Zcc800hwg.operator Manual.pdf

ZCC800H Crawler Crane

Operator’s Manual

Edition 1

04, 2017

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

To Users Zoomlion appreciates your selection of ZOOMLION crawler crane for your application. No one should operate the crane unless they read and understand the information in this manual. This manual contains the instructions and data on the safety and operation of the crawler crane. Follow the operation procedures to make sure that your machine operates at MAXIMUM EFFICIENCY. The operator must keep this manual in the cab of the crane. If there is anything in the manual that is not clear or you do not understand, please contact our service technician. We (Zoomlion) are NOT responsible for damages from an operator who does not obey the instructions in the OPERATOR’S MANUAL. The OPERATOR’S MANUAL is an important part of the crane. If the crane becomes the property of a different person, make sure that the manual stays in the cab of the crane. The data (data, specifications, illustrations) in this manual is for cranes in production at the time of this manuals publication. We reserve the right to make changes to this manual at any time, without obligation. The manual has been translated to be best of our knowledge. Zoomlion assumes no liability for translation errors. The Chinese version of the OPERATOR’S MANUAL is solely applicable for factual accuracy. This manual applies to ZCC800H crawler crane. Thank you!

Copyright Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science and Technology Co., Ltd. Copyright © 20XX, Zoomlion Heavy Industry Science and Technology Co., Ltd. All rights reserved.

I

Operator’s Manual for Crawler Crane

Safety Instructions DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this manual to show important instructions. In this manual, the labels follow the paragraph or item they apply to. The markers are as follows: Refers to a dangerous situation which, if you do not prevent, will cause

DANGER

death or injury. Refers to a possible dangerous situation which, if you do not prevent,

WARNING

could cause death or injury. Refers to a possible dangerous situation which, if you do not prevent, may

CAUTION

NOTICE

II

cause light or moderate injury. Refers to a situation which, if you do not prevent, may cause property or equipment damage.

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Contents

To Users .............................................................................................................................................. I Safety Instructions ............................................................................................................................ II Chapter 1

Safety

1.1

Foreword .......................................................................................................................... 1-1

1.2

Note .................................................................................................................................. 1-3

1.3

Alarms and warnings ........................................................................................................ 1-3

1.4

Component safety features .............................................................................................. 1-3

1.5

Features for operator safety ............................................................................................. 1-3

1.6

Environmental safety ........................................................................................................ 1-4

1.7

Personal protective equipment (PPE) .............................................................................. 1-4

1.8

Measured noise level........................................................................................................ 1-5

1.9

Vibration levels ................................................................................................................. 1-5

1.10

Organizational safety measures ..................................................................................... 1-5

1.11

Personnel qualification, requirements and responsibilities ............................................. 1-6

1.12

Safety advice regarding specific operational phases ..................................................... 1-6

1.13

Special Hazards.............................................................................................................. 1-6

Chapter 2 2.1

2.2

2.3

2.4

Description of Crane

Product model .................................................................................................................. 2-1 2.1.1

Product name plate and its position ..................................................................... 2-1

2.1.2

Engine type and its manufacturer......................................................................... 2-3

2.1.3

Intended use of the crane ..................................................................................... 2-3

2.1.4

Crane design calculation ...................................................................................... 2-3

Terminology ...................................................................................................................... 2-5 2.2.1

Boom configurations ............................................................................................. 2-5

2.2.2

Description of main components .......................................................................... 2-7

Product description ......................................................................................................... 2-11 2.3.1

Crane undercarriage .......................................................................................... 2-11

2.3.2

Crane superstructure .......................................................................................... 2-11

2.3.3

Overall dimensions ............................................................................................. 2-13

Technical data ................................................................................................................. 2-14 2.4.1

Main technical parameters ................................................................................. 2-14

2.4.2

Specification of load hook and application of rope reeving ................................ 2-15

III

Operator’s Manual for Crawler Crane

2.4.3

Rope reeving and specification of wire rope ...................................................... 2-15

2.4.4

Lifting height ....................................................................................................... 2-17

2.4.5

Lifting capacity chart ........................................................................................... 2-20

Chapter 3

Safety Guidelines

3.1

Operational planning ........................................................................................................ 3-1

3.2

Safety technical notes ...................................................................................................... 3-2

3.3

3.2.1

Safety instructions for crane operator .................................................................. 3-2

3.2.2

Safety instructions for the rigger ........................................................................... 3-3

3.2.3

Safety instructions for the signalman ................................................................... 3-4

3.2.4

Safety instructions for crane operating crew ........................................................ 3-4

3.2.5

Points for attention during crane operation .......................................................... 3-4

3.2.6

Safety signs .......................................................................................................... 3-5

Slings .............................................................................................................................. 3-13 3.3.1

Slings introduction .............................................................................................. 3-13

3.3.2

Sling identification tags ....................................................................................... 3-13

3.3.3

Angle of choke .................................................................................................... 3-14

3.3.4

D/d ratio .............................................................................................................. 3-14

3.3.5

Load angle factor ................................................................................................ 3-15

3.3.6

Load share .......................................................................................................... 3-16

3.3.7

Load angle factor chart ....................................................................................... 3-17

3.3.8

Sling safety ......................................................................................................... 3-17

3.3.9

Sling safety guide ............................................................................................... 3-18

3.3.10 Taglines ............................................................................................................... 3-18 3.3.11 3.4

Load center of gravity ....................................................................................... 3-19

Requirements for operating site ..................................................................................... 3-20 3.4.1

Selecting an operating site ................................................................................. 3-20

3.4.2

Slopes and trenches ........................................................................................... 3-20

3.4.3

Permissible ground pressure .............................................................................. 3-21

3.4.4

Checking safety measures ................................................................................. 3-22

3.5 Working weather ............................................................................................................. 3-22 3.6

Electromagnetic influences ............................................................................................. 3-22

3.7

Underground cables ....................................................................................................... 3-24

3.8

Checking safety measures ............................................................................................. 3-28

3.9

3.8.1

Counterweight .................................................................................................... 3-28

3.8.2

Hoisting winch and hoisting rope ........................................................................ 3-29

Crane operation with a load ............................................................................................ 3-30 3.9.1

