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!
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 2 Safety
I
QY30V532.4T/20Y
II
QY30V532.4T/20Y
Chapter 5 Equipment
III
QY30V532.4T/20Y
IV
QY30V532.4T/20Y
Chapter 9 Diagnostics
V
OPERATING INSTRUCTIONS FORR ZOOMLION ® TRUCK CRANE
中联 汽车起重机使用说明书
1.1.1 Model
Fig. 01-01
For name plate of the chassis, please refer to Fig. 01-02.
Fig. 01-02
01-1
Description of crane
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.
Fig. 01-04
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.
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.
Fig. 01-05
01-3
Description of crane
10
11
12
13
14
15
9 16
8
7
17
6
Fig. 01 – 06
1. Rear fixed outrigger 2. Toolbox 3. Rear axle
01-4
Description of crane
6
5
1 7
10
11
12
13
15
14
Fig. 01 – 07
13. The 5th outrigger 14. Special purpose chassis 15. Main hook
01-5
Description of crane
– 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.
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.
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.
Hoist Consisting of hydraulic motor, winch reducer, hoisting limit switch, lowering
mechanism limit switch and hoist rope.
Load Including mentor, pressure sensor, length sensor and angle sensor.
moment
limiter
01-7
Description of crane
1.2.3 Boom
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
Min. main
boom length:
10.6m
Fig. 01 – 08
01-8
Description of crane
Fig. 01-9-1
Fig. 01-9-2
Fig. 01-9-3
01-9
Description of crane
Max. gradeability % 40
01-10
Description of crane
Offset ° 5, 17, 30
Number of axles 3
Front mm 2040
Treads
Rear mm 1830/1830
Displacement ml 8300
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
Cab capacity 2
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
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)
When the crane is working within the rated lifting capacity, the max. support strength
per outrigger is 38 t.
01-12
Description of crane
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.
1.3.5 Hook
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
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
01-15
Description of crane
01-16
Description of crane
01-17
Description of crane
01-18
Description of crane
01-19
Description of crane
01-20
Description of crane
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
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.
(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.
01-24
OPERATING INSTRUCTIONS FORR ZOOMLION ® TRUCK CRANE
中联 汽车起重机使用说明书
Chapter 2 Safety
Safety
a) When driving the crane on road, all national and regional traffic regulations must be
observed;
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;
e) Comply with the safety signs on the crane to avoid serious injuries or casualties;
Danger
Do not allow the hook block to impair the driver’s field of vision when driving the
crane on public roads!
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!
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
The crane operator must obtain or receive the necessary information in a timely fashion
before driving to the work site. In particular:
c) Route;
h) Weight and dimensions of the loads to be lifted and the required hoisting height
and boom projection;
Based on the above information, the crane operator must assemble the equipment
required to operate the crane:
3) Jib;
Warning
02-3
Safety
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;
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
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:
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.
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.
d) Hearing is qualified;
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.
c) Be able to estimate and monitor the distance, height, clearance and load correctly;
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.
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.
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.
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.
Danger
If the safety distance can not be maintained, fill and level up the slope and ditch.
Otherwise the crane can topple over!
Support area = crane support force / load bearing capacity of the ground.
02-7
Safety
3. Cohesive ground:
B
Sludgy 0
Soft 0.4
Firm 1.0
Semi-compact 2.0
Hard 4.0
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.
a) The placement location has been selected in such a way that the crane can be
operated with the least possible radius;
02-9
Safety
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.
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:
02-10
Safety
Danger
02-11
Safety
02-12
Safety
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;
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
(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
Tap elbow with one hand; then With forearm vertical, extended
use regular signal. fingers pointing up, move 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.
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.
02-16
Safety
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
02-18
中联
OPERATING INSTRUCTIONS FORR ZOOMLION
汽车起重机使用说明书
® TRUCK CRANE
3.1.1 Overview
Fig. 03-01
1. Rotating beacon(optional)
3. Handrail
4. Key hole
5. Door handle
6. Mirrors (R)
7. Side turn signal
9. High/low beam
Note
The rotating beacon is optional.
03-1
Operation – crane chassis
Fig. 03-02
1. Instrument console
5. Clutch pedal
8. Driver’s seat
9. Centre console
03-2
Operation – crane chassis
Fig. 03-03
1. Ignition starter switch
3. Steering wheel
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.
03-3
Operation – crane chassis
1
3
2
Fig.03-04
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.
