

Pulley block (shaft) on main Inject with ZG-3 lubricating


6 Every 10 days
/ auxiliary hook grease pump grease

Lower articulated-point Inject with ZL-2 lubricating


7 Every month
shaft of derricking cylinder grease pump grease

Grease or inject
ZL-2 lubricating
8 Slewing ring and gear Every 10 days with grease
grease
pump

Sliding surfaces of sliding ZL-2 lubricating


9 Every 10 days Grease
beam grease

L-CKD150
Every 12
10 Main and auxiliary winches Add oil industrial closed
months
gear oil
Grease or inject
ZL-2 lubricating
11 Main boom main shaft Every day with grease
grease
pump

L-CKD150
Every 12
12 Slewing reducer Add oil industrial closed
months
gear oil

Inject with ZL-2 lubricating


13 Pulley block (shaft) on jib Every 10 days
grease pump grease

07-11
Maintenance and service

Ser. Names of lubricating Lubricating Lubricating Lubricating


No. points interval method grease type

Inject with ZL-2 lubricating


14 Propeller shaft for oil pump Every day
grease pump grease

Grease or inject
Sliding blocks on main ZL-2 lubricating
15 Every 10 days with grease
boom grease
pump

Caution

(1) The sliding surfaces which are not listed in the above table must be greased
regularly;

(2) The lubricating grease of different brands cannot be mixed;

(3) Inject grease into bush, shaft and bearing until the used grease flows out;

(4) If the piston rod of derricking cylinder is partly exposed when the boom is
secured on the boom support, grease the exposed section every month.

07-12
Maintenance and service

— Lubricating graph – superstructure

07-13
Maintenance and service

7.4 Adjusting, cleaning and replacing parts

7.4.1 Tables for regular adjusting, cleaning and replacing parts

— Table for parts regular adjusting

Ever y Ever y 3 Ever y 6 Ever y


Item
month months months ye ar
Adjust the adjusting bolt under the service brake
pedal to make its free stroke vary from 10 mm to ○
22 mm.
Adjust the brake drum regulators of right and left
brakes on the front and rear axles to ensure that

the clearance between brake drum and brake
shoe varies from 0.3 mm to 0.5 mm.
Adjust the angle between push rod of brake
chamber and brake arm to make it more than
900, and then stop the crane and try to depress ○
service brake pedal to ensure that the push rod
and brake arm move smoothly.
Adjust the free stroke of clutch pedal to make it

vary from 25 mm to 30 mm.
Deaerate the hydraulic pipelines of clutch. ○
Adjust the free clearance of steering wheel to
ensure the free turning angle does not exceed
30° wherever the steering wheel is located. The
adjusting steps are shown as follows:
1. loosen the locking nuts on the side cover of

steering gear;
2. screw the bolt in or out until proper free
clearance of steering wheel is achieved;
3. screw down the locking nuts with a tightening
torque of 130 – 180 N.m.
Adjust the tie rod of front steering axle to ensure
the toe-in of front axle is 0 – 4 mm (the toe-in

should be measured at the position where the
maximum diameter of tire is reached.).
Adjust the limit screw on the steering knuckle of
front axles to ensure that the maximum steering

angle of inner wheel of 40° and the maximum
steering angle of outer wheel is 33°.
Adjust the position of adjusting bolts on the
inner end or outer end of release lever to ensure

each inner end is located in the same plane,
and the error is not more than 0.25mm.
Adjust engine cooling fan, air compressor and

generator belt.
Regularly demount the wheels and install them

in specified positions as shown in Fig. 07 – 06.

07-14
Maintenance and service

Caution
After replacing the clutch friction lining, adjust the clearance between clutch
release bearing and release fork to 3mm-5mm, and then adjust the meshing
position of clutch lever spline.

Fig. 07 – 06

— Table for parts regular cleaning

Ever y Ever y Ever y 3 Ever y 6 Ever y


Item
day month months months ye ar
Drain water in the brake system.
Pull the draw ring of manual water

drain valve downwards to drain
water.
Wash fuel filter ○

Wash water tank ○


Blow the air filter cartridge evenly

from inside with compressed air
Wash air filter cartridge ○
Clean the filter screen of steering

reservoir
Clean hydraulic system of the clutch ○

07-15
Maintenance and service

— Table for parts regular replacing

Every Every 2 Every 4


Item
year years years
Diaphragm and rubber parts of pressure regulating

valve of air dryer
Air filter cartridge ○

Shims and rubber parts of service brake valve ○

Brake hose ○

Hose connecting the air compressor and pressure



regulating valve

Brake chamber diaphragm ○

Shims and rubber parts of the relay valve ○

Shims and rubber parts of quick release valve ○

Shims and rubber parts of parking brake valve ○

Shims and rubber parts of tee valve ○

Piston cup and dust ring of clutch master cylinder ○


Shims, cup and rubber parts of clutch booster

cylinder
Air filter cartridge ○

Hydraulic piston of clutch booster cylinder ○

Hoses of power steering gear ○

Diesel oil hose inside the engine hood ○

Diesel oil hose outside the engine hood ○

7.4.2 Wire rope

Regularly checking the rope is required, especially before using and after installing.
Moreover, check the wire rope strictly if special tightening force is acting on the rope, or
invisible damages and new damages occur on the rope.

Suspended wire ropes, rope end connections and drive elements of some wire ropes
must be checked at regular intervals so as to ensure that the drum and the pulley can
rotate smoothly on their mounting positions, and no obvious indentation of wire rope
occurs in the track of wire rope.

Caution

After the rope is used for a period of time, its strength will be reduced to such an
extent that the danger may occur if the rope continues to be used.
07-16
Maintenance and service

— Take-down criteria
a) There is 10% broken rope in one strand (excluding the break caused by
damage to the rope core);

b) The diameter is reduced by more than 7% of its nominal diameter;

c) The wire rope is reverse bent or knot;

d) The wire rope is seriously deformed; wire core is revealed, birdcage deformed
and is in corrosion.

Caution

The wire ropes must be taken down when one of the above situations occur.

e) Tension caused by rope coming out from the pulley;

f) Damage caused by heavy objects;

g) Damage caused by electric welding or gas welding;

h) Damage caused by short circuit;

i) Damage caused by the effect of heat.

Caution

The wire ropes, in accordance with the wearing conditions, can be taken
down when one of the above 5 situations occur.

— Methods for replacing the hoist rope


Before replacing the hoist rope, ensure the following two prerequisites are met:
a) Level the crane on firm and flat ground;

b) Telescope in the boom completely.

07-17
Maintenance and service

Ser. Tools
Operating steps Points for attention
No. required

Lower the main hook and set it on


the ground. Caution

Operate carefully to avoid


the rope is wound on the
drum out of order.

Take out the press nipple from the Leave the parts in Wrench
top boom section or the main safekeeping. Do not lose
hook. them.

Pull out the wire rope from the Leave the parts in Steel stick,
press nipple. safekeeping. Do not lose hand hammer
them. and wrench

Lower the hook, reeve out the


rope from the drum and pull out Caution
the wire rope manually. The lowering limit switch
will be activated when
only 3 hoist rope windings
4 are left on the main winch.
Press the bypass key
switch to release the
limitation until the wire
rope is reeled off
completely.

07-18
Maintenance and service

Ser. Tools
Operating steps Points for attention
No. required

Take down the rope from the main Keep the chock well. Steel stick
winch; and hand
hammer

Reeve the new wire rope over all Thin steel


pulleys in order. Caution wire
Do not reeve the wire rope
disorderly. The wire rope
end should be fused or
6 tied by a thin steel wire.

Fix the wire rope end onto the Hand


main winch. Install the wedge correctly; hammer
The wire rope end cannot
come out from the outside of
drum.

Spool up the wire rope. Thin steel


Operate carefully to avoid wire
that the rope is wound on
the drum out of order.
8 The wire rope end should be
fused or tied by a thin steel
wire.

07-19
Maintenance and service

Ser. Tools
Operating steps Points for attention
No. required
Reeve the wire rope between the Pay attention to the reeving
rooster sheave and hook pulley order.
block in the corresponding
reevings.

Mount the press nipple and rope Mount the chock properly. Hand
lock onto the wire rope. hammer and
Caution wrench

Set the rope end on the


10
side of the press nipple
with bevel.
The rope lock seat is set
on the rope with load.

Mount the press nipple onto the Wrench


top boom section or the main hook
according to rope reevings.

11

Derrick the boom up and Do not lower the hook Steel stick
telescope it out. Lower the hook excessively to avoid rope and hand
until only 3 hoist rope windings are damage. hammer
left on the drum.

12

07-20
Maintenance and service

Ser. Tools
Operating steps Points for attention
No. required

The max. permissible lifting Hand


Reeve the wire rope on the drum capacity can not be hammer and
with a load whose weight is 30% exceeded. wrench
of the max. permissible lifting
capacity per strand.
Weight of the load: W = 0.3 NP

13

Rope reeving: N
Max. permissible lifting capacity
per strand: P
14 Unload the load from main hook.

— Adjusting the wire rope for main boom

If the telescopic boom section 4 or the telescopic boom section 3 cannot be fully
telescoped in, the boom extension / retraction rope may be not properly rectified. At
this time, adjust the wire rope according to the following methods:
a) Adjusting the boom retraction rope for top boom section

1) Open the cover on the head of top boom section to reveal the nut at the
end of boom retraction rope. Please refer to Fig. 07 – 07;

2) Remove the locking nut, and then screw down the adjusting nut with the
socket wrench until the boom extension rope II is just tightened.

Fig. 07 – 07

07-21
Maintenance and service

b) Adjusting the boom retraction rope for telescopic boom section 3

The boom retraction rope end is symmetrically located on both sides of


telescopic boom section 3. Unscrew the locking nut and screw down the
adjusting nut until the boom extension rope I is just tightened.

Fig. 07 – 08

Caution

(1) Support the crane on the firm and flat ground;

(2) The boom extension rope cannot be adjusted;

(3) Do not screw down the adjusting nut excessively. Otherwise the wire
rope will be over-tightened. Screw down the locking nut again after
adjustment;

(4) When adjusting the locking nut, do not rotate the threaded rod.

— Maintenance and service of wire rope


a) Take preventive measures to prevent wire rope from breaks, corrosion or other
damage;
b) When the rope is unwound from a drum, it must be ensured that the rope is not
kinked or twisted;

c) When cutting off the wire rope, take preventive measures against strand
breaks;

d) When installing wire rope, do not drag the wire rope on the unclean ground or
wind it onto the other object to avoid being scraped, worn, pressed and
excessively bent;

e) Keep the wire rope in good lubricating status;

f) Before using a new wire rope, check the wire rope qualify certificate to ensure

07-22
Maintenance and service

the mechanical performance and specification comply with the requirements;

g) Regular checks, including checks on the rope end connection and pulleys,
should be carried out daily before operation.

7.4.3 Replacing the hook

The most frequent discard criteria for the hook are as follows (welding up of hook’s
disfigurement is not allowed):

a) There’s crack and crevasse on the surface of the hook;

b) The hook’s split degree should not exceed 10% of original dimension;

c) The abrasion of the dangerous sectional plane reaches 10% of original dimension;

d) The wear extent of the sectional plane in point where wire rope suspended
exceeds 10% of original height;
e) The torsion and deformation of hook exceeds 10°;

f) There is plastic deformation in dangerous sectional plane such as the tail of hook,
the screw threaded part and hook web.