IV

Operating conditions ........................................................................................... 3-30

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

3.9.2

Instructions for safety operation ......................................................................... 3-33

3.9.3

Preparation for crane operation .......................................................................... 3-38

3.9.4

Notes for crane operation ................................................................................... 3-38

3.9.5

Checks after operation ....................................................................................... 3-40

3.10

Hand signals for controlling crane operations .............................................................. 3-41

Chapter 4 4.1

4.2

4.3

4.4

4.5

4.6

Crane Operation

Operation and controlling instrument ............................................................................... 4-1 4.1.1

Operator’s cab assy. ............................................................................................. 4-1

4.1.2

Left control box ..................................................................................................... 4-3

4.1.3

Right control box................................................................................................... 4-6

4.1.4

Safety control........................................................................................................ 4-9

Instructions for digital display system ............................................................................. 4-15 4.2.1

Load moment limiter ........................................................................................... 4-15

4.2.2

Instrument panel ................................................................................................. 4-16

Startup of the crane ........................................................................................................ 4-19 4.3.1

Adjustment of crane operator’s seat .................................................................. 4-19

4.3.2

Inspection before startup .................................................................................... 4-21

4.3.3

Turning on power and relevant preparations ...................................................... 4-22

Safety device .................................................................................................................. 4-26 4.4.1

Emergency stop button ...................................................................................... 4-26

4.4.2

Battery master switch ......................................................................................... 4-26

4.4.3

Flashing light ...................................................................................................... 4-26

4.4.4

Load moment limiter ........................................................................................... 4-27

4.4.5

Angle indicator .................................................................................................... 4-27

4.4.6

Lowering limiter .................................................................................................. 4-28

4.4.7

Hoisting limiter .................................................................................................... 4-29

4.4.8

Derricking limiter ................................................................................................. 4-30

4.4.9

Anemometer ....................................................................................................... 4-30

4.4.10

Crane inclinometer ........................................................................................... 4-30

Operation of crane .......................................................................................................... 4-31 4.5.1

Operation of travel gear ...................................................................................... 4-31

4.5.2

Operation of hoisting winches ............................................................................ 4-38

4.5.3

Derricking mechanism ........................................................................................ 4-42

4.5.4

Operation of slewing mechanism ....................................................................... 4-46

4.5.5

Simultaneous operation ...................................................................................... 4-48

4.5.6

Crawler carrier extending & retracting mechanism ............................................ 4-48

Rope reeving .................................................................................................................. 4-51

V

Operator’s Manual for Crawler Crane

4.6.1

Hoisting rope guidance and reeving ................................................................... 4-51

4.6.2

Derricking rope reeving ...................................................................................... 4-57

Chapter 5 5.1

5.2

Safety-technical notes ...................................................................................................... 5-1 5.1.1

Notes on assembly ............................................................................................... 5-1

5.1.2

Checking safety measures ................................................................................... 5-1

5.1.3

Checking wire rope, load hook, rope pulley and anchoring rod ........................... 5-2

5.1.4

Raising and lowering boom .................................................................................. 5-4

Unloading and assembly of basic machine ...................................................................... 5-5 5.2.1

Unloading of basic machine ................................................................................. 5-5

5.2.2

Assembly of basic machine .................................................................................. 5-6

5.3

Assembly of rear counterweight ....................................................................................... 5-8

5.4

Installation of undercarriage wedge block ...................................................................... 5-10 5.4.1

Description of undercarriage wedge block ......................................................... 5-10

5.4.2

Installation of undercarriage wedge block .......................................................... 5-11

5.5

Available boom configurations ........................................................................................ 5-14

5.6

Boom configurations and anchoring rods combination .................................................. 5-15

5.7

5.8

VI

Assembly and Dismantling

5.6.1

Main boom configuration .................................................................................... 5-15

5.6.2

Main boom with fixed jib configuration ............................................................... 5-26

Assembly and dismantling of main boom ....................................................................... 5-35 5.7.1

Preparation for assembly.................................................................................... 5-35

5.7.2

Assembly of main boom ..................................................................................... 5-35

5.7.3

Electrical connection to main boom .................................................................... 5-40

5.7.4

Raising main boom ............................................................................................. 5-41

5.7.5

Lowering and dismantling main boom ................................................................ 5-43

Assembly and dismantling of main boom with fixed jib .................................................. 5-45 5.8.1

Preparation for assembly.................................................................................... 5-45

5.8.2

Assembly of fixed jib ........................................................................................... 5-45

5.8.3

Electrical connection to fixed jib ......................................................................... 5-51

5.8.4

Raising main boom with fixed jib ........................................................................ 5-53

5.8.5

Lowering and dismantling main boom with fixed jib ........................................... 5-55

5.9

Assembly and dismantling of tip boom ........................................................................... 5-56

5.10

Transport dimensions and weights of main components ............................................. 5-58

5.11

Transport means and points for attention ..................................................................... 5-61 5.11.1

Transport means and relevant notes ................................................................ 5-61

5.11.2

Other requirements ........................................................................................... 5-61

Operator’s履带起重机操作手册 Manual for Crawler Crane Chapter 1 第一章 安全操作说明

Safety

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Chapter 1

Safety Safety

1.1 Foreword Thank you for purchasing ZOOMLION crawler crane produced by Zoomlion Heavy Industry Science and Technology Co., Ltd. We are glad to provide high-quality and high-efficiency service for you. The operating manual is intended to put you in a position to operate the crane safely and utilize its capabilities to the fullest extent. Certain terminologies are used in the operator’s manual, and in order to avoid misunderstandings while operating, these terminologies should be used consistently.

DANGER (1) Only qualified and especially trained personnel are permitted to work on the crane! (2) If this is not assured, the chance of causing a serious accident is greatly increased! All regulations and guidelines applicable to the job site such as accident prevention regulations, and all guidelines and regulations stated in the Operator’s Manual must be strictly adhered to. All accident prevention and operating guidelines and regulations, etc. assume that the crane is strictly used for lifting and transporting the loads, which are not stuck. Any other application or use does not constitute specified and proper use. Any risks associated with unspecified and improper use are the sole responsibility of the crane’s owner, operator or user.