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
Rotate the end of this steering column switch to activate the windshield wiper.
The windshield wiper has 4 stages:
INT: Intermittent
OFF: Off
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
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
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.
Caution
- Dashboard assy.
Fig. 03-06
03-6
Operation – crane chassis
1. Tachometer
3. Odometer
7. Voltmeter
- Instruments
03-7
Operation – crane chassis
- Display unit
Fig. 03 – 07
03-8
Operation – crane chassis
Illuminates: Illuminates:
Extinguishes:
Caution
03-9
Operation – crane chassis
03-10
Operation – crane chassis
condition.
Extinguishes:
Engine starts.
Caution
03-11
Operation – crane chassis
Extinguishes:
03-12
Operation – crane chassis
above 15 km/h.
Note
15 Control light
Vehicle direction of turning right
Illuminates:
It is located on the outside of clutch pedal and on the left side of driver.
It is an electron pedal.
03-13
Operation – crane chassis
Fig. 03 – 08
2 Media player
4 Range selector
03-14
Operation – crane chassis
- Media player
Fig. 03 – 09
1 Display
3 SD card slot
4 USB port
POWER MODE
BND SEL
03-15
Operation – crane chassis
MUT DSP
g) Button h) Button
Pause.
1 2 SCAN
k) Preset button 3 (receive) l) Preset button 4 (receive)
3D 4 RDM
m) Preset button 5 (receive) n) Preset button 6 (receive)
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
Jog the selector leftwards, rightwards, forwards and backwards to select and
changeover the gear.
If the service brake fails to operate owing to insufficient air pressure, the parking
brake can be used as an emergency brake.
03-17
Operation – crane chassis
Fig. 03 – 10
03-18
Operation – crane chassis
Caution
Pressed: Pressed:
The front fog light illuminates. The rear fog light lights up.
Note
03-19
Operation – crane chassis
diagnosis
Illuminates: Illuminates:
Warning
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
b) Interior illumination
03-21
Operation – crane chassis
Caution
Do not drive the vehicle if the doors are not properly closed and locked!
03-22
Operation – crane chassis
Note
a) Seat adjustment
03-23
Operation – crane chassis
Adjust and fasten the three-point seat belt to suitable position before setting off.
Caution
All occupants must be belted in before setting off in the crane and during
driving.
- 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.
3.1.12 Attachments
a) Sun visor
The sun visor is located above front windshield inside driver's cab.
03-24
Operation – crane chassis
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.
3.2.1 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.
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.
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 60C
and the pointer should be within the green area.
d) Start vehicle slowly with low gear. Never engage the clutch when engine is running
at excessively high speed (above 1600 rpm).
a) Checks:
1) Check engine oil level and check engine oil for clean;
b) Before starting the engine, ensure the following prerequisites are met:
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
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.
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
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.
- 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.
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
03-29
Operation – crane chassis
Caution
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
- 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;
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.
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
d) In sharp turning, decelerate the vehicle in time and shift into the low gear.
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.
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
Caution
Depressing the clutch pedal and engine control pedal at the same time
can deactivate the exhaust 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
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;
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!
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;
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
b) Press the PTO switch to deactivate the PTO, and then the control light for PTO
extinguishes;
03-33
Operation – crane chassis
d) Release the clutch pedal slowly, and then the crane is in non-working state.
a b c d
Fig. 03 – 14
Caution
(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.
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
c) Once the warning lights light up, decelerate immediately and stop the vehicle at a
safe place for checks;
1) Check the brake system for functional work before driving on a descending
gradient;
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
(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
03-35
Operation – crane chassis
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:
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;
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.
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
4.1.1 Overview
1 13
2
12
3 11
5 10
6
9
7
8
Fig. 04 – 01
3 Right joystick
6 Instrument console
10 Left joystick
11 Operator’s seat
04 - 1
Operation – crane superstructure
1 2 3 4
5 6 7
Fig. 04 – 02
4 Cigarette lighter
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
7 Switch Set-up
16 Cigarette lighter
04 - 3
Operation – crane superstructure
04-4
Operation – crane superstructure
7 Switch Set-up
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:
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”).
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:
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:
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:
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:
04-6
Operation – crane superstructure
⑦ The “Jib” working condition exits from the load moment limiter.
Warning
04 - 7
Operation – crane superstructure
Warning
If the “derrick up” crane movement is disabled, turn the switch to release the
limitation.