7.4.4 Replacing the oil return line filter cartridge

The oil return line filter is installed on the hydraulic reservoir to filter the impurities, thus
to maintain the extreme cleanliness when topping up the oil tank.

WY-type filter has a perpetual alnico which can filter the iron grain bigger than 1um in
the oil and also partly filter the magnetism and none-magnetism mixture. Thus it can
greatly improve the working reliability and prolong the service life of the hydraulic
system.

The texture of the filter is non-woven chemical fabric with the advantage of the high
filtering precision, big oil-through capacity, low original pressure loss, great pollution
tolerance capacity and so on. And its filter precision can be calibrated by the absolute
filter precision. Its filter ratio and efficiency meet the requirements of ISO.

Unscrew and remove the filter cover to replace the oil return line filter.

The filtered impurities will not flow into the hydraulic reservoir if the filtered is replaced,
because the hydraulic oil flows into the hydraulic reservoir via the inner layer of the filter.

a) Replacing intervals:

Vehicle Replace
Replace filter
delivery Every 6 months
After the first 2 months filter cartridge
date cartridge

07-23
Maintenance and service

When the oil temperature is above 40℃ and the warning light “Filter cartridge
soiled” lights up, replace the filter cartridge immediately.

Caution

Shut off the hydraulic pump when replacing the filter cartridge.

b) Replacing procedures:

Ser.
Procedures Tools required
No.

Remove the top cover;

1 Hydraulic Wrench
reservoir

Take out the spring and the perpetual alnico


units;

Spring
2

Take out the filter cartridge and then replace it;

3 Wrench

Mount the spring and the perpetual alnico


units;
Spring

07-24
Maintenance and service

Put on the top cover.

5 Wrench

7.4.5 Cleaning the diesel oil filter

Fig. 07 – 09

Steps for cleaning the diesel oil filter are as follows.

a) Place a container below the oil drain plug of oil filter;

b) Unscrew the air relief cock and oil drain plug to drain out diesel oil and impurities;

c) Screw off the long central threaded rod and remove oil filter, filter cartridge, spring
seat and spring;

d) Clean the parts except filter cartridge with diesel oil;

Caution

Do not wash the filter cartridge!


e) Check whether the filter is blocked or polluted. If it has been blocked or polluted
seriously or it is used for 1000 hours, change it with an original new one. Replace
the O-ring and washer if the filter is replaced;

07-25
Maintenance and service

f) Set a new washer into the long central threaded rod and put it into the oil filter.
Install the spring, spring seat, filter cartridge and washer or O-ring one after
another. Screw the long central threaded rod into the filter cover until it is
tightened;

g) Discharge air with manual oil pump;

h) Check the filter for leaks.

7.4.6 Cleaning the air filter

Fig. 07 – 10

a) Remove the dust in the air filter in the following steps:

1) Screw off the butterfly nut and pull out the side cover;

2) Remove the filter cartridge;

3) Sweep the air filter and side cover, and then screw down the nut after
inserting the filter cartridge;

4) Press the side cover towards air filter and screw down the butterfly nut.

b) Wash the air filter in the following steps:

Fig. 07 – 11

1) Dissolve the washing fluid into 40℃ warm water;

2) Put the filter cartridges into washing liquid for 30 minutes, and wash them
with washing liquid for about 4 – 5 times;
07-26
Maintenance and service

3) Take out the filter cartridges and wash with tap water. The impulse of water
should not be too high;

4) Dry the filter cartridge in the air. It can be dried with fan if needed. But do not
dry it with flame or compressed air;

5) After air-drying the filter cartridge, check the filter paper for proper condition
with bulb. If the paper is in poor condition or the shim is damaged, replace it
with a new one.

7.4.7 Cleaning the cooling system

When you are ready to wash the cooling system, ensure the temperature of cooling
water is above 85℃ and then wash the cooling system while warming up the machine.
If water temperature is too low, the thermostat will be switched off and the cooling water
can not flow to the radiator to wash the cooling system,
Wash the cooling system in the following steps:

a) Screw off the water drain cocks on the radiator and the engine to drain cooling
water completely;

b) After pulling up the pressure-relief handle on the radiator lid and screwing off the
cap, inject tap water (soft water) and detergent until it rises to water inlet;

c) In order to make washing liquid circulate in the whole cooling system, close the
engine hood and run the engine to raise the water temperature to 85℃. At this
time, the indoor heater control knob should be switched on;

d) Run the engine at idle speed without load for 30 minutes under this condition;

e) Stop the engine and drain off washing liquid;


f) Inject tap water and run the engine for several minutes, then drain off the water.
Repeat this operation for 2 – 3 times to clean the inside of all parts of cooling
system;

g) Inject antirust or antifreeze in certain quantities, and then inject soft water until it
rises to the radiator orifice;

h) Run the engine for several minutes to fully deaerate the cooling system;

i) Stop the engine and check the water level. If it is not enough, supply water until it
rises to the neck of the radiator.

07-27
Maintenance and service

7.4.8 Deaerate air from clutch brake fluid

Fig. 07 – 12

a) Open the rubber cover of the air relief bolt on clutch booster cylinder, and place a
container beneath it;

b) Depress the clutch pedal for several times. At the same time, another person
screws off the air relief bolt to discharge the brake fluid and air;

c) Screw down the air relief bolt and release the clutch pedal;

d) Repeat the steps b) and c) until there is no bubbles in the discharged brake fluid;

e) Screw down the air relief bolt and put on the rubber cover.

7.4.9 Battery maintenance and service

The battery of this vehicle meets the national standard GB/T 5008.1 - 2005. If there are
no malfunctions in electrical devices, charge the battery at any time if necessary. If the
battery cannot be charged or is under-charged, check the generator for malfunctions
and rectify it immediately.

Pay attention to the following items:

a) Often check and screw down the liquid air plug, keep a free flow through the
exhaust vent and make the battery in the clear and dry status;

b) After ordinary charge, check whether the electrolyte level is about 10 – 15mm
above the top edge of the battery plates. If not, top up with distilled water;

c) For idle battery, if it is not used for more than a month, disconnect it with the
electrical system of the crane. If the crane is not used for a long time, charge the
battery every three months;

d) The battery terminals and connecting wires should be kept clean so that the
battery can come into contact with the wire. The battery and terminals should be
cleaned with soda water or pure water and terminals are daubed with Vaseline.

07-28
Maintenance and service

7.4.10 Tires / wheels

— Inflating the tires

Before inflating the tires, ensure that following prerequisites are met:

a) The tires are correctly fitted to the rim;

b) The clamp collar is correctly seated;

c) The maximum permissible tire pressure must not be exceeded;

d) Check pressure of tires only when they are in cold status.

Danger

(1) Damaged tires, insufficient tire pressure or the same tire with different
pressure may cause increased accidents!

(2) When checking the tire pressure on the vehicle or when replacing tires,
please ensure beforehand that the clamp collar is correctly assembled. If
not, please obtain the assistance of a specialist. Otherwise, risk of
accident may occur! Check that wheel disks are safe before starting off.

— Changing the wheel


The wheel is one of the most important safety components on the vehicle. For this
reason, please check rim and wheel disk for the following conditions when
changing the tires:

a) Excessive rust or corrosion;

b) Bent rim flange;

c) Cracks in the rim;

d) Cracks in the wheel spoke;

e) Damage to wheel clamp collar;

f) Damage to bolt, nut and bolt hole;

g) Damage to accessories of rim.

If damaged rims are found during checking:

– Remove them and replace them with new parts.

If paint damage or minor rust formation is found:

– Repair the wheels by removing the rust using commercially available paint.
Pay special attention to having a perfect surface in the tire seating area.

Danger

No welding work is permitted on rims and wheel disks, particularly repairs to


worn pin holes and changing disk wheel. Disk wheel with worn pin holes

07-29
Maintenance and service

must be scrapped immediately. Repairing these highly-stressed disk wheel


components causes structural transformations in the material that can lead
to premature overload breakage.

— Limit of vehicle speed


As the highest vehicle speed of tires is limited (The maximum vehicle speed of tires
used in this crane is 80 km/h), never overdrive. Otherwise, the tire will be
overheated and its service life will be shortened. Override is also harmful for
maintenance of the vehicle.

Do fix your attention on driving. Get out of the way from obstacles (e.g. pits in the
ground) in the front. Slow down to drive over if they cannot be avoided.

— Storage of tires
Tires must be placed vertically. They should be stored in cool and dry places
instead of exposed to the sun to prevent them from ageing.

Tires are made of rubber. Do not contact them with chemical substances such as
oil, acid and hydrocarbon during driving, parking or storing to avoid corrosion,
deformation and softening.

Tire projecting rims or tire bead toes should be protected during transportation and
installation, so as to keep its tightness.

07-30
ZOOMLION ® OPERATING INSTRUCTIONS
R FOR TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 8 Crane inspections


Crane inspections

8.1 Inspection of a new crane

a) Before the new crane is used for the first time, check the following items. If there is
anything abnormal, remedy as soon as possible:

1) Check whether attached documents, attached spare parts and attached tools
are complete and are in good condition according to the Delivery Technical
Documents List;

2) Check the main steel bearing structures e.g. slewing table, main boom and
chassis frame body, etc. for crack and deformation;

3) Check safety devices for functional work;

4) Check parts, e.g. slewing mechanism, derricking mechanism, telescoping


mechanism and hoist mechanism etc. for connection and tightness;

5) Check parts, e.g. drive system, steering system, brake system, suspension
system and wheels, etc. for connection and attachment;

6) Check oil, air and water pipelines and fittings in each system for leakage;

7) Check lubricant level; check lubricant filling conditions and coolant level at
each lubricating point;

8) Check tire pressure, door locks, windows and each control mechanism;

9) Check steering system and brake system for functional work;

10) Check wires for all electrical appliances for proper seating; check electrical
devices, instruments and battery for functional work;

11) Check engine attachments and drive belt for tightness.


b) Observe pressure gauge and water thermometer all the time when the new crane
is in operation. Bring the vehicle to a standstill and check immediately once
something abnormal is found in the instruments.

c) Perform the following inspections after the new crane has traveled for 50 km to 100
km for the first time.

1) Check whether wheel nuts are tightened (maximum permissible tightening


torque for wheel nut is 550 N. m - 600N. m);

2) Check engine coolant level and engine oil level;

3) Check lubricant level in transmission, PTO and driving axles;

4) Inspect engine, drive device and shafts for any leakage or loose components;

5) Check that propeller shaft is properly seated;

6) Check that there are no other loose carriage components.

7) Inspect tire condition and inflation.

08 - 1
Crane inspections

Tire code Tire t ype Rated pressure of Rated pressure


single tire of double tire

11.00-20(18- layer) Diagonal tire 0.91MPa 0.84MPa

12.00-20(18- layer) Diagonal tire 0.81MPa 0.74MPa

11.00R20(18- layer) Radial ply tire 0.93MPa 0.86MPa

12.00R24(20- layer) Radial ply tire 0.84MPa 0.84MPa

12.00R20(18- layer) Radial ply tire 0.84MPa 0.84MPa

12R22.5(16- layer) Radial ply tire 0.85MPa 0.85MPa

Caution

(1) Early failures caused by various aspects will easily occur in the early running
period. Therefore, check strictly.

(2) Tires used in the vehicle must be in accordance with tire pressure limit
values listed in the above table according to the specifications in the actual
tire supply state.

08 - 2
Crane inspections

8.2 Re-inspections

8.2.1 General

This crane has been tested and commissioned at the manufacturer’s facilities prior to
shipment in accordance with the latest national standards.