CAUTION Using these instructions in the manual: 

makes you easier to become familiar with the crane



avoids malfunctions due to improper operation

CAUTION Observing these instructions in the manual: 

increases reliability in operations



extends the service life of the crane



reduces repair costs and downtime

Always keep the operator’s manual handy in the crane operator’s cab - it is an integral part of the crane. Operate this crane if you are well familiarized with the capabilities and limitations of the crane, and always follow these operating instructions.

ZCC800HWG.1 CRAWLER CRANE

1-1

Operator’s Manual for Crawler Crane

If you have received additional information about the crane from us, e.g. in the form of technical information letters, then this information must also be followed and kept with the operator’s

Safety

manual. If there is anything in the operator’s manual or the individual chapters that you do not understand, please do not hesitate to ask us or our distributors before you begin operation. Any parts of the operating manual may not be copied or distributed, nor used for competitive purpose. All rights are reserved by Zoomlion. The operator’s manual must be read and the regulations in it must be observed by all persons operating, maintaining, or otherwise working on this crane. The

content

with

respect

“

WARNING ”, “

to

safety

is

marked

with

“

DANGER

”,

CAUTION ” and so on. And the safety instructions involved

in the manual are only the conventional contents. The following terms that are used in the operator’s manual “DANGER”, “WARNING”, and “CAUTION” are intended to point out certain important rules of conducting all persons who work with the crane.

DANGER The term “DANGER” is used whenever the nonobservance of the warning given may insure or lead to life-threatening hazards and damage to the crane.

WARNING The term “WARNING” is used whenever serious personal injury and damage to the crane can occur if the operating instructions are not observed and adhered to.

CAUTION The term “CAUTION” is used whenever the observance of certain instructions or notes is economically meaningful to the utilization of the crane.

CAUTION (1) When welding work is conducted on the crane, the operator should unplug all power source plugs of controllers and cut off the master power. Otherwise, he should take all consequences incurred. (2) The safety devices built into the crane system deserve your special attention. They must always be checked to see that they are functioning properly. If they do not function or function incorrectly, the crane should not be operated. Your motto must always be Safety First.

1-2

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

1.2 Note Read this manual and familiarize yourself with any associated documents before operating this crane. b)

Ensure that a copy of this manual is available for any persons installing, using, maintaining or repairing this equipment. Training should be provided to ensure safe working practices. Initial commissioning and staring must only be undertaken by a competent engineer who has read this manual and fully understood the information involved in it.

c)

To avoid the risk of electric shock always isolate this equipment from the power supply prior to carrying out any maintenance adjustment or removing any guards or covers.

d)

Always follow the procedures outlined in the Operator’s Manual and Maintenance Manual.

e)

If in doubt, do not take personal risk.

f)

Only trained personal can be allowed to install, operate, maintain, and commission this equipment.

1.3 Alarms and warnings To assure personnel safety, please observe the following warnings. a)

You can be injured if you do not obey the safety instructions as indicated on warning stickers.

b)

Ensure that safety instructions and warnings attached to the crane are always complete and perfectly legible.

c)

Keep warnings and instruction labels clean.

d)

Replace unreadable or missing labels with new ones before operating the crane. Make sure replacement parts include warning or instruction labels where necessary.

CAUTION For the position of warnings and instruction labels, please see chapter 3 "Safety Guidelines".

1.4 Component safety features a)

Do not use this equipment with guards removed or incorrectly fastened.

b)

Do not use this equipment with safety devices maladjusted or removed.

1.5 Features for operator safety a)

Safety component – crane emergency stop button. Ensure the button is functional.

b)

Steps, handrails, tread plates and fixed guards are provided to assist the personnel to climb on the crane.

ZCC800HWG.1 CRAWLER CRANE

1-3

Safety

a)

Operator’s Manual for Crawler Crane

1.6 Environmental safety Safety

1.6.1 A regular service should be taken on the crane strictly in accordance with maintenance procedures to ensure that engine emission is close to a minimum value. 1.6.2 Consumable materials a)

Diesel spillages must be dealt with immediately to avoid fire hazard and pollution.

b)

Only use the lubricating oil recommended in the maintenance manual.

c)

Local and national regulations must be observed when disposing of waste.

d)

Potentially harmful waste used on this crane includes such items as hydraulic oil, fuel, coolant, filters and batteries, etc.

e)

Use leak-proof containers for draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

f)

Do not pour waste onto the ground, into sewer system or into any water source.

g)

Ensure that all consumable and replaced parts are disposed of safely and with minimum environmental impact.

1.6.3 Machine disposal. This machine must only be disposed of by a specialist machine breaker.

1.7 Personal protective equipment (PPE) Loose or baggy clothing can get caught in running machinery. Where possible when working close to engines or machinery, only do so when they are stopped. If this is not practical, remember to keep tools, test equipment and all other parts of your body well away from the moving parts. For reasons of safety, long hair must be tied back or otherwise secured, garments must be close fitting and no jewellery such as rings may be worn. Correctly wear personal protective equipment. Recommended personal protective equipment includes:

1-4

a)

Hard hat

b)

Safety glasses/Goggles

c)

Hearing protection

d)

Close fitting overalls

e)

Safety boots

f)

Industrial gloves

g)

High visibility vest or jacket

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

1.8 Measured noise level According to EN13000 Annex G and 2000/14/ EC standards, the sound pressure level and sound power level are 68.77 dB (A) and 100.87 dB (A) respectively. The sound pressure level measured using ISO 7731 at the position 1 m away from the warning device is 105 dB(A).

1.9 Vibration levels Suitable seating has been installed to reduce the risk of whole body vibrations, in line with current industry standards. 2

2

According to ISO 2631-1:1997, the crane body vibrations are A (1): 1.4m/ s , A (4): 0.7m/ s , A 2

(8): 0.5m/ s under normal operating condition.