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.
Right position:
Pressed:
Positions P and O:
Position I:
04 - 9
Operation – crane superstructure
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
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.
04-10
Operation – crane superstructure
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.
04 - 11
Operation – crane superstructure
Warning
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.
When the switch is deactivated, any of the following prerequisites must be met:
04-12
Operation – crane superstructure
Warning
And also deactivate the deadman switch when the operation is done.
Warning
Warning
Never press the free swing button when the load is lifted away from the
ground during normal operation!
Depress the engine control pedal to accelerate slewing, derricking, telescoping and
hoisting movements.
Fig. 04 – 06
04 - 13
Operation – crane superstructure
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.
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.
The following icon is displayed in load moment limiter during set-up working condition.
The following icon is displayed in load moment limiter during bypassing “derrick up”
working condition.
The following icon is displayed in load moment limiter during bypassing “hoist up”
working condition.
04-14
Operation – crane superstructure
The following icon is displayed in load moment limiter during bypassing “hoist down”
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
04 - 15
Operation – crane superstructure
Ensure that the following prerequisites are met before starting up:
4) The oil level must be between the Min. and Max. marks on the oil dipstick.
Warning
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
Check fuel reserve at fuel gauge in driver cab. Add it timely once it is not sufficient.
Caution
04-16
Operation – crane superstructure
If the fuel tank has been run dry, always deaerate the whole fuel system
before adding fuel.
1) Check lubricating conditions of each moving part of the crane. Add lubricating
oil or grease timely to ensure lubricating effect;
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;
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.
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.
The ignition starter switch on the instrument panel can be used to switch on the
engine if the following prerequisites are met:
04 - 17
Operation – crane superstructure
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.
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
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
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
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
Fig. 04 – 12
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.
04 - 21
Operation – crane superstructure
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.
Pressure gauge 3: monitor the pressure of oil circuits in main winch, auxiliary
winch.
Fig. 04 – 13
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.
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!
b) Check the crane location, ground condition and surface bearing condition;
c) Check wire ropes (including wire rope’s connections, winding drum and pulleys);
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;
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.
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.
a) Outrigger control direction illustrations and points for attention are printed in
the outrigger control label;
Move lever 2 downwards and move lever 1 downwards: extend the 5th
outrigger.
Caution
Warning
04 - 25
Operation – crane superstructure
1
2
3
4
5
6
Fig. 04 – 15
– Outrigger extension
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
3) Observe the level gauge. Once the vehicle is leveled, move levers to
neutral positions.
1
2
43
65
Fig. 04 – 17
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.
04 - 27
Operation – crane superstructure
1
2
43
65
Fig. 04 – 18
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.
1
3 2
6 54
Fig. 04 – 19
Caution
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
1
3 2
6 54
Fig. 04 – 20
4) Walk to the other side of the crane to retract vertical cylinders on the other
side.
Fig. 04 – 21
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.
Fig. 04 – 23
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.
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
(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
4.5.3 Derricking
Deflect the joystick leftwards (direction ③): derrick main boom up;
Deflect the joystick rightwards (direction ④): derrick main boom down.
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
(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
Fig. 04 – 26
Deflect the joystick forwards (direction ①): telescope the telescopic boom sections
out;
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
Warning
(1) The telescopic cylinder and boom extension / retraction ropes may be
damaged;
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:
Caution
Fig. 04 – 28
Caution
The parameters shown in the lifting height chart do not include the deflection
of main boom.
04 - 35
Operation – crane superstructure
Fig. 04 – 29
Note
Fig. 04 – 30
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:
Results:
Fig. 04 – 31
Fig. 04 – 32
– Spooling up / reeling off auxiliary winch
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:
Fig. 04 – 34
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
(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.
(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
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:
④
③
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.
Fig. 04 – 37
Caution
(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;
04 - 41
Operation – crane superstructure
(5) Ensure there is enough space for the crane slewing operation;
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:
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
04-42
Operation – crane superstructure
Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick
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.
04-44
Operation – crane superstructure
Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick
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.
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
Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick
04 - 47
Operation – crane superstructure
Simultaneous Illustration
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick
a b c d
See Fig. 04 – 38
04-48
Operation – crane superstructure
– The main boom has been fully telescoped in and turned to the side or rear working
area.
e) When rope reeving is in odd reeving number, install the pouch socket onto the
hook;
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
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;
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.
e) Before assembling and dismantling the jib, ensure that the following prerequisites
are met:
6) The hoist rope has been correctly placed in the rope pulleys with the rope
securing tubes to prevent it from jumping out;
Danger
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.