The safety level achieved during initial commissioning may not be attainable during
operation.

Examples of the root cause of such deviation include; e.g., rust, corrosion, effects of
forced operations, changes in the environment and changes to the mode of operation.

The inspection frequency varies with the application situations and the operating
conditions, but the minimum interval is one year. For details, please refer to the relevant
standards of GB3811 and GB/T6068.

If the crane is sold to foreign countries or regions, please apply local standards for
reference.

Warning

There is a risk of weakening the supporting components when major changes or


repairs are made to the crane!

In such cases, the operator must have the crane inspected by a competent
inspector before putting it back into service.

A competent inspector is someone who has a thorough understanding of cranes based


on technical training and experience and is knowledgeable about the relevant national
occupational safety regulations, accident prevention regulations and generally
accepted engineering principles and is able to assess that the crane is safe to operate.

A professional engineer is someone who has rich experience in designing,


manufacturing and maintaining lifting equipment (e.g., crane) and is knowledgeable
about the relevant regulations and standards and is able to use necessary equipment to
inspect, so as to access whether lifting equipment are safe and to determine what
measures to be taken.

Re-inspection of crane is principally a visual inspection, wherein the inspector and


engineer appraise the condition of the crane and its components. The purpose of the
inspections is to prevent accidents by detecting deficiencies in a timely fashion.

A number of important examples of items that are particularly important during the
periodic crane inspections are listed in the following: We wish to advise that only
competent inspector and professional engineer take sole responsibility for the
inspections that they carry out. This chapter does not necessary cover the entire scope
of the inspections.
A checklist for periodic inspections recommended for ZOOMLION truck cranes and all
terrain cranes is included in Appendix 1 to assist the inspectors.

08 - 3
Crane inspections

If the inspector has any questions, they should be directed to ZOOMLION’s service
department or other relevant departments.

Danger

Risk of accident!

Adhere to the following inspection guidelines and intervals.

8.2.2 Steel bearing structures inspection

Steel bearing components such as telescopic boom, slewing table, chassis frame,
outriggers and rims must be carefully inspected, at the very least during the annual
recommended crane inspections. Even though weld joints are not normally situated at
maximum load locations, it is nevertheless important that they be inspected with
particular care during the periodic inspections. Please refer to Fig. 08 – 01 – 01, Fig. 08
– 01 – 02 and Fig. 08 – 01 – 03.

If the crane was subjected to excessive operating loads; e.g.; due to an unusual impact,
the load-bearing components must be inspected immediately. If damages (e.g., cracks)
are apparent in any part of the steel structure, the total extent of the damage must be
determined by qualified specialists using appropriate material test methods: e.g.,
ultrasound or X-rays. The specialists should then advise whether or not the damaged
area can be repaired by welding or other means.

The following diagrams are samples of the load-bearing weld designs. The welds or
steel structural zones that require inspection may be present more than once and in
various forms. The joints or zones must be inspected all around at the locations
identified by arrows.

Warning

The scope and extend of all inspections remain the sole responsibility of the
inspectors. The following diagrams are provided to assist the inspector. The
diagrams are only examples and are not necessarily 100% complete!

08 - 4
Crane inspections

Boom

Fig. 08 – 01 – 01

Slewing Chassis
table frame

Fig. 08 – 01 – 02

08 - 5
Crane inspections

Jib

Fig. 08 – 01 – 03

8.3 Inspection during break-in period

Perform the following inspections and maintenances after 200 hours of lifting operation.

a) Check conditions of each mechanism.

b) Clean dust and oil on each part of the complete vehicle, and check each assembly
for leakage of oil, water, gas and electricity. Adjust and repair them.

c) Check that connecting bolts for each part are properly seated.

d) Check and rectify all safety devices.

08 - 6
Crane inspections

8.4 Periodic crane inspections

8.4.1 Inspecting the rims

The tires, and therefore the rims, are important vehicle safety related components. They
must be tested in accordance with Chapter 8.2.2 “Steel bearing structures inspection” in
this chapter.

In addition, rims must be checked for crack at the very least during the annually
specified crane inspection. Immediately replace any rims that show evidence of cracks
or crack formation.

After driving a maximum of 40,000 km, the operator shall routinely inspect the rims,
regardless of the actual duty cycle they were exposed to.

8.4.2 Inspecting the brake systems

The brake system on cranes must be inspected annually.

– Structural inspection

Check that the following requirements are met:

a) Pipe and hose lines are not aged, not corroded and are properly routed;

b) Devices are properly installed and fastened;

c) The air reservoir is not damaged and no external corrosion is visible;

Warning

No welding or heat treatments can be conducted on the reservoir walls.

d) Water has been removed from the air reservoir;

e) Each connection in the pipe lines are proper connected, moving parts are flexible
and are not damaged;

f) The brakes are properly adjusted.

– Function and performance test

a) Function test

1) Air pressure regulation;

2) Check for leaks of system and pressure of air reservoir;

3) Check safety valve, switch for air pressure control light and warning device;

b) Performance test

1) Check the function of the brake:

Depress the brake pedal: Friction linings contact the brake drum.

Release the brake pedal: Friction linings immediately return to their starting
position.
08 - 7
Crane inspections

2) Check effectiveness of brake:

– Measure brake path

At an applied pressure of 0.8MPa and initial speed of 30km/h, the brake


path should be smaller than 10m.

– Determine brake performance on brake test bench

– Inspection intervals for brake

Check the following items in regular intervals besides function test and performance
test:

a) Check the condition of the friction lining every 3 month;

b) Dismantle brake drum and check the condition of each component inside the brake
every 12 months.

Warning

Do not brake after dismantling the brake drum.

If the remaining lining thickness is less than 1mm from rivet, it is imperative that the
friction linings are replaced; Replace worn or oily friction lining.

Warning

Always replace all the friction linings on each axle simultaneously.

c) Brake drum rotation:

Fig. 08 - 02

Caution

The diameter should not be over 0.75% of nominal diameter during brake
drum rotation.

Danger

Replace the brake drum no later than when its inner diameter exceeds the
maximum permissible value. If this is not done, the brake drum can fail,
08 - 8
Crane inspections

which can cause fatal accidents.

d) Replace the springs, sealing elements and dust cover inside the brake at least
every 2 years.

Danger

All the brake maintenance and repair work may only be carried out by
authorized and trained expert personnel! Danger of fatal accidents due to
erroneous maintenance or repair on the brake!

e) Carry out a brake structure, function and performance test again on all wheels after
completion of assembly work.

8.4.3 Inspecting the hoist and slewing mechanisms

The hoisting and slewing mechanisms are designed using planetary gear reducers.
Even though the hoisting and slewing mechanisms are designed for long life, an
external visual inspection is not adequate, since their life can be significantly affected by
bad maintenance, defective seals, improper operation or overuse. The inspection must
therefore be carried out by a competent inspector in accordance with the following
requirements:

a) 1000 hours of operation, minimum once per year;

b) Inspecting oil level

For hoisting winch reducer, we recommend that the oil is drained and the amount
compared to the specified oil quality;

Evaluating oil color

Assume that the oil has been overheated if it is black and /or a burnt oil smell is
detected. Change the oil;

c) Evaluation of foreign substances found in the oil

If gear oil is polluted seriously, change it even if it has not reached the oil change
intervals. Refer to the following table:

Oil changing
Items Test method
index

Appearance Abnormal Visual

Kinematic viscosity change rate (40℃) % > +15 or -20 GB/T265

Moisture, % > 0.5 GB/T260

Mechanical impurities, % ≥ 0.5 GB/T511

08 - 9
Crane inspections

Corrosion grade of copper sheet (100℃,3h),


3b GB/T5096

OK value measured from Timken method,N
133.4 GB/T11144

d) Visual inspection

The reducer shall be checked for leakage, since loss of oil, in addition to polluting
the environment, can lead to gear failure.

e) Inspecting the brakes

Check the brakes each time the drive devices are inspected.

If the brakes are invalid, they shall be dismantled to determine the cause. Do not
use the crane until the failures are removed. Whenever a planetary drive device is
dismantled because of accumulated pollutants in the oil, the brakes shall also be
inspected.

Warning

Only qualified personnel with specialized knowledge shall be used to do the


repair work.

f) Documenting the completed inspection and tests

The results of each inspections and maintenance work, including the contents,
tasks and data, shall be documented by the competent or authorized inspector.

The “design life” is not equal to the real life of the mechanism. The actual life is
affected by many additional outside factors, for example:

1) Overload;

2) Inadequate maintenance:

- Oil is not changed in a timely manner

- Using the wrong type of oil

- Too much or too little oil

- Contamination during oil changes

3) Improper operation: extreme acceleration or braking of the load;

4) Assembly errors during repair and maintenance;

5) Undetected leakage;

6) Incorrectly set safety devices or safety devices defects;

7) Extreme environmental conditions:

- Extreme temperatures

- Corrosive atmosphere

08 - 10
Crane inspections

- Dust and dirt

Caution

The reducers must be repaired after using for 10 years.

8.4.4 Inspecting the hooks

The hooks must be often inspected for distortion and for thread corrosion / wear and
tear by a competent inspector.

The purpose of the inspections is to avoid accidents by detecting deficiencies in a


timely fashion. Stop using the hook after finding it.

Any deficiencies determined by the inspector must be documented, corrected, and


subsequently repaired or replaced.

Caution

Weld repair of hook’s disfigurement is not allowed.

8.4.5 Inspecting the wire rope pulleys

Inspect the entire wire rope pulley assemblies for damage and crack at least once a
year.

If wire rope pulleys are subjected to any impacts (e.g., with buildings) or are subjected
to other outside forces other than load forces, they must be immediately visually
inspected for damage or cracks.

Danger

Risk of accident when damaged or cracked!

Replace wire rope pulley as soon as possible.

Also check for wear on the rope groove. Replace the pulley if the bottom of the rope
groove has been worn down more than 1/4 of the rope diameter.

8.4.6 Inspecting the crane wire ropes

Wire ropes shall be checked regularly. Strict inspection must be made to the ropes
which are to be newly used after installation. Furthermore, if wire ropes are subjected to
special tightening force or damages to ropes are invisible or damages just appear,
particular attention must be paid to checking safety of wire ropes in the following
aspects:

a) Type and number of wire breaks;

b) Position and time of wire breaks;

c) Rope diameter reduction during working;

d) External and internal wear, corrosion and deformation;

08 - 11
Crane inspections

e) Damage caused by the effects of heat;

f) Total time for being placed.

For take-down criteria, please refer to the Chapter 7 “Maintenance and service”.

Furthermore, the rope end connections must be checked regularly for reliability. Visible
impression shall not be appeared at the contacting position between wire rope and
drum and between wire rope and pulley.

Special attention must be paid after any events that may lead to changes to the rope
and whenever the rope starts to be used again after being take down and then
re-installed.

8.4.7 Inspecting the mounting of the load bearing equipment

Check that the mounting bolts for the slewing ring, slewing reducer and winch reducer
are properly seated at least once a year.

Slewing ring connection mounting bolts are pre-stressed at the factory, so that no
loosening of the bolted connections will occur during normal crane operation.

However, the bolted connection may become overloaded and the bolts may be
permanently stretched if the crane is overloaded or if a fixed load is pulled free. It is
therefore important to check these bolts for proper seating during the annual crane
inspection or after an overload has occurred.