1.10 Organizational safety measures a)

The crane must only be operated by a suitably qualified operator who holds a current license in line with National / International legislation.

b)

Understand the service procedure before doing work. Keep the area clean and dry.

c)

Never lubricate, clean, service or adjust the crane while it is moving (excluding central lubrication).

d)

Keep hands, feet and clothing clear of power driven parts and running nip-points.

e)

Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage immediately. Replace worn and broken parts. Remove any build-up of grease, oil and debris.

f)

Disconnect battery ground cable and power supply before making adjustments on electrical systems.

g)

Disconnect battery ground cable and ECM connecting cable and unplug all plugs of controllers before welding on machine.

h)

During maintenance only use the correct tool for the job.

i)

Never make any modifications, additions or conversions which might affect safety without the manufacturer’s approval.

j)

In the event of safety relevant modifications or changes in the behavior of the machine during operation, stop the machine and lock it out immediately and report the malfunction to the competent authority / person.

ZCC800HWG.1 CRAWLER CRANE

1-5

Safety

The condition of working site may affect the noise levels.

Operator’s Manual for Crawler Crane

1.11 Personnel qualification, requirements and responsibilities Safety

a)

Any work on and / or with the crane must be executed by trained, reliable and authorized personnel only.

b)

Maintenance work must only be undertaken by suitable qualified engineers with specialist knowledge of this crane.

c)

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

1.12 Safety advice regarding specific operational phases 1.12.1 Standard operation a)

Take necessary precautions to ensure that the crane is used in a safe and reliable state.

b)

This crane is a conventional assembly & dismantling machine. Do not apply the crane for other purpose.

c)

Operate the crane only for its designed purpose and only if all guarding, protective and safety orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are in place and fully functional.

d)

Ensure that any local barriers erected to stop unauthorized entry to this equipment are in place.

e)

Before starting the engine ensures it is safe to do so.

1.12.2 Malfunction In the event of any malfunction or operational difficulty, stop the crane immediately.

1.12.3 Unguarded areas a)

In-running nip points on moving machinery can cause serious injury or even death.

b)

Do not reach into unguarded machinery. Your arm could be pulled in and amputated.

c)

Stop the crane before removing any safety devices.

d)

Limit access to the machine and its surrounding where barrier guards are appropriately erected to reduce the risk of residual mechanical hazards, falling lifted loads.

1.13 Special Hazards 1.13.1 Electrical energy 1.13.1.1 External considerations and hazards a)

When working with the crane, maintain a safe distance from the overhead electric lines. If overhead lines are in the immediate vicinity, a risk assessment must be completed prior to operating this crane.

1-6

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

b)

If your machine comes into contact with a live wire:

Vacate the area

-

Warn others against approaching and touching the crane.

-

Report the incident and have the live wire de-energized.

Safety

-

1.13.1.2 Machine – Electrical a)

The electrical equipment of the crane must be inspected at regular intervals. Defects such as loose connections or scorched or otherwise damaged cables must be rectified immediately.

b)

Use only original fuses with the specified current rating.

c)

Switch off the machine immediately if trouble occurs in the electrical system.

d)

This crane is wired on a negative earth. Always observe correct polarity.

1.13.1.3 Battery a)

Always disconnect battery leads before carrying out any maintenance to the electrical system.

b)

Recharge the battery in a well ventilated area.

c)

The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce explosive gases. Avoid contact with the skin, eyes or clothing.

d)

No smoking when maintaining battery.

e)

Wear appropriate PPE.

1.13.2 Gas, dust, steam, smoke and noise a)

Always operate internal combustion engines out of doors or in a well ventilated area.

b)

If the crane is operated for maintenance purposes in an enclosed area, ensure that there is sufficient ventilation.

c)

Observe the rules and regulations at different working site.

d)

Dust found on the crane or produced during work on the crane must not be removed by blowing with compressed air.

e)

Toxic dust / waste must only be dampened by authorized persons, and then placed in a sealed container and marked, to ensure safe disposal.

1.13.3 Welding or naked flames a)

Welding, flame cutting and grinding work on the crane must only be carried out if this has been expressly authorized, as there may be a risk of explosion and fire.

b)

No welding should be undertaken on this crane as it will affect its structural integrity.

c)

Avoid all naked flames in the vicinity of this crane.

ZCC800HWG.1 CRAWLER CRANE

1-7

Operator’s Manual for Crawler Crane

1.13.4 Hydraulic equipment Safety

a)

Work on hydraulic system must be carried out by persons having special knowledge and experience of hydraulic system.

b)

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Sprayed oil may cause personal injury.

c)

Always relieve pressure from the hydraulic system before carrying out any kind of maintenance or adjustment work.

d)

Depressurize all components and pressure pipes (of hydraulic system or compressed air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

e)

Hydraulic lines and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

1-8

f)

Only fit replacement components of a type provided by the manufacturer.

g)

Always practice extreme cleanliness servicing hydraulic components.

h)

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

i)

Once the fluid is injected into the skin, seek medical help immediately.

ZCC800HWG.1 CRAWLER CRANE

Operator’s履带起重机操作手册 Manual for Crawler Crane Chapter Description of Crane 第二章 2起重机的描述

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Chapter 2 Description of Crane 2.1 Product model 2.1.1 Product name plate and its position Product name plate and its position are shown in the figures 2-1 and 2-2.

Description of Crane

Figure 2-1

ZCC800HWG.1 CRAWLER CRANE

Product name plate

2-1

Operator’s Manual for Crawler Crane

Description of Crane Figure 2-2

2-2

Position of product name plate

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.1.2 Engine type and its manufacturer Engine type: WP7G270E301 Engine manufacturer: Weichai Power Co.,Ltd.

2.1.3 Intended use of the crane It is prohibited to transport people with this equipment! In many cases, there have been serious loads). Under such circumstances, they have no control over the crane movements and are not protected against bumps or falls. Even the smallest error can cause vital injury! In exceptional cases, please consult the responsible authorities concerning safety regulations. It is expressly forbidden to use the crane for jumps with rubber ropes (bungee jumping)! Using the crane for such jumps represents a misuse of the crane and entails extreme danger for life and limb! The crane is designed exclusively for assembly and lifting operation, i.e. lifting loads, non-continuous use of the crane. Any other type of use or otherwise use which goes beyond its limits specified, such as handling of general cargo or grab operation, are not classified as intended use. The manufacturer shall not be liable for any damage caused. The operator bears full responsibility for this type of misuse. The use of two hoisting winches for lifting loads (twin hook operation) is only permitted following consultation from the crane manufacturer. The intended use also includes the observation of Lifting Load Capacity Chart, Operator’s Manual and Maintenance Manual.