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 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
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;
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.
Fig.05-07
05-6
Equipment
5.2.4 Dismantling
After jib operation, dismantle the jib in the reverse steps of assembly.
Caution
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;
Fig. 05-08
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!
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
Fig. 06 – 01
a) The description of symbols on display screen are shown as follows:
set
Auto
Temperature
Refrigeration
Vehicle body
06 - 1
Additional equipment
3) .OFF button
4) AUTO button
Press AUTO twice, press A/C or defrosting air supply: exit auto operating mode。
5) A/C button
6) Circulation button
06 - 2
Additional equipment
8) Mode button
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;
(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
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
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.
The rotary switch is used to control the temperature in the cab by adjusting the
temperature of air blew out.
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
(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.
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
This control light is used to indicate whether the power is switched on.
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
For the selection of the fuel type, please refer to the following table.
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.
– 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
06 - 9
Additional equipment
06 - 10
OPERATING INSTRUCTIONS FOR ZOOMLION
R ® TRUCK CRANE
中联 汽车起重机使用说明书
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
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.
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.
07-1
Maintenance and service
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.
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
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
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
Aviation
Type of oil L-HM L-HM L-HS
hydraulic oil
Viscosity grade 68 46 32 10
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.
— Changing steps
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);
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
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.
Fig. 07 – 01
The highest working temperature of hydraulic oil is 80°C.
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
Before delivery, each moving part has been topped up with L-CKD150 industrial closed
gear oil in accordance with GB5903-1995 standard.
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;
Fig. 07 – 02
07-5
Maintenance and service
b) Slewing reducer
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
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.
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
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
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.
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
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
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
Grease or inject
ZL-2 lubricating
8 Slewing ring and gear Every 10 days with grease
grease
pump
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
07-11
Maintenance and service
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;
(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
07-13
Maintenance and service
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
07-15
Maintenance and service
Brake hose ○
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);
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.
Caution
The wire ropes, in accordance with the wearing conditions, can be taken
down when one of the above 5 situations occur.
07-17
Maintenance and service
Ser. Tools
Operating steps Points for attention
No. required
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
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
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
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
13
Rope reeving: N
Max. permissible lifting capacity
per strand: P
14 Unload the load from main hook.
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
Fig. 07 – 08
Caution
(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.
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;
f) Before using a new wire rope, check the wire rope qualify certificate to ensure
07-22
Maintenance and service
g) Regular checks, including checks on the rope end connection and pulleys,
should be carried out daily before operation.
The most frequent discard criteria for the hook are as follows (welding up of hook’s
disfigurement is not allowed):
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.
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.
1 Hydraulic Wrench
reservoir
Spring
2
3 Wrench
07-24
Maintenance and service
5 Wrench
Fig. 07 – 09
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;
Caution
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;
Fig. 07 – 10
1) Screw off the butterfly nut and pull out the side cover;
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.
Fig. 07 – 11
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.
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;
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
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.
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.
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
Before inflating the tires, ensure that following prerequisites are met:
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.
– 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
07-29
Maintenance and service
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
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;
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;
10) Check wires for all electrical appliances for proper seating; check electrical
devices, instruments and battery for functional work;
c) Perform the following inspections after the new crane has traveled for 50 km to 100
km for the first time.
4) Inspect engine, drive device and shafts for any leakage or loose components;
08 - 1
Crane inspections
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
In such cases, the operator must have the crane inspected by a competent
inspector before putting it back into service.
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!
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
Perform the following inspections and maintenances after 200 hours of lifting operation.
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.
08 - 6
Crane inspections
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.
– Structural inspection
a) Pipe and hose lines are not aged, not corroded and are properly routed;
Warning
e) Each connection in the pipe lines are proper connected, moving parts are flexible
and are not damaged;
a) Function test
3) Check safety valve, switch for air pressure control light and warning device;
b) Performance test
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
Check the following items in regular intervals besides function test and performance
test:
b) Dismantle brake drum and check the condition of each component inside the brake
every 12 months.
Warning
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
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
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.