Completely remove loose bolts, plus the two adjacent ones, and immediately check for
damage.

Inspect the bolts, particularly for cracks or permanent distortion. Replace any bolts that
have stretched more than 2% (referred to their original length) or that have cracks or
other damage. If any bolts have stretched or are otherwise damaged, also replace the
two adjacent bolts.

For tightening torque of mounting bolts, please refer to Appendix 2.

8.4.8 Inspecting the oil and fuel reservoirs

Oil and fuel reservoirs shall be inspected at least once a year and checked all around
for leakage during the periodic inspections every year.

Repairs shall only be carried out by trained and knowledgeable specialists.

Improper repairs; e.g., welding, hard or soft soldering is not permitted, particularly if the
Customer Service Department at ZOOMLION has not been consulted!

8.4.9 Inspecting the hydraulic system

Check whether all elements and pipe lines in the hydraulic system are in good condition
from the following aspects:

a) Check whether mounting bolts for hydraulic pump are properly seated, and
whether abnormal vibration, noise and leakage occur during load application;

08 - 12
Crane inspections

b) Check whether air filters in hydraulic oil tank and oil return pipe line are blocked
and whether outlet of flange leaks oil;

c) Check whether slewing and hoisting motors leak oil, stop running or run abnormally,
and check their housings for deformation and cracks;

d) Check each connection at pipe lines in the hydraulic system for tightness and oil
leakage; check pipe clamps for tightness and cracks; check hoses for aging,
distortion and damages;

e) Check motions:

1) Check connected oil pipe fittings for proper seating;

2) Check mounting bolts for proper seating;

3) Check for leaks.

8.4.10 Inspecting the electrical system

Regular inspection can not only prolong service life of the vehicle, but also can improve
safety and comfort for the operation of vehicle.

Regularly inspected components listed in the following table are for vehicles which work
in dustless environment for 200h per month in temperatures between -20℃ – + 40℃.
Once the crane is used in harsh conditions or is used in coastal, desert and cold region,
shorten the inspection and maintenance intervals according to actual conditions.
Inspection
interval in Periodic inspection interval
break-in period
Component inspected
Every Every
60 200 Every Every
three six
hours hours month year
months months
Battery acid levels ○ ○ ○
Battery acid proportion ○
Starter commutator and
electrical brush ○
Generator ○
Check electrical wiring
joints for tight fit and ○
damage
Check lighting system for
its function ○ ○
Check horn, air
conditioning, heater and ○ ○ ○
defroster for their functions
Check wiper for function,
and check windshield
water-injector for function ○ ○ ○
and liquid level
Check each instrument
and control light for their ○ ○
08 - 13
Crane inspections

Inspection
interval in Periodic inspection interval
break-in period
Component inspected
Every Every
60 200 Every Every
three six
hours hours month year
months months
functions
Check each switch for
functional work ○
Note

Check the component marked with “○" within corresponding intervals.

Caution

Dismantle and inspect the starter and generator, and then replace damaged
components.

The assembly, disassembly, dismantling and re-assembly should be carried out


gently and stably with specialized tools. Damages to components should be
avoided.

– Battery

Superstructure and chassis are all equipped with two batteries connected in series
(12V for each battery). Single wire system is adopted in the complete vehicle and
the negative terminal is grounded through battery master switch. Batteries of this
vehicle meet the national standard GB/T 5008.1 - 2005.

In normal situations, if there are no malfunctions in electrical devices, batteries are


charged when the generator is supplying electricity for electrical devices.

If the battery is found not be charged or be under-charged which has affected the
starting of starting motor, the generator and the voltage regulator should be
inspected to eliminate the defects immediately.

Furthermore, keep batteries surface dry and clean. Clear off contamination and
electrolyte with a piece of cloth dampened with 10% density soda water and wipe
them with a piece of dry cloth.

If the crane is not in use for a long time, remove the batteries and charge them
once every three months. If it is not used within one month, cut off the circuit to
avoid self-discharging.

– Starting motor

Starting motor is a key component for the starting of engine. Therefore, often
inspect fastener of starting motor for firm connection, inspect conductive wire for
tight contact and inspect insulation of conductive wire for damage.

Clear off contamination and grease it for corrosion protection.

08 - 14
Crane inspections

In addition, remove dust cover from the motor regularly to inspect whether surface
of the commutator is smooth, whether carbon brush inside the bracket is seized,
and whether pressure of carbon brush spring is normal and clear off accumulated
dust.

Once the carbon brush wears excessively or surface of commutator is burnt


seriously or other failures occur, remove it to repair.

– Generator

Rated operating current: 70A

Voltage: 28 Volt DC

Maintenance should be applied to the engine every 1000 hours.

Clear off dust and oil on the surface of generator (especially on the terminal post),
and keep ventilation channel on.

Observe contact condition of carbon brush ring and check carbon brush for wear
and tightening condition.

Do not use megohm meter or power higher than 30V to test the engine and only
use universal meter to detect it.

8.4.11 Inspecting the safety devices

Function test shall be carried out on safety devices, such as load moment limiter,
hoisting limit switch and lowering limit switch before crane operation.

a) The inspection of load moment limiter can be carried out as follows:

1) Telescope out the boom to its maximum length; lift the boom from its minimum
working radius to its maximum working radius; check the display of weight in
load moment limiter to ensure that weight deviation does not exceed ±5% of
load weight.

2) Telescope out the boom to its maximum length; measure actual radius at its
minimum working radius; measure the actual radius at its 45°; compare the
two values and the deviation between them shall not exceed ±5%.

b) The inspection of hoisting limit switch can be carried out as follows:

– Install hoisting limit switch and lift the hook without load slowly.

– Do not stop lifting until the hook reaches the limit weight of hoisting limit
switch.

– Observe whether the hoisting limit switch is activated.

c) The inspection of lowering limit switch can be carried out as follows:

– Telescope out the boom to its maximum length;

– Lift the boom to its maximum angle and reel off the wire rope slowly;

08 - 15
Crane inspections

– Require another person to observe rope guiding condition;

– Check whether the lowering limit switch is activated when only 3 hoist rope
windings are left on the winch.

– Check main / auxiliary winch in the same method.

Danger

Risk of serious accident due to abnormal operation of safety devices!

08 - 16
Crane inspections

8.5 Inspection interval

Components of the vehicle (including diesel engine) will wear in different grades during
operation. Maintenances should be carried out in accordance with operating
instructions for vehicle and diesel engine. When necessary, tests and maintenances
should be carried out regularly according to the requirements of local environment
protection department.

Regular inspection can not only prolong service life of the vehicle, but also can improve
safety and comfort for the operation of vehicle.

Maintenances should be carried out in accordance with the checklist and actual
operating conditions for crane. Regularly inspected components listed in the following
table are for vehicles which work in dustless environment for 200h per month in
temperatures between -20℃ – + 40℃. Once the crane is used in harsh conditions or is
used in coastal, desert and cold regions, shorten the inspection and maintenance
intervals according to actual conditions.

For individual units, the manufacturer’s specifications must be observed.

The maintenance tasks on the crane superstructure are carried out entirely on
operating hours.

The maintenance tasks on the crane chassis are carried out based either on operating
hours or by kilometers traveled.

8.5.1 Inspection interval - chassis


Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
Engine
Check reducer box for
distortions and cracks ○ ○ ○
Check reducer bearing
for wear ○ ○ ○
Check engine RPM and
deaerating state ○ ○ ○
Tighten air cylinder
cover manifold ○ ○
Check valve clearance ○ ○
Tighten fixing bolts for
engine ○
Wash fuel filter screen ○ ○
Discharge sediments in
fuel tank ○
Change coolant ○
Check tightening state of
radiator cover ○
Check V-shaped belt for ○ ○
08 - 17
Crane inspections

Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
tightness and damage

Caution

a) For maintenance and service of parts for engine, please refer to related chapters in
Maintenance and Service Manual for Diesel Engine.

b) Antifreeze, anti-rusting and anti-corrosion additive, which have certain toxicity, are
added in the engine coolant and engine oil. Do not contact with skin repeatedly for a
long time. Dispose them in accordance with local environmental laws and regulations
after using it.
Drain out the water
accumulated in the air ○ ○ ○
reservoir
Check air pressure and
air rising state ○ ○ ○
Clean or
Air filter wash ○ ○
Replace ○
Replace filter cartridge ○ ○
Discharge
sediments ○ ○
Fuel filter Replace
filter ○
cartridge
Discharge
sediments ○ ○
Oil-water
Replace
separator
filter ○
cartridge
Check oil
level and
Engine oil polluted ○
state
Replace ○ ○
Power system
Check each part of
power system for air and ○ ○ ○
oil leakage
Check play of clutch
pedal and performance ○ ○ ○
of clutch
Check control system of
transmission for ○ ○
vibration
Check connecting parts
of propeller shaft for ○ ○
08 - 18
Crane inspections

Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
proper seating
Check propeller shaft for
swing and spline for ○
vibration
Check bearing of
propeller shaft for ○ ○
vibration
Check intermediate
bearing of propeller shaft ○
for proper seating
Check rear axle flange
and driving flange for ○
proper seating
Check oil
Brake fluid level ○ ○
of clutch
Replace ○
Check oil
Gear oil for level ○ ○
transmission
Replace ○ ○
Check oil
Gear oil for level ○ ○
rear axle
Replace ○ ○
Fill grease for clutch
changeover mechanism ○
and fork shaft
Wash deaerating nipple
on the transmission and
blow with compressed ○ ○
air
Driving system
Check each part of front
axles and rear axles for
proper seating, crack, ○
damage and
deformation.
Check wheel screw cap
for proper seating ○ ○ ○
Check bearing for front
wheel hub for vibration ○
Check bearing for rear
wheel hub for vibration ○
Check tire pressure (tire
tread depth, abnormal
abrasion, metal sheet, ○
stone and foreign
matters)
Check tire rotation ○

08 - 19
Crane inspections

Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
Check wire hoop for
damage ○ ○ ○
Replace lubricating
grease and oil seal for ○
wheel hub bearing
Steering system
Check steering system
for oil leakage ○ ○ ○
Check each part (drag
rod, arm, hoses, and
pipelines) of steering
system for proper ○ ○ ○
seating, vibration and
damage
Check play and
operating state of ○ ○ ○
steering wheel
Check performance of
power steering gear ○
Positioning of front
wheels ○
Check leftward and
rightward rotation angle ○
Oil for Check oil
power level
steering Replace ○ ○
Brake system
Check each part of
brake system for air and ○ ○ ○
oil leakage
Check each part of
brake system for proper
seating, vibration and ○ ○ ○
damage
Check play of brake
pedal or stroke of brake ○ ○ ○
chamber push rod
Brake performance ○ ○ ○
Clearance of brake lining ○ ○
Check brake lining for
abrasion ○
Check brake drum for
abrasion ○
Check performance of
parking brake and
control reliability of ○ ○ ○
parking brake hand lever

08 - 20
Crane inspections

Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
Check friction loss
between parking brake ○
drum and friction lining
Check performance of
brake chamber and
friction loss of friction ○
parts
Check clearance
adjusting arm for crack ○
Check oil
Brake fluid level

Replace ○ ○
Suspension system
Check each part of
suspension system for
proper seating, vibration ○ ○ ○
and damage
Check leaf spring for
damage ○
Check shock absorber
for oil leakage and ○
damage
Electrical system
Battery acid levels ○ ○ ○
Battery acid proportion ○
Starter commutator and
electrical brush ○
Generator ○
Caution

Dismantle and then inspect the starter and generator. Replace damaged components.

The assembly, disassembly, dismantling and re-assembly should be carried out gently and
stably with specialized tools. Damages to components should be avoided.
Check electrical wiring
joints for tight fit and ○
damage
Chassis accessories
Check lighting system
for its function and ○ ○
damage
Check horn, air
conditioning, heater and
defroster for their ○ ○ ○
functions
Check wiper, windshield
water-injector for their ○ ○ ○
08 - 21
Crane inspections

Inspection interval
New vehicle Every Every Every
Component inspected Every Every 3 Every 6 Every
60 200 200 500 1000
month months months year
hours hours hours hours hours
functions and liquid level
Check each instrument
and control lights for ○ ○
their functions
Check every type of
switches for functional ○
work
Check switch and
control light of PTO for ○ ○
functional work
Change lubricating oil for
PTO ○
Caution

Change with new lubricating oil after the new PTO has been worked for 20 hours.
Check exhaust pipe and
silencer for proper ○ ○
seating and damage
Check exhaust silencer
for functional work ○
Check door locks for
functional work ○
Check driver’s cab and
mudguard for proper ○ ○
seating and damage
Fill grease to each part
of chassis ○ ○

08 - 22
Crane inspections

8.5.2 Inspection interval - superstructure

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

Slewing mechanism
Check slewing
table for crack ○ ○
and deformation
Check oil level
and pollution
grade for reducer ○ ○
and slewing ring
Check reducer
and slewing ring
housing for crack, ○ ○
deformation and
oil leakage
Check reducer
and slewing ring
for abnormal ○ ○
noise and
vibration
Check mounting
parts of reducer
and slewing ring ○ ○
for proper seating
Check working
pressure of ○ ○ ○
hydraulic motor
Check oil pipe
fittings for proper
seating and oil ○ ○
leakage
Derricking mechanism
Check
articulated-point
of derricking
cylinder for ○ ○
abrasion and
damage
Check locking
plate bolts of pivot
pin of derricking ○ ○
cylinder for proper
seating

08 - 23
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

Check derricking
cylinder for oil ○ ○
leakage
Check derricking
cylinder for
vibration and ○ ○
noise
Check whether
derricking
cylinder will
retract ○ ○
inadvertently
during operation
check hoses for
aging, distortion ○ ○
and deformation
Telescoping mechanism
Check main boom
for crack, bending ○ ○
and damage
Check locking
plate bolts of pivot
pin of basic boom ○ ○
for proper seating
Check
articulated-point
pin sleeve of main ○ ○
boom for abrasion
and damage
Check lubricating
state of main
boom sliding ○ ○
surfaces
Check boom
support for
deformation and ○ ○
crack
Check working
state (pulsation,
noise and working
sequence) of ○ ○
telescopic
cylinder
Check telescopic ○ ○
08 - 24
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

cylinder for oil


leakage
Check balance
valve for ○ ○
functional work
Check oil pipe
fitting for proper ○ ○
seating
Check hoses for
aging, distortion ○ ○
and damage
Check jib for
bending, crack ○ ○
and deformation
Check lubricating
state of
connecting pin ○ ○
and pin sleeve for
jib
Check rooster
sheave for
bending, crack ○ ○
and deformation
Check lubricating
state of
connecting pin ○ ○
and pin sleeve for
rooster sheave
Check wire rope,
and lubricate ○ ○
when necessary
Hoisting mechanism
Check hydraulic
motor for proper ○ ○
seating and crack
Check hydraulic
motor for oil ○ ○
leakage
Check hydraulic
motor housing for
deformation and ○ ○
crack
Check hydraulic
motor for noise ○ ○
08 - 25
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

and vibration
Check oil pipe
fittings for proper
seating and oil ○ ○
leakage
Check reducer for
proper seating。 ○ ○
Check reducer for
noise ○ ○
Check reducer
box for crack and ○ ○
deformation
Check reducer
bearing for ○ ○
abrasion
Check balance
valve for oil ○ ○
leakage
Check oil pipe
fittings of balance
valve for proper ○ ○
seating and oil
leakage
Check balance
valve for pulsation ○ ○
Check wire rope,
and lubricate ○ ○
when necessary
Parts in hydraulic system
Check hydraulic
oil tank for proper
seating and ○ ○
damage
Check hydraulic
oil tank for crack ○ ○
and oil leakage
Check oil level,
pollution grade ○ ○
and viscosity
Check hydraulic
pump for proper
seating and ○ ○
damage
Check hydraulic ○ ○
08 - 26
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

pump for
abnormal noise,
vibration and heat
generation
Check hydraulic
pump for leakage ○ ○
Check whether air
enters into oil ○ ○
suction pipeline
Check hydraulic
pump for normal ○ ○
output pressure
Check fittings for
hydraulic pump
pipeline for proper ○ ○
seating and oil
leakage
Check control
valve for ○ ○
functional work
Check control
valve for oil ○ ○
leakage
Check bolts of
control valve for ○ ○
proper seating
Check setting
pressure of relief ○ ○
valve
Check main oil
cylinder for ○ ○
functional work
Check main oil
cylinder for oil ○ ○
leakage
Check connecting
parts of pipelines ○ ○
for proper seating
Check connecting
parts of pipelines ○ ○
for oil leakage
Check pipe clamp
for proper seating ○ ○
and crack

08 - 27
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

Check hoses for


aging, distortion ○ ○
and damage
Control system
Check joysticks
and pedals for ○ ○
functional work
Check lighting
system for ○ ○
functional work
Check wiper and
windshield for ○ ○
functional work
Check
instruments and
control lights for ○ ○
functional work
Check switches
for functional ○ ○
work
Check nuts and
bolts for
operator’s cab for ○ ○
functional work
Check windows,
doors and door
locks for ○ ○
functional work
Safety devices
Check load
moment limiter for ○ ○
functional work
Check hoisting
limit switch for ○ ○
functional work
Check lowering
limit switch for ○ ○
functional work
Check main boom
angle indicator for ○ ○
functional work
Check the 5th
outrigger ○ ○
overpressure

08 - 28
Crane inspections

Inspection interval

New vehicle

Component
Every Every Every
inspected Every Every 3 Every 6 Every
200 500 1000
60 200 month months months year
hours hours hours
hours hours

warning device
for functional
work
Outrigger
Check vertical
cylinders for ○ ○
functional work
Check outriggers
and their
horizontal ○ ○
cylinders for
functional work
Check control
valve for ○ ○
functional work
Check level
gauge for ○ ○
functional work
Others
Check chassis
frame for
distortion, ○ ○
bending and
crack
Check
accessories for ○ ○
damage and loss

08 - 29
Crane inspections

Appendix 1: Inspection checklist

Inspection category 1: Crane documents


Component inspected A B C D Comments
Operating instructions
Spare parts catalog
Attached spare parts list
Attached tools list

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 2: Signs / labeling


Component inspected A B C D Comments
Factory name plate
Operating illustration
Warning labels and
instructions
Other safety labels

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 30
Crane inspections

Inspection category 3: Driver’s cab

Component inspected A B C D Comments

Doors

Windows (curtain)

Windshield wipers

Outside mirrors

Seats
Air conditioning, air venting
device
Player

First-aid kit

Emergency lamp

Fire extinguisher

Warning triangle board

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 31
Crane inspections

Inspection category 4: Engine and its peripheral system

Component inspected A B C D Comments

Engine

Suspension

Fuel tank

Fuel filter

Fuel lines

Air intake system

Silencer

Exhaust system

Water tank

Intercooler

Oil levels

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 5: Drive mechanism

Component inspected A B C D Comments

Axles

Wheels

Clutch

Transmission

Propeller shaft
Non hydro-pneumatic
Leaf springs
suspension axle
Vibration damper

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 32
Crane inspections

Inspection category 6: Chassis - control systems

Component inspected A B C D Comments

Engine speed regulator

Drive device

Shift of gear

Steering

Monitoring indicators
Engine braking
performance
Outrigger controls

Axle suspension

Axle suspension

Rear axle steering

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 7: Chassis - air pressure system

Component inspected A B C D Comments

Air compressor

Air reservoir

Valves

Piping

Hoses

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 33
Crane inspections

Inspection category 8: Chassis - electrical system

Component inspected A B C D Comments

Motors

Generators

Battery

Wiring

Fuses

Brake lights

Warning lights

Corner marker lights

Reversing lights

Front / rear fog lamps

Front / rear turn signals

License plate lamp

Side marking lights

Headlamp

Signaling devices

Battery master switch

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 34
Crane inspections

Inspection category 9: Superstructure

Component inspected A B C D Comments

Telescopic boom

Slewing table

Counterweights
Counterweight operating
device
Positioning device for
slewing table
Slewing ring: Tilting free
play
Slewing ring
Slewing ring: Mounting
bolts
Slewing reducer
Slewing reducer: Mounting
bolts
Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 10: Superstructure - operator’s cab

Component inspected A B C D Comments

Doors

Windows / Windshield

Windshield wipers

Seat

Air conditioning

Ventilation

Function control button

Emergency hammer

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 35
Crane inspections

Inspection category 11: Superstructure – hoisting mechanism and its accessories

Component inspected A B C D Comments

Main winch

Auxiliary winch

Wire rope pulley


Wire rope end
connection
Wire rope for main winch
Wire rope for auxiliary
winch
Pulleys

Main hook

Auxiliary hook

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 12: Superstructure - hydraulic system

Component inspected A B C D Comments

Oil tanks

Oil filters

Pumps

Motors

Valves

Piping

Hoses

Oil cylinders

Pressure relief valves

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 36
Crane inspections

Inspection category 13: Superstructure - electrical system

Component inspected A B C D Comments

Switches

Wiring

Fuses

Lighting and signals

Electric horn

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 14: Superstructure – safety and control devices

Component inspected A B C D Comments

Hoisting limit switch

Lowering limit switch

Load moment limiter

Angle indicator

Angle sensor

Pressure sensor

Wind speed sensor

Level gauge

Length detector

Emergency stop

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

08 - 37
Crane inspections

Inspection category 15: Superstructure - hand-hold and protection devices

Component inspected A B C D Comments


Grab handles and
ladders / treads
Hood

Doors

Baffle

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Inspection category 16: Others

Component inspected A B C D Comments

Platform

Attached tools

Securing device for hook

Boom support

Welding structures

Inspection criteria:

A: in good condition B: to be repaired / replaced

C: repaired / replaced D: to be re-inspected

Assessment:

Satisfactory = × Unsatisfactory = - Not required = 0

Note

Inspection of the crane carrier vehicle roadworthiness is also fulfilled if it has


already been certified by the road traffic department certification authority. For
truck cranes that are not certified for use on public roads, a competent or
authorized inspector must conduct the tests to validate the vehicle’s
roadworthiness.

08 - 38
Crane inspections

Appendix 2: Tightening torque of mounting bolts

Strength grade(GB/T3098.1-2000)

8.8 10.9
Diameter of
Specification Yield strength limit for bolt material max
mounting hole
(GB/T5782-2000) (MPa)
(mm)
640 900

Pre-tightening torque MA(N·m)

M10 11 44 62

M12 13.5 77.5 110

M14 16 120 170

M16 18 190 265

M18 20 260 365

M20 22 370 520

M22 24 500 700

M24 26 640 900

M27 30 950 1350

M30 33 1300 1800

Pre-tightening force FA(103N)

M33 36 293 412

M36 39 344 484

M39 42 414 581

M42 45 473 665

M45 48 553 777

M48 52 623 876

M52 56 749 1054

M56 62 863 1214

M60 66 1008 1418

08 - 39
OPERATING INSTRUCTIONS FOR ZOOMLION
R
® TRUCK CRANE
中联 汽车起重机使用说明书

Chapter 9 Diagnostics
Diagnostics

9.1 Diagnosis and troubleshooting

If failures occur during crane operation, carry out a thorough checks and analysis to find
out the causes, and remedy them. Troubleshooting for common failures is listed in the
following tables for reference.

For serious failures, please contact our company or distributor.

9.2 Chassis, troubleshooting

– Emergency measures

If there is no compressed air supplied when the air brake system is failed, the
springs installed in the brake chamber for intermediate and rear axles are actuated
to make the vehicle in brake state.

If you want to move the vehicle compulsorily, the parking brake condition must be
released. Detailed steps are as follows:

 Loosen the nuts at the chamber tail with spanner;

 Screw out the threaded rod for about 64mm.

Warning

Once air source is supplied or the faults are rectified, screw in the threaded
rod timely; otherwise, parking brake will not be in function.

Caution

Force of spring under working conditions is about 800kgf; therefore,


dismantling must be carried out by specialists with special attention.

If the engine defects cannot be eliminated according to Maintenance and Service


Manual for QSC series Diesel Engine and the following tables, send the vehicle to
factory for repairing.

09 - 1
Diagnostics

9.2.1 Clutch

Problem Causes Remedy


Free stroke of clutch pedal is too small. Check and adjust
Pressure spring has reached the softness limit or
Replace spring
breaks off.
Wash with
Friction lining is oily. gasoline or
kerosene
Friction lining surfaces are hardened, head of
Skid around, Replace friction
rivet is revealed, or its surfaces have reached
powerless when lining
wear limit.
climbing the
ascending Rivets for driven disc steel plate and groove hub
Re-rivet
gradients and flange loose.
abnormal smell Groove of groove hub and the spline groove of
the 1st shaft of transmission have reached wear Replace
limit and even skid.
Rectify release
bearing bushing
Release bearing bushing is seized. and the 1st
bearing cover of
transmission
Continue to use
Clutch lining hub and bearing groove of the 1st when noise is not
shaft of transmission loose. aloud, replace
when it is serious
Release lever or bracket pin wear and loose. Replace
Release bearing lacks oil or wears. Return spring Lubricate bearing
has reached the softness limit, breaks off or falls and replace
Abnormal noise
off. return spring
Friction lining worn, rivets loosened, head of rivet
Replace friction
revealed, torsional spring damaged and spline
lining
worn.
Pedal shaft is insufficiently lubricated, and return Lubricate pedal
spring of the pedal has reached the softness limit shaft and replace
and falls off. spring
Adjust to the
Free stroke of clutch pedal is too large.
standard value
Driven disc is deformed, or friction lining is
Replace
The clutch is not damaged.
disengaged Replace with
completely, standard friction
causing it is lining or add
difficult to The new friction lining is over-thick or the front
metal shim in
engage the gear and rear driven discs are mounted at wrong
proper thickness
or gear sounds. positions.
between clutch
cover and
flywheel housing
Bracket bolt of release lever or support ring pin of Tighten
09 - 2
Diagnostics

Problem Causes Remedy


release fork looses.
The height of release lever is different. Adjust
Air leakage occurs in oil pipe fitting, or oil leakage Deaerate, replace
occurs in main cylinder and booster. cup or piston

09 - 3
Diagnostics

9.2.2 Transmission

Problem Causes Remedy


The input shaft of transmission and the guide
Check and
bearing inside the engine flywheel are not
replace
concentrically installed.
Gears collide violently during gearshift, thus Check and
causing engaging gear end surfaces to wear. replace
Engaging gear has been worn to the shape of Check and
pyramid. replace
Locking spring weakened or damaged, causing
Check and
pressure on the positioning steel ball of fork shaft
replace
insufficient.
Throw-out of
gear occurs in Positioning groove of fork shaft has reached wear Check and
the main limit. replace
transmission. Connecting rod of gearshift mechanism is
improperly adjusted, thus causing engaging gear
Adjust or replace
and sliding sleeve not to engage in the whole
length.
Throw-out of gear occurs after decelerating when
the vehicle is driving in full-power or when it is Operate correctly
pushed by outside force.
In off-road driving conditions, the range selector Adjust tightness
will swing leftwards and rightwards. When locking of gearshift
spring force is overcome, throw-out of gears control
occurs. mechanism
Collision occurs during gearshift. Operate correctly
Normal wear after a long period of operation. Replace
Throw-out of Propeller shaft is not properly installed, or
Check, adjust and
gear occurs in vibration occurs caused by balance block falling
replace
the auxiliary off.
transmission. Check and
replace
Air line system pressure is not sufficient.
high-pressure
valve
Connecting fork or bushing in the connecting rod Check, adjust,
of gearshift mechanism wears, or is improperly replace and
engaged, adjusted and poorly lubricated. lubricate
Main shaft distortion, and fork or main shaft spline
bending make spline of the 2nd shaft sliding Replace and
sleeve or synchronizing gear sleeve is engaged lubricate
It is difficult to on the main shaft.
shift gears. Breakage of the shell, excessively large
tightening torque for locking screw on the Replace and
gearshift shaft, causes fork shaft bending and fork tighten to required
shaft surfaces collision. As a result, fork shaft is torque
engaged into the upper cover shell.
Tighten to
Locking screws on the gearshift shaft loose.
required torque
09 - 4
Diagnostics

Problem Causes Remedy


Check. Fill oil to
Improper lubrication. Oil level is too low or too required level.
high or oil brand is incorrect. Replace with
qualified oil.
Turn off the
Driving on the ascending gradient over 12° for a engine to lower
Transmission long time, or the ambient temperature is too high. the temperature
temperature of the engine oil.
reaches the
upper limit. Drive the vehicle
Driving the vehicle at low speed for a long time.
at proper speed.
Check and adjust
engine control to
Engine RPM is excessively high. make engine
RPM fulfill the
requirements.
It is caused by collision of gear
faces inside the transmission. It
can be distinguished from bright
spots appeared after strong
Rubdown with
milling of gear face. Knocking
oilstone or
sound will be louder when the
grinding wheel
gear bears load. Therefore, if the
noise sounds once the gear is
engaged, it indicates that the gear
defects.
Knocking
Abnormal noise. If ball or roller of bearing is
sound
damaged, pitting appears on the
roller bed, or the roller bed falls Replace
off. As a result, noise sounds from
each gear at low speed.
If cracks appear after gear is
cracked by load or during
assembly, knocking sound will be
Replace
heard at low speed and
screaming will be heard at high
speed.
It is caused by normal wear of the
gear, including pitting after a long
Replace
period of operation. Whistling will
Whistling be heard before it is damaged.
sound
Gear is improperly engaged. It
can be distinguished by uneven Replace
wear of gear face.
Abnormal noise
It is caused by “gears matching”
error. Roaring sound will be heard
Roaring when “gears matching” of the
Check and adjust
sound transmission is incorrect during
re-assembly or when gears rotate
on the auxiliary shaft.
Sound Sound sounds like “Click-clack” Check, adjust or
09 - 5
Diagnostics

Problem Causes Remedy


sounds like will be heard if the axial clearance replace
“Click-clack” between bearings of auxiliary
shaft and main shaft is
excessively large or when torque
is changing its direction. Enlarged
center distance of shaft, which
caused by excessively large radial
clearance of auxiliary shaft
bearing, will bring the load acting
on gear top and breakage of gear
teeth.
Check power
No power supply in the complete vehicle.
supply and rectify
Check
Engine cannot Neutral switch is not energized. corresponding
be switched on. lines and rectify
Replace
Control pin of neutral switch is seized or the
corresponding
switch is on / off all the time.
parts
Reverse gear, Range selector is not properly adjusted.
gradient Range selector cannot be in position of reverse
Check and adjust
–climbing gear gear, hill-climbing gear or gears 7 and 8 due to
or gears 7 and 8 improper adjustment.
cannot be Inner chamber of single-H valve of transmission is Check, rectify or
engaged. interfered. replace
Gears are not Range selector is interfered. Check and adjust
clear and cannot
be changed Fork shaft for gear1/2 and guide block for gear
directly. The Replace
1/2 of transmission, or fork shaft for gear 3/4 and
neutral position damaged parts
guide block for gear3/4 of transmission defect.
is not correct.
Contactor of single-H valve is seriously worn,
Replace or rectify
causing high gears invalid.
Contactor of single-H valve is retracted and
Replace or rectify
seized, causing low gears invalid.
Reverse gear Dismantle
speed cannot be single-H valve
changed by and changeover
changeover Inside of single-H valve of transmission is manually. If it is
switch for high / improperly adjusted or worn. normal, remove
low gear range. gasket of the
valve and then
install to try again.
Single-H valve of transmission is completely
Replace single-H
damaged by collision (no matter whether the
valve
appearance is damaged or not)
One of the gears Rectify two sides
is difficult to be The head of range selector is excessively big. of the head,
engaged or without rectifying

09 - 6
Diagnostics

Problem Causes Remedy


disengaged. the arc on the two
sides of the head.
Guide block interferes. Replace or rectify
Before setting off,
engage the gear
after the clutch
The range pedal is
selector will depressed for a
sound when few seconds.
engaging the Improper operation. Change gear
gear before according to the
starting off and vehicle speed
during driving. during driving. Do
not upshift or
downshift 2 or
more gears.

09 - 7
Diagnostics

9.2.3 Propeller shaft

Problem Causes Remedy

Universal joint cross trunnion, needle roller wear Replace


Abnormal noise and loose or needle roller broken. damaged one
during vehicle
Propeller shaft spline and expansion joint Replace
start,
splineway have reached wear limit. damaged one
accelerating and
decelerating. Spline in the 2nd shaft of transmission and flange Replace
splineway have reached wear limit. damaged one
Periodical noise Propeller shaft bent or propeller shaft flange not Replace
during driving. welded properly to shaft tube. propeller shaft
The higher the Fixing bolts for intermediate bearing bracket loose Tighten or
speed is, the and deviate from original position. replace
louder the noise
is. In a serious Bolts connecting adjacent propeller shafts loose. Tighten
condition, the
whole vehicle
flutters and
Propeller shaft balance block falls off. Replace or repair
steering wheel is
not flexible.
Intermediate bearing deviate from original position
Noise during Adjust or replace
and has reached wear limit.
driving. The
higher the speed Bearing ball of intermediate bearing falls off. Replace bearing
is, the louder the
noise is. Add #2 lithium
Insufficient oil in Intermediate bearing.
base grease

09 - 8
Diagnostics

9.2.4 Intermediate and rear axles

Problem Causes Remedy


Noise sounds like "si" during accelerating or
decelerating: meshing clearance of gears too Adjust
small or poorly meshed.
Observe after
New gear poorly meshed
breaking-in.
Noise sounds like "clash" on descending gradients
or during changing vehicle speed jerkily. Noise Adjust or replace
fades away or decreases during normal driving: gear.
meshing clearance of gears too large.
Abnormal noise Continuous noise during driving. The higher the
speed is, the louder the noise is. But noise fades Adjust or replace
away or decreases during sliding: the bearings (on bearing.
hub, main reducer or differential) wear and loose.
Gear oil level too low or oil viscosity do not meet Add oil according
requirements. to requirements.
No noise during straight driving but noise sounds
during turning: clearance of bearings on both
Adjust or replace
sides of reducer too large. Differential gear or
thrust bearing shim wears.
Bearing installed too tightly. Meshing clearance
Adjust
too small.
Fill oil to required
Oil level too low.
Heat generation level.
Replace with
Lubricant viscosity too low. required
lubricant.
Oil seal invalid. Replace it
Replace
Axle journal wear.
damaged one.
Drain oil to
Oil leakage Oil level too high
required level.
Sealing gasket damaged. Replace it
Bolt loose. Tighten
Vent cap soiled. Clean

09 - 9
Diagnostics

9.2.5 Steering system

Problem Causes Remedy


Oil pump serious inner wear results in hard Replace and
steering check
Seal elements of oil pump damaged, resulting in Replace seal
oil leakage elements
Check the oil
level and fill
Oil level is too low and the oil viscosity does not
required oil.
comply with the requirement, resulting in
Deaerate. Check
insufficient steering power. Air enters into the
oil level and pipe
system.
fittings for
tightness.
Check and
Drive elements of oil pump damaged.
replace
Repair safety
Spring of safety valve in oil pump is fatigue or
valve and replace
Hard steering breaks, resulting in oil over-returned.
spring.
Check, clean and
Oil leakage occurs in oil pipe fittings and pipes are
replace the pipes
blocked or bent.
and fittings.
Clean filter and
Filter soiled, poor cleanliness cartridge. Oil
change.
Rectify or replace
Serious inner leakage occurs in steering gear.
sealing ring
Front wheels blocked (brake cannot return to Rectify the
original position) blocked parts
Replace bearing
Steering knuckle main pin, thrust bearing and
and adjusting
adjusting shim damaged, resulting in clearance
shim. Adjust
too large or small.
clearance.
Inner leakage Rectify oil pump
Fill oil equalizing
reservoir up to
Oil level is too low.
overflow on filler
neck
Quick steering is
hard Oil seal for steering wheel is damaged or has
Replace oil seal
reached wear limit, resulting inner leakage.
Deaerate and
check connecting
Air enters in.
parts for
tightness.
Steering is Floating brass bush of steering pump is blocked
sometimes hard and does not contact with wheel end-face tightly Rectify oil pump.
or sometimes all the time.
uncontrolled Sealing ring of piston in steering gear is polluted. Clean it.

09 - 10
Diagnostics

Problem Causes Remedy


Thrust bearing ring in screw rod of steering gear
Replace bearing.
damaged.
Hydraulic oil level is too low or is polluted or air Add oil, change
enters into the system. oil or deaerate.
Bearing of knuckle spindle damaged. Replace bearing.
Oil leakage occurred in the two sides of piston in Replace seal
steering gear are not the same. ring.
Air enters into one of the chambers. Deaerate
Left steering is
uncontrolled Check and
while right Mounting screws in steering gear and power
tighten the
steering is hard, cylinder bracket loose.
and vice versa screws.
Clearance between ball head pins of drive rod is
Check or replace
too large.
Check and inflate
Tire pressure of left / right steering wheel does not
to specified
meet the specified one.
pressure.
One of the steering wheels is in brake state for a Adjust or rectify
long time. brakes.
The clearance of left / right steering wheel are not Adjust bearing
same (one is too loose while the other is too tight clearance or
or blocked). replace bearing.
The vehicle
Check and
cannot drive in a Air enters into oil and direction is not stable.
straight line eliminate.
Steering wheels uneven wear. Tire rotation.
Check the
blocked parts.
Check whether
Steering axles are blocked.
input shaft is
blocked by radial
resistant force.
Vehicle axles are not properly seated, such as
Check and
steering axles do not aligned with the intermediate
adjust.
/ rear axles or improperly seated.
Steering drive rod is improper adjusted or has Adjust clearance
reached wear limit. or replace rods.
Loosen the
Free clearance locking nuts in the
of steering wheel side cover of
too large Drive pair in steering gear wear makes large
steering gear.
clearance.
Tighten it to
proper clearance.
Tighten torque is

09 - 11
Diagnostics

Problem Causes Remedy


130 to 180N.m.
Check and
Mounting screws in steering gear or tightening
tighten the
screws in suspension bracket loose.
screws.
Clearance between ball head pins of drive rod is
Check or replace.
too large.
Check and
Clearance of angle drive gear is too large.
adjust.
Fill oil equalizing
reservoir up to
Oil level is too low or air enters into the system.
overflow on filler
neck or deaerate.
Check the oil line
Oil line is poorly sealed and air enters into it. and take good
seal measures.
Check air
pressure. Inflate
Left / right steering wheel are not inflated equally. the left / right
Front wheel wheel with the
swings same pressure.
Check and
U-bolt of front leaf spring loose.
tighten.
Check and
Wheels loose.
tighten.
Check and
Connecting components of drive rod loose.
tighten.
Connecting components of drive rod lacks of Check and fill
lubricant. lubricant.
Steering gear is inner blocked. Check and rectify.
Steering wheel Distribution valve is polluted, resulting in slide
Clean and rectify.
cannot rebound valve being blocked.
smoothly Centering spring damaged. Replace spring.
Check and
Oil leakage caused by oil seal damage.
replace oil seal.
Oil leakage
Check and
occurs in Oil leakage occurs in O-ring.
replace O-ring.
steering gear
Check and
Oil pipe leaks oil or is damaged.
replace oil pipes.
Oil leakage occurs in connecting parts of oil pipe Check the leaking
Oil leakage fitting. point.
occurs in Oil viscosity too low. Use specified oil.
steering gear Check and
Joint face of hydraulic elements loose.
tighten.
Abnormal noise Oil pipes in hydraulic pipe lines blocked. Check oil line and

09 - 12
Diagnostics

Problem Causes Remedy


during steering replace damaged
one.
Replace oil
Displacement of oil pump is unstable.
pump.
Oil level in the oil tank too low. Fill oil.
Bubbles appears
Check pipes for
in hydraulic oil Pipes are not tightened and air enters in.
tightness.
tank
The vehicle does
not have firm
control of the Clean flow control
Flow control valve blocked.
ground when valve.
driving at high
speed

09 - 13
Diagnostics

9.2.6 Brake system

Problem Causes Remedy


Check and adjust
brake. The
clearance
Uneven brake force. between brake
drum and brake
shoe is about 0.3
Brake bias
to 0.5mm.
The air pressures inflated to the tires are not Check and inflate
same. pressure.
Check and
Brake shoe is not wear to the same extent. replace brake
shoe.
Check and adjust
brake. The
clearance
The clearance between brake shoe and brake
between brake
wheel hub is too small.
drum and brake
shoe is about 0.3
Brake locked to 0.5mm.
Brake chamber push rod returns un-smoothly. Repair or replace
Brake main valve and relay valve are cross
Repair or replace
connected inside.
Check and
Parking brake is unreleased. release parking
brake.
Inner leakage occurs in brake chamber. Repair or replace
Brake is invalid
Air leakage occurs in pipe line and valve. Repair or replace
and responses
Air drier invalid. Repair or replace
lag
Four-circuit protection valve invalid. Repair or replace
Coil of transversal and longitudinal solenoid valve
Repair or replace
damaged.
Spool of transversal and longitudinal solenoid
Differential lock Repair or replace
valve blocked.
does not work.
Air leakage occurs in end cover and pipe line of
Repair or replace
transversal and longitudinal solenoid valve.
Actuating cylinder of differential lock invalid. Repair or replace

09 - 14
Diagnostics

9.2.7 Electrical system

Problem Causes Remedy


Bulb damaged. Replace
Rectify and
The working Fuse burnt out.
replace
lights do not
Poor grounding. Rectify
illuminate.
Conducting wire broken. Rectify
Switch or relay invalid. Rectify or replace
Control lights on Switch invalid. Replace
instrument
console do not Conducting wire defects. Rectify
light up.

Warning light Check air line


Brake pressure is lower than 0.55Mpa.
“Brake pressure system.
too low” lights up Switch invalid. Replace
all the time. Conducting wire defects. Rectify
Rectify and
Fuse burnt out.
replace
Wiper does not Switch invalid. Rectify or replace
work.
Motor damaged. Replace
Conducting wire defects. Rectify
Rectify and
Fuse burnt out.
replace

Horn does not Switch invalid. Rectify or replace


work. Relay defects. Replace
Conducting wire defects. Rectify
Horn defects. Replace
Rectify and
Fuse burnt out.
Buzzer does not replace
work. Conducting wire defects. Rectify
Buzzer defects. Replace
Warning light Driving belt for generator looses or breaks off. Rectify or replace
“Charge Generator defects. Rectify or replace
monitoring”
lights up . Conducting wire defects. Rectify

Warning light Engine coolant temperature exceeds the Check engine


“Engine coolant maximum permissible value. cooling system.
temperature too Temperature sensor defects. Replace
high” lights up. Conducting wire defects. Rectify
Check engine
Warning light Engine oil pressure is lower than the minimum
lubricating
“Oil pressure too permissible value.
system.
low” lights up.
Engine oil pressure sensor defects. Replace

09 - 15
Diagnostics

Problem Causes Remedy


Conducting wire defects. Rectify
Check air line
Air pressure is lower than 0.55Mpa.
system.
Warning light
“Parking brake Parking brake lever invalid. Replace
closed” lights up. Low air pressure switch invalid. Replace
Conducting wire defects. Rectify
Warning light Detecting switch for “Door not closed well” invalid. Replace
“Door not closed
well” lights up. Conducting wire defects. Rectify

Warning light Rectify and fill


Coolant level in expansion water tank is too low.
“Engine cooling coolant.
water level too Switch invalid. Replace
low” lights up. Conducting wire defects. Rectify
Warning light Engine defects. Rectify
“Engine defects”
lights up. Conducting wire defects. Rectify
Rectify and
Fuse burnt out.
replace
No power supply
on the complete Ignition starter switch invalid. Rectify or replace
vehicle. Battery master switch invalid. Replace
Conducting wire defects. Rectify
Rectify and
Fuse burnt out.
replace
Ignition starter switch invalid. Rectify or replace

Starting motor Neutral switch invalid. Replace


does not work. Starting motor defects. Rectify or replace
Relay K17 damaged. Replace
Engine ECU defects. Rectify or replace
Conducting wire defects. Rectify
Switch invalid. Replace

Outrigger Relay K14 damaged. Replace


accelerator is PTO signal switch damaged. Replace
invalid. Engine ECU defects. Rectify or replace
Conducting wire defects. Rectify
Engine control pedal invalid. Replace
Relay K14 broken. Replace
Engine control is
PTO signal switch damaged. Replace
invalid.
Engine ECU defects. Rectify or replace
Conducting wire defects. Rectify

09 - 16
Diagnostics

9.2.8 PTO

Problem Causes Remedy


Oil seal or paper gasket breakage. Replace
Paper gasket is not sealed or just one face is Seal the two faces
sealed with sealant. with sealant.
Oil leakage
The PTO side cover is not tightly contacted Remove the side
with end-face of the housing of transmission cover of PTO and
rear cover. rectify.
Air leakage occurs in end cover and pipe line
Rectify or replace
of PTO solenoid valve.

PTO does not Spool of PTO solenoid valve blocked. Rectify or replace
work. Coil of PTO solenoid valve damaged. Rectify or replace
PTO control cylinder invalid. Rectify or replace
Intermediate shaft of transmission damaged. Check and replace
Gear is pitting corrosion seriously or broken. Replace
Bearing is pitting corrosion seriously or needle
Abnormal noise Replace bearing
roller or ball broken.
Bolts in hollow shaft end loose. Tighten or replace

09 - 17
Diagnostics

9.2.9 Tires

Problem Causes Remedy


Adjust the tie rod of
The insides of tires front axles for
on the steering steering along the
axles are seriously Toe-in too small or in negative value. stretching direction
worn to the same and increase the
extent toe-in value to
specified one.
Adjust the tie rod of
The outsides of front axles for
tires on the steering along the
steering axles are Toe-in too large. retracting direction
seriously worn to and decrease the
the same extent toe-in value to
specified one.
Steering axles and driving axles are not Adjust the axles in
The insides of tires aligned or the axles are improperly seated. proper position.
on the steering When one steering axle is in straight-line
axles on one side driving, another steering axle is not in
are seriously worn, Adjust the tie rod
straight-line driving. and drag link of
while the outsides
of tires on the front steering axles
Caution to make the two
steering axles on
another side are steering axles drive
If the crane is only equipped with single in straight line.
seriously worn steering axle, this kind of fault will not
occur.
Reinstall wheels or
Tires are standing wave: wheels deformed.
replace.
Saw-tooth wear Check whether too
Tires are standing wave: wheels not rotating in
much talcum
equalization.
powder in tires.
Adjust the brake
Wheels are in brake or semi-brake mode for a
clearance to
One side wheels long time.
specified one.
seriously wear
The specification or size of wheels on this side
Replace
does not meet the requirements.
Drive axles are not aligned. Adjust
Close transversal
Transversal or longitudinal differential lock or longitudinal
Tires on driving switch is not closed, resulting in the driving differential lock
axles seriously axles in locking mode for a long time. during normal
wear driving.
Transversal or longitudinal differential lock is
Rectify, or replace
defective, resulting in the driving axles in
the defective one.
locking mode for a long time.
Overloading caused by putting excess weight Remove the weight
Tire bursting
on the crane during driving. and replace

09 - 18
Diagnostics

Problem Causes Remedy


wheels.
Replace. Do not
drive the vehicle at
Vehicle is driving at high speed for a long time.
high speed for a
long time.
Tires damaged. Replace
Tires reach the wear limit. Replace

09 - 19
Diagnostics

9.3 Superstructure, troubleshooting

9.3.1 Electrical system

Problem Causes Remedy

Bulb damaged. Replace

Fuse burnt out. Rectify and replace


The working light
does not Poor grounding. Rectify
illuminate.
Conducting wire defects. Rectify

Switch invalid. Rectify or replace


Control lights on
Switch invalid. Replace
instrument
console do not
Conducting wire defects. Rectify
light up.
Warning lights Hoisting limit switch and lowering limit switch
Rectify
“Main / auxiliary damaged.
winch approaching
Cable reel defects. Rectify
upper limit” and
“Main / auxiliary
winch approaching
lower limit” lights up Conducting wire defects. Rectify
all the time and
buzzer sounds.
Fuse burnt out. Rectify and replace

Switch invalid. Rectify or replace


Wiper does not
work.
Motor damaged. Replace

Conducting wire defects. Rectify

Fuse burnt out. Rectify and replace

Switch invalid. Rectify or replace


Horn does not
Relay defects. Replace
work.
Conducting wire defects. Rectify

Horn defects. Replace

Fuse burnt out. Rectify and replace

Relay defects. Replace


Buzzer does not
work.
Conducting wire defects. Rectify

Buzzer defects. Replace

09 - 20
Diagnostics

Problem Causes Remedy

Circuit of conducting ring broken. Rectify or replace


No power supply
to the PTO signal switch damaged. Replace
superstructure.
Conducting wire defects. Rectify

Circuit breaker burnt out or loose. Rectify or replace

The engine cannot Conducting wire defects. Rectify


be started in
operator’s cab. Ignition starter switch damaged. Replace

Circuit of conducting ring broken. Rectify or replace

Emergency off switch damaged. Rectify or replace


Deadman switches on the joysticks is not
No crane Rectify or replace
pressed.
movement can be
initiated. Conducting wire broken. Rectify

Solenoid valve invalid. Rectify or replace

Hoisting limit switch invalid. Replace

Cable reel short-circuited. Rectify


Hoisting limit
switch does not Relay defects. Replace
work.
Conducting wire defects. Replace

Solenoid valve invalid. Rectify or replace

Lowering limit switch invalid. Rectify or replace

Lowering limit Relay defects. Replace


switch does not
work. Conducting wire defects. Replace

Solenoid valve invalid. Rectify or replace

09 - 21
Diagnostics

9.3.2 Hydraulic pump

Problem Causes Remedy

Oil level too low. Fill oil

Air enters into the oil suction pipe or the pipe


Rectify
is blocked.

Mounting bolts loose. Tighten

Hydraulic oil polluted. Change oil and filter


Abnormal noise.
Propeller shaft vibration. Rectify

Universal joint wear. Replace

Hydraulic pump defects. Replace

Butterfly valve is not completely open. Open it completely

09 - 22
Diagnostics

9.3.3 Outrigger

Problem Causes Remedy

Setting pressure of relief valve of chassis


Adjust
control valve is improperly adjusted.
Outriggers do not
Spool of relief valve blocked. Rectify
work

Chassis control valve invalid. Rectify

Inner leakage occurs in chassis control valve. Rectify


Outriggers move
too slowly Setting pressure of relief valve of chassis
Adjust
control valve is too low.
Outrigger vertical
Two-way hydraulic lock invalid. Rectify
cylinder
inadvertently
retracts when Inner leakage occurs in oil cylinder. Rectify
lifting load

Piston rod of Two-way hydraulic lock invalid. Rectify


vertical cylinder
inadvertently Inner leakage occurs in oil cylinder. Rectify
extends during
driving Oil leak due to invalid oil cylinder seal. Rectify

09 - 23
Diagnostics

9.3.4 Slewing mechanism

Problem Causes Remedy

Brake lining is worn and has reached the wear


Brake invalid. Replace
limit.
Setting pressure of relief valve of chassis
Adjust
control valve is too low.
Setting pressure of relief valve of slewing
Adjust
valve is too low.
Setting pressure of slewing cushion valve is
Adjust
too low.
The slewing
mechanism does Slewing valve invalid. Replace
not work.
Slewing motor damaged. Rectify or replace

Slewing reducer defects. Rectify

Brake is not activated. Rectify

Setting pressure of relief valve of chassis


Adjust
control valve is too low.
Setting pressure of relief valve of slewing
Adjust
valve is too low.
The slewing
movement is Slewing valve defects. Rectify
abnormally slow.
Slewing cushion valve defects. Rectify

Slewing motor defects. Rectify

09 - 24
Diagnostics

9.3.5 Derricking mechanism

Problem Causes Remedy

Setting pressure of main relief valve is too


Adjust
low.
Oil cylinder cannot
Main valve has inner oil leakage. Rectify
be extended.

Oil cylinder has inner oil leakage. Rectify

Derricking-control balance valve defects. Rectify or replace


Oil cylinder cannot
be retracted. Setting pressure of relief valve of main valve
Adjust
is too low.

Oil cylinder Oil cylinder has inner oil leakage. Rectify


retracts
automatically. Derricking-control balance valve defects. Rectify

09 - 25
Diagnostics

9.3.6 Telescoping mechanism

Problem Causes Remedy


Telescoping-control balance valve defects. Rectify
Boom cannot be Setting pressure of relief valve of main valve is
Adjust
telescoped in. too low.
Main valve has inner oil leakage. Rectify
Setting pressure of relief valve of main valve is
Adjust
Boom cannot be too low.
telescoped out. Control valve defects. Rectify
Main valve defects. Rectify

Boom Oil cylinder has inner oil leakage. Rectify


inadvertently Telescoping-control balance valve defects. Rectify
telescoped in. Cylinder, valve or fitting leaks. Rectify
Boom cannot be
telescoped in Boom retraction rope loose. Adjust
completely.

Note

For the structure of telescopic cylinder is very complex, it is difficult to be


dismantled. Therefore, it can only be maintained by specialized person appointed
by manufacturer or trained specialist.

Telescopic cylinder Seal elements at guide sleeve damaged. Replace


leaks. Piston rod surfaces damaged. Rectify or replace
Inner Seal elements invalid. Replace
leakage Cylinder inner surface damaged. Replace
Inner leakage occurs in balance
Telescopic cylinder Replace or rectify
valve.
retracts Balance
automatically. O-ring outside the balance valve
valve Replace O-ring
damaged.
defects
Surface of the mounting hole of
Rectify or replace
balance valve damaged.
Telescopic Piston or piston rod blocked (blocked by Dismantle, rectify or
cylinder can not be foreign matters or cylinder deformed) replace
extended or
retracted. Balance valve or control pipeline blocked. Rectify or replace

09 - 26
Diagnostics

9.3.7 Hoisting mechanism

Problem Causes Remedy

Setting pressure of relief valve of main valve


Adjust
is too low.

Winch motor defects. Replace


Hook cannot be
Main valve defects. Rectify
lifted.

Combination control valve defects. Rectify

Winch brake is not open. Rectify

Setting pressure of relief valve of main valve


Adjust
is too low.

Winch motor defects. Rectify

Main valve defects. Rectify


Hook cannot be
lowered.
Combination control valve defects. Rectify

Balance valve defects. Rectify

Winch brake is not activated. Rectify

09 - 27
中联
OPERATING INSTRUCTIONS FORR ZOOMLION
汽车起重机使用说明书
® TRUCK CRANE

Chapter 10 Transportation and storage


Transportation and storage

10.1 Transportation and points for attention

The crane can be driven by its power or be transported by train or other carriers for a
long distance. During transportation, the wheels should be stopped with wooden
wedges, and the complete vehicle should be secured with wire ropes. Lock the doors
and the windows, and take preventive measures against rain. The lifting positions on
the chassis frame and slewing table are shown in the Fig. 10 - 01:

Fig. 10 – 01

Warning

Slings must be of enough strength!

10 - 1
Transportation and storage

10.2 The storage conditions and the points for attention in storage

If the crane remains idle for a long time, the following protective measures should be
taken:

a) Lock the doors and the windows and switch off control instruments;

b) Wipe off dust and oily filth to keep the crane clean;

c) Fully retract all the piston rods of the cylinders (except vertical cylinders);

d) Extend the vertical cylinders to keep tires away from the ground;

e) Inflate the tires to specified pressure and put wooden blocks beneath the tires;

f) Turn off the engine and switch off the battery master switch;

g) If the battery is not used over a month, disconnect the connecting wire from the
battery to the electrical system; if it is not used for a long period, charge it every
three months;

h) The surfaces of all exposed components should be greased to prevent them


against corrosion with rust;

i) Clean out dust and sand from wire ropes and grease those with ZG-3 graphite
calcium based grease;

j) The crane should be stored in a garage. If not, preventive measures against rain,
thunder and freeze should be taken;

k) Start the machine at an interval of three months and operate all the mechanisms at
idle speed for at least an hour to check whether they work normally;

l) Besides routine cleaning and maintenance, there is a need to carry out a thorough
inspection and maintenance for the crane which has been stored for more than one
and a half years. Replace diesel oil filter cartridge, air filter cartridge, clean cooling
system, change diesel oil and coolant according to actual conditions;

m) Assign a person to keep the crane in the perfect condition and make it ready for
operation at any time.

10 - 2