2.1.4 Crane design calculation 2.1.4.1 General The crane has been constructed using state of the art technology and in accordance with recognized safety regulations. Nevertheless, its use can lead to hazards for the life and limb of the operator and third parties, and/or damage to the machine and other objects. Use the crane only when it is in full working order and only for its intended use, paying attention at all times to safety and potential hazards, and in observance of the Operator’s Manual and Maintenance Manual.

CAUTION Have any malfunctions which might impair safety rectified immediately.

ZCC800HWG.1 CRAWLER CRANE

2-3

Description of Crane

injuries when people have been transported using this equipment (or even on the hook or on

Operator’s Manual for Crawler Crane

2.1.4.2 Classification of the crane The crane is classified as follows in accordance with ISO 4301-2, GB/T 3811 and GB/T 14560 standards: a)

Operating class: U1

b)

Load collective class: Q2

c)

Crane group: A1

All important components of the crane are designed and manufactured for normal assembly

Description of Crane

operation. Operating conditions or types of use other than assembly operation require the permission of the manufacturer and normally lead to a reduction in the lifting capacities.

2.1.4.3 Service life Classification of the crane is based on a total operating life (service life) of 20 years under the following conditions: a)

The crane is operated as an assembly and lifting crane. The load capacity charts specified for the crane are for assembly operation only. General cargo handling or grab operation can only be permitted following express permission from the manufacturer under suitable conditions.

b)

The entire number of the crane’s load cycles is less than 32000. (for example, 5 load cycles each day – 10 load cycles each day, 200 days each year) A “load cycle” encompasses processes which begin when a load is lifted and end when the crane is ready to lift the next load, including the time of crane operation and normal break.

c)

The load spectrum coefficient of the crane should comply with the load collective class (lift the rated load rarely, but the medium-duty load frequently). For example: For 1/6 of the load cycles, the crane is placed under the maximum load; For 1/6 of the load cycles, the crane is with 73% of the maximum load; For 1/6 of the load cycles, the crane is with 47% of the maximum load; For 3/6 of the load cycles, the crane is with 20% of the maximum load; “Load” herein means the total weight of lifting load and load handling devices (for example, lifting load + load hook + sling). Under these circumstances, assuming that the maintenance work is carried out properly, the theoretical service life can be more than 20 years. Harder operating conditions naturally lead to a reduction in the service life.

CAUTION (1) The winch must comply with the calculation formula for theoretical residual life. For details, refer to Maintenance Manual. (2) Some components (for example, wire rope, pulley and bearing) are not designed for the entire service life of the crane, but they must be replaced after a certain amount of time of using. For relevant information, please see Maintenance Manual.

2-4

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.2 Terminology 2.2.1 Boom configurations There are four boom configurations for this crawler crane, please see the figures 2-3 and 2-4. The description of boom configurations will be shown in the table 2-1.

Description of Crane

S-1

SF-1

Figure 2-3

ZCC800HWG.1 CRAWLER CRANE

Boom configurations

2-5

Operator’s Manual for Crawler Crane

Description of Crane S-2

SF-2

Figure 2-4

Table 2-1 Configuration no. S-1

2-6

Boom configurations

Description of boom configurations

Description

Parameters

Main boom

Main boom: 13m-58m

SF-1

Main boom with fixed jib

Main boom: 37m-49m

Fixed jib: 6m-18m

S-2

Main boom with fixed jib

Main boom: 37m-49m

Fixed jib: 6m-18m

SF-2

Main boom with fixed jib

Main boom: 37m-49m

Fixed jib: 6m-18m

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.2.2 Description of main components The components of crane undercarriage and slewing table are shown in the figures 2-5, 2-6 and 2-7. They are described in the table 2-1.

Description of Crane

1.1

1.2

1.4

1.3

1.5

Figure 2-5

ZCC800HWG.1 CRAWLER CRANE

Crane undercarriage

2-7

Operator’s Manual for Crawler Crane

2.1 2.2

Description of Crane

2.3

2.4

2.5

2.6

Figure 2-6

2-8

2.7

2.8

Slewing table

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Description of Crane

3.2

3.1

3.7 3.3

3.6

3.4

3.5

Figure 2-7

ZCC800HWG.1 CRAWLER CRANE

Overview of slewing table from above

2-9

Operator’s Manual for Crawler Crane

Table 2-2 No.

Description of main components

Names of the components

No

Names of the components

Description of Crane

1.1

Additional support

2.6

Hoisting winch 2

1.2

Crawler carrier assy.

2.7

Hoisting winch 1

1.3

Undercarriage central section assy.

2.8

Operator’s cab

1.4

Horizontal anchoring rods

3.1

Slewing mechanism

3.2

Fuel tank

1.5

Crawler carrier extending & retracting cylinder

2.1

A-frame assy.

3.3

Air-conditioning condenser

2.2

Main boom pivot section

3.4

Engine

2.3

Main boom tilting-back support

3.5

Hydraulic oil tank

2.4

Rear counterweight

3.6

Main valve

2.5

Derricking winch

3.7

Electrical control box

Note: The illustrations above are simplified to make them easier to understand. They are for reference only. For actual components of superstructure and undercarriage, please take the product as the standard.

2-10

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.3 Product description 2.3.1 Crane undercarriage a)

Undercarriage central section Self-manufactured and high-rigid welded structure made of high-strength structural steel

b)

Travel gear Crawler travel gear with flat track pad track-carrier plate

c)

Travel drive The crawlers are driven independently via axial piston motor and planetary reducer at the rear side of crawler carriers. Allow such traveling movements available as traveling straight ahead/backwards, turning on the spot, turning with a crawler and differential steering.

d)

Crawler carrier extending & retracting mechanism The extending and retracting of crawler carrier is controlled by a horizontal cylinder. The cylinder directional control valve, undercarriage control valve and undercarriage control lever are fitted in the front of undercarriage central section. After pulling out the undercarriage control lever, the horizontal cylinder can be controlled by travel gear pedal (with hand lever) to achieve the extending and retracting of crawler carrier.

2.3.2 Crane superstructure a)

Slewing table Self-manufactured and high-rigid welded structure made of high-strength structural steel. Connected to undercarriage by a 1-row roller slewing ring for 360°continuous rotation

b)

Crane engine In-line six cylinder engine, manufactured by Weichai Power, type WP7G270E301, rated power 199kW at 2000rpm, maximum torque 1200N.m at 1200rpm-1500rpm

CAUTION When the crane is working at an altitude of 2500 meters or less, the rated output power of engine will not decrease. While the crane is working at an altitude of more than 2500 meters, the rated output power of engine will decrease. For details, please consult local engine service department or technical department of Zoomlion crawler crane manufacturing company. c)

Crane drive Driving force, supplied by diesel engine, is transmitted to a variable dual pump and three gear pumps.

ZCC800HWG.1 CRAWLER CRANE

2-11

Description of Crane

Equipped with track roller, track-carrier roller, drive sprocket and driven sprocket as well as

Operator’s Manual for Crawler Crane

d)

Hoisting winches The crane is fitted with two hoisting winches: hoisting winch 1 and hoisting winch 2. Both of them consist of hydraulic motor, winch reducer, normally closed brake, lowering limiter, hoisting limiter, wire rope as well as main and auxiliary load hooks.

e)

Derricking winch Composed of built-in axial piston hydraulic motor, balance valve, winch reducer and normally closed brake, derricking pulley block as well as wire rope;

Description of Crane

Fitted with a ratchet wheel mechanism f)

Slewing mechanism Composed of built-in axial piston hydraulic motor, planetary gear reducer, slewing brake valve, brake and pinion gear as well as slewing ring. The superstructure can carry out 360° slewing motion through pinion gear’s driving slewing ring.

g)

Counterweight 27t in total Consisting of a 2.7t counterweight base plate, four 3.825t counterweight plates and two 4.5t central counterweight plates Fitted on the rear section of slewing table

h)

Crane operator’s cab Spacious and comfortable, all-steel construction cab, with luxury instrument desk, operating and control instruments, heating & cooling air conditioning, hydraulic cushioned seat. Overall of operator’s cab outside (L × W × H): 1850mm×900mm×1650 mm

i)

Safety device Many types of safety and warning devices, whether mechanically controlled, electronically controlled or hydraulically controlled, are fitted on the crane to ensure safe operation of the crane. Such devices include but not limited to load moment limiter, monitor (optional), main boom angle indicator, derricking limiter, hoisting limiter, safety catch, balance valve, overflow valve, ratchet wheel mechanism for derricking winch

j)

Electrical system 24V DC, negative ground, two batteries of 165Ah each

CAUTION The classification group of ZCC800H crawler crane is A1, and the classification groups of mechanisms are: traveling mechanism (M1), slewing mechanism (M2), hoisting winch (M3) and derricking mechanism (M2).

2-12

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.3.3 Overall dimensions The overall dimensions of crane are shown in the figure 2-8. Unit: mm

Description of Crane

Figure 2-8

ZCC800HWG.1 CRAWLER CRANE

Overall dimensions of crane

2-13

Operator’s Manual for Crawler Crane

2.4 Technical data 2.4.1 Main technical parameters Main technical parameters of this crawler crane are shown in the table 2-3. Table 2-3 Main technical parameters Item

Description of Crane

Unit

Value

Max. lifting capacity × radius

t×m

80×4

Deadweight with basic boom

t

72.8

Main boom length

m

13-58

Fixed jib length

m

6-18

Max. lifting capacity on fixed jib

t

7

Fixed jib angle

°

10, 30

Max. length of main boom with fixed jib

m

49＋18

Hoisting winch 1 (on the th

4 rope layer) Max. single rope

Hoisting winch 2 (on the

speed of winches

4 rope layer)

m/min

125 (110, with free-fall function)

m/min

125

m/min

93

Slewing speed

rpm

0-2

Traveling speed

km/h

0-1.67

％

30

MPa

0.083

m

13.5×3.4×3.2

kW/r/min

199/2000

N. m/r/min

1270/1200-1500

th

Derricking winch (on the th

4 rope layer)

Gradeability Ground pressure Overall dimensions (L×W×H) (with A-frame and main boom pivot section) Rated power / rotational Engine (Weichai

speed

power)

Max. output torque / rotational speed

4200×5440×800 Distance between track center × crawler contact length × crawler width

mm

(crawler carrier extended) 2600×5440×800 (crawler carrier retracted)

Noise level outside the operator’s cab during Noise

dB (A)

≤107

dB (A)

≤79

operation Noise level in the operator’s cab during operation

2-14

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.4.2 Specification of load hook and application of rope reeving The load hooks used in the crane are described in details in the table 2-4. Table 2-4

Specification of load hook

Rope reeving applied

Weight of load hook (kg)

80 t

12

1250

50 t

7

920

30 t

4

600

16 t

2

490

8t

1

264

Description of Crane

Type of load hook

CAUTION The specification of load hook in above table is not the standard load hook configuration. It is subject to the contract signed with the customer.

2.4.3 Rope reeving and specification of wire rope a)

Rope reeving for different boom lengths is shown in the table 2-5. Table 2-5

Application of rope reeving

Main boom/fixed jib

Rated lifting capacity (t)

Rope reeving

13

80

12

16

66.8

11

19

51.8

10

22

51.7

8

25

41.5

7

28

40.7

6

“Main boom”

31

33.8

6

configuration

34

33.5

5

37

28.4

5

40

23.8

4

43

23.2

4

46

22.6

3

49

17.8

3

52

17.8

3

55

14.3

3

58

14

2

length (m)

ZCC800HWG.1 CRAWLER CRANE

2-15

Operator’s Manual for Crawler Crane

“Main boom with

Main boom/fixed jib

fixed jib”

length (m)

configuration

6-18

Rated lifting capacity (t)

Rope reeving

7

1

CAUTION (1) If the crane is working with hoisting rope reeving less than the value listed in the

Description of Crane

above table, single hoisting rope load must be checked to make sure that the max. permissible load capacity of single hoisting rope is not exceeded. (2) Maximum permissible load capacity of single rope is 7000kg. (3) If the maximum tension force of rope is exceeded, there is a risk of breaking off wire rope and damaging the reducer and motor. b)

Specification of wire rope Table 2-6

Description and intended use Rotation-resistance or not

Parameters of wire rope

Wire rope for hoisting winch 1

Wire rope for hoisting winch 2

Derricking rope

Yes

Yes

No

35×7IWS-1960

35×7IWS-1960

6T (29)+7×7-20-1910

Nominal rope diameter

24mm

24mm

20mm

Rope length

240m

160m

150m

Minimum breaking load

406kN

406kN

290kN

Left-hand ordinary lay

Left-hand ordinary lay

Right-hand lang lay

Type of rope

Direction and type of lay Tensile strength of rope c)

1960N/mm

2

1960N/mm

2

1910N/mm

2

Use length of hoisting rope and derricking rope In transport condition, the longest length of derricking rope is about 138 m. “Main boom” configuration: when main boom length is 55m and rope reeving is 3, the longest possible hoisting rope for winch 1 is 226m. “Main boom with fixed jib” configuration: when main boom length is 49 m and fixed jib length is 18 m, the longest possible hoisting rope for winch 2 is 134 m.

2-16

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

2.4.4 Lifting height a)

Lifting height on S boom

60 56

Description of Crane

52 48 44

Lifting height (m)

40 36 32 28 24 20 16 12 8 4

0

4

8

12

16

20

Figure 2-9

32 24 28 Working radius (m)

36

40

44

48

52

56

Lifting height on S boom

CAUTION (1) The boom lifting height curve is drawn without considering boom deflection. (2) The X-axis indicates the working radius in meters, and the Y-axis indicates the lifting height in meters. (3) For S boom configuration, main boom = 13m-58m. ZCC800HWG.1 CRAWLER CRANE

2-17

Operator’s Manual for Crawler Crane

b)

Lifting height on SF boom

68 64 60 56

Description of Crane

52 48 44

Lifting height (m)

40 36 32 28 24 20 16 12 8 4

0

4

8

12

16

20

24

28

32

36

40

44

48

52

56

60

Working radius (m)

Figure 2-10

Lifting height on SF boom

CAUTION (1) The boom lifting height curve is drawn without considering boom deflection. (2) The X-axis indicates the working radius in meters, and the Y-axis indicates the lifting height in meters. (3) For SF boom configuration, main boom = 37m-49m, fixed jib = 6m-18m, and fixed jib angle = 10°.

2-18

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

64 60 56 52

Description of Crane

48

Lifting height (m)

44 40 36

32 28 24 20

16 12 8 4

0

4

8

12

16

20

24

28

32

36

40

44

48

52

56

60

64

Working radius (m)

Figure 2-11

Lifting height on SF boom

CAUTION (1) The boom lifting height curve is drawn without considering boom deflection. (2) The X-axis indicates the working radius in meters, and the Y-axis indicates the lifting height in meters. (3) For SF boom configuration, main boom = 37m-49m, fixed jib = 6m-18m, and fixed jib angle = 30°.

ZCC800HWG.1 CRAWLER CRANE

2-19

Operator’s Manual for Crawler Crane

2.4.5 Lifting capacity chart

CAUTION The lifting capacity in the following table is given in t. The sign “*/*” indicates “lifting capacity/radius”.

a)

Lifting capacity on S-1 boom

Description of Crane

Table 2-7

Lifting capacity on S-1 boom

Main boom length (m) Radius (m)

13

16

19

22

25

28

31

34

37

Radius (m)

4

80

5

68

66.8

6

52.3

52

51.8

51.7

7

42.3

42

41.9

41.7

40

39.5

8

35.5

35.2

35

34.8

34.6

33.97

33.8

33.5

9

29.5

29.3

29.2

29.1

29

28.9

28.8

28.6

28.4

9

10

26.7

26.4

26.2

26

25.7

25.3

25

24.8

24.6

10

12

19.5

19.4

19.3

19.2

19.1

19

18.9

18.8

18.7

12

17.2

17

16.9

16.6

16.2

16

15.8

15.5

14

14.37

14.2

13.9

13.6

13.4

13.1

12.9

16

12.2

11.9

11.6

11.4

11.1

11

18

20

10.3

10

9.8

9.7

9.5

20

22

8.5

8.45

8.4

8.3

8.2

22

7.7

7.65

7.6

7.5

24

6.8

6.75

6.7

26

28

6

5.9

28

30

5.5

5.4

30

4.2

32

14 16 18

24 26

32

2-20

4 5 6 7 8

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-7

Lifting capacity on S-1 boom

Main boom length (m) Radius (m)

40

43

46

49

52

55

58

9

Radius (m) 9

10

23.8

23.2

22.6

12

18.6

18.6

18.2

17.8

17.8

14

15.5

15.2

15

14.7

14.5

14.3

14

14

16

12.8

12.7

12.5

12.3

12.1

12

11.5

16

18

10.9

10.7

10.5

10.3

10.2

10

9.9

18

20

9.4

9.3

9.2

9

8.9

8.8

8.6

20

22

8.2

8.2

8.1

8

7.9

7.7

7.5

22

24

7.45

7.2

7.1

7

6.9

6.8

6.6

24

26

6.6

6.5

6.4

6.2

6

5.8

5.7

26

28

5.8

5.7

5.6

5.55

5.5

5.4

5.1

28

30

5.3

5.2

5.1

5

4.8

4.6

4.5

30

32

4.2

4.2

4.1

4

4

4

3.8

32

34

4.1

4.1

4

3.9

3.8

3.7

3.4

34

36

3.8

3.7

3.5

3.4

3.2

2.9

36

38

3.2

3.1

3.05

3

2.9

2.6

38

2.8

2.7

2.6

2.5

2.3

40

2.3

2.3

2.2

2

42

2

1.8

1.6

44

46

1.6

1.3

46

48

1.5

1

48

0.8

50

42 44

50

12

Description of Crane

40

10

Note: The lifting capacities highlighted in gray are determined by the strength.

ZCC800HWG.1 CRAWLER CRANE

2-21

Operator’s Manual for Crawler Crane

b)

Lifting capacity on SF-1 boom Table 2-8

Lifting capacity on SF-1 boom

Main boom

37

length (m) Fixed jib

6

length (m)

12

18

Description of Crane

Fixed jib angle (°) Radius (m)

10

30

10

7

6

12

7

6

7

14

7

6

7

16

7

6

7

6

5.5

18

7

6

7

6

5.5

20

7

6

7

6

5.5

4

22

7

6

7

6

5.5

4

24

7

6

7

6

5.5

4

26

6.7

6

6.7

6

5.5

4

28

6.1

5.5

6.1

5.5

5.5

3.5

30

5.4

4.8

5.4

4.8

5

3.5

32

4.9

4.4

4.9

4.4

4

3.3

34

4.3

4

4.3

4

4

3.2

36

3.9

3.7

3.7

3.2

38

3.5

3.4

3.5

3.1

3.2

3.2

3

40

2-22

10

30

10

30

5.5

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-8

Lifting capacity on SF-1 boom

Main boom

40

length (m) Fixed jib

6

length (m)

12

18

Fixed jib angle (°) 10

30

10

10

7

12

7

6

7

14

7

6

7

16

7

6

7

6

5.5

18

7

6

7

6

5.5

20

7

6

7

6

5.5

4

22

7

6

7

6

5.5

4

24

7

6

7

6

5.5

4

26

6.4

6

6.1

5.4

5.5

4

28

5.5

5.5

5.5

4.8

5

3.7

30

5.2

5

5

4.2

5

3.7

32

4.4

4.3

4.3

4

4

3.5

34

4

3.9

3.9

4

4

3.5

36

3.6

3.5

3.6

3.5

3.8

3.3

3.1

3.2

3

3.2

3.1

2.7

2.7

2.6

2.5

2.4

2.5

2.3

38 40 42

ZCC800HWG.1 CRAWLER CRANE

30

10

Description of Crane

Radius (m)

30

5.5

2-23

Operator’s Manual for Crawler Crane

Table 2-8

Lifting capacity on SF-1 boom

Main boom

43

length (m) Fixed jib

6

length (m)

12

18

Fixed jib angle (°)

Description of Crane

Radius (m)

10

30

10

30

10

12

7

14

7

6

7

16

7

6

18

7

20

7

6

5.5

6

7

6

5.5

7

6

7

6

5.5

4

22

7

6

7

6

5.5

4

24

7

6

7

6

5.5

4

26

6.3

5.5

6.3

6

5.5

4

28

5.5

4.7

5.5

5.4

5.4

4

30

4.8

4.3

4.8

4.7

5

4

32

4.2

4.2

4.2

4.1

4.5

4

34

4

4

4

4

4

3.5

36

3.6

3.6

3.7

3.6

3.6

3.5

38

3.3

3.3

3.4

3.4

3.3

40

3.1

3

3.1

3.1

42

2.7

2.7

2.7

2.7

2.5

2.5

2.5

44

2-24

30

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-8

Lifting capacity on SF-1 boom

Main boom

46

length (m) Fixed jib

6

length (m)

12

18

Fixed jib angle (°) 10

30

10

12

7

14

7

6

7

16

7

6

7

18

7

6

7

6

5.5

20

7

6

7

6

5.5

22

7

6

7

6

5.5

4

24

6.5

6

7

6

5.5

4

26

6

5.8

5.9

5.7

5.5

4

28

5

4.9

5

4.9

5

4

30

4.7

4.6

4.6

4.5

4.8

4

32

4

4.3

4

4

4.4

3.8

34

4

3.7

4

3.7

3.8

3.5

36

3.5

3.5

3.5

3.5

3.5

3.3

38

3.2

3.2

3.2

3.2

3.2

3.2

40

2.9

2.9

2.9

3

3

3

2.6

2.5

2.6

2.5

2.5

2.5

2.4

2.4

42 44

ZCC800HWG.1 CRAWLER CRANE

30

10

30

5.5

2-25

Description of Crane

Radius (m)

Operator’s Manual for Crawler Crane

Table 2-8

Lifting capacity on SF-1 boom

Main boom

49

length (m) Fixed jib

6

length (m)

12

18

Fixed jib angle (°)

Description of Crane

Radius (m)

10

30

10

12

7

14

7

6

7

16

7

6

7

18

7

6

7

6

5.5

20

7

6

7

6

5.5

22

7

6

7

6

5.5

4

24

6.5

6

6.5

6

5.5

4

26

5.7

5.5

5.7

5.5

5.5

4

28

5.1

5

5

5

4.9

4

30

4.5

4.4

4.6

4.4

4.5

4

32

4

4

4

4

4

3.7

34

4

4

3.6

3.6

3.5

3.5

36

3.4

3.3

3.3

3.4

3.2

3.3

38

3

3

3

3.2

3

3.2

40

2.8

2.8

2.8

2.8

2.8

3

42

2.5

2.5

2.5

2.5

2.5

2.7

2.2

2.2

2.3

2.3

2.3

1.9

1.9

1.9

1.8

44 46

2-26

30

10

30

5.5

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Note: (1) The values in the lifting capacity charts are applicable to 360°working range. (2) The value in the lifting capacity charts is the rated lifting capacity of crane, which is the permissible maximum lifting capacity under various boom configurations. It includes the weight of load hook and other load handling devices. Please see the figure 2-12.

Description of Crane

Actual load

Rated lifting capacity =

Figure 2-12

+ Weight of load hook, wire rope and other load handling devices

Rated lifting capacity

(3) The radius in the lifting capacity charts is the horizontal distance from central axle of slewing ring to centerline of hook when crane is loaded. (4) Crane operation with main boom and fixed jib: If main load hook is not detached from main boom head, the actual lifting capacity on fixed jib should be calculated from this formula: rated lifting capacity – main load hook’s weight – auxiliary load hook’s weight – sling’s weight – wire rope’s weight. (5) Crane operation with main boom (but some sections of fixed jib are not dismantled): The actual lifting capacity on main boom is calculated in accordance with following formula:

 L cos(