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:
For hoisting winch reducer, we recommend that the oil is drained and the amount
compared to the specified oil quality;
Assume that the oil has been overheated if it is black and /or a burnt oil smell is
detected. Change 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
08 - 9
Crane inspections
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.
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
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:
5) Undetected leakage;
- Extreme temperatures
- Corrosive atmosphere
08 - 10
Crane inspections
Caution
The hooks must be often inspected for distortion and for thread corrosion / wear and
tear by a competent inspector.
Caution
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
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.
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:
08 - 11
Crane inspections
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.
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.
Oil and fuel reservoirs shall be inspected at least once a year and checked all around
for leakage during the periodic inspections every year.
Improper repairs; e.g., welding, hard or soft soldering is not permitted, particularly if the
Customer Service Department at ZOOMLION has not been consulted!
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:
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
Caution
Dismantle and inspect the starter and generator, and then replace damaged
components.
– 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.
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.
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.
– Generator
Voltage: 28 Volt DC
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.
Function test shall be carried out on safety devices, such as load moment limiter,
hoisting limit switch and lowering limit switch before crane operation.
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%.
– 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.
– Lift the boom to its maximum angle and reel off the wire rope slowly;
08 - 15
Crane inspections
– Check whether the lowering limit switch is activated when only 3 hoist rope
windings are left on the winch.
Danger
08 - 16
Crane inspections
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.
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.
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
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
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
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
Inspection criteria:
Inspection criteria:
08 - 30
Crane inspections
Doors
Windows (curtain)
Windshield wipers
Outside mirrors
Seats
Air conditioning, air venting
device
Player
First-aid kit
Emergency lamp
Fire extinguisher
Inspection criteria:
08 - 31
Crane inspections
Engine
Suspension
Fuel tank
Fuel filter
Fuel lines
Silencer
Exhaust system
Water tank
Intercooler
Oil levels
Inspection criteria:
Axles
Wheels
Clutch
Transmission
Propeller shaft
Non hydro-pneumatic
Leaf springs
suspension axle
Vibration damper
Inspection criteria:
08 - 32
Crane inspections
Drive device
Shift of gear
Steering
Monitoring indicators
Engine braking
performance
Outrigger controls
Axle suspension
Axle suspension
Inspection criteria:
Air compressor
Air reservoir
Valves
Piping
Hoses
Inspection criteria:
08 - 33
Crane inspections
Motors
Generators
Battery
Wiring
Fuses
Brake lights
Warning lights
Reversing lights
Headlamp
Signaling devices
Inspection criteria:
08 - 34
Crane inspections
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:
Doors
Windows / Windshield
Windshield wipers
Seat
Air conditioning
Ventilation
Emergency hammer
Inspection criteria:
08 - 35
Crane inspections
Main winch
Auxiliary winch
Main hook
Auxiliary hook
Inspection criteria:
Oil tanks
Oil filters
Pumps
Motors
Valves
Piping
Hoses
Oil cylinders
Inspection criteria:
08 - 36
Crane inspections
Switches
Wiring
Fuses
Electric horn
Inspection criteria:
Angle indicator
Angle sensor
Pressure sensor
Level gauge
Length detector
Emergency stop
Inspection criteria:
08 - 37
Crane inspections
Doors
Baffle
Inspection criteria:
Platform
Attached tools
Boom support
Welding structures
Inspection criteria:
Assessment:
Note
08 - 38
Crane inspections
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
M10 11 44 62
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
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.
– 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:
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
09 - 1
Diagnostics
9.2.1 Clutch
09 - 3
Diagnostics
9.2.2 Transmission
09 - 6
Diagnostics
09 - 7
Diagnostics
09 - 8
Diagnostics
09 - 9
Diagnostics
09 - 10
Diagnostics
09 - 11
Diagnostics
09 - 12
Diagnostics
09 - 13
Diagnostics
09 - 14
Diagnostics
09 - 15
Diagnostics
09 - 16
Diagnostics
9.2.8 PTO
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
09 - 18
Diagnostics
09 - 19
Diagnostics
09 - 20
Diagnostics
09 - 21
Diagnostics
09 - 22
Diagnostics
9.3.3 Outrigger
09 - 23
Diagnostics
09 - 24
Diagnostics
09 - 25
Diagnostics
Note
09 - 26
Diagnostics
09 - 27
中联
OPERATING INSTRUCTIONS FORR ZOOMLION
汽车起重机使用说明书
® TRUCK CRANE
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
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;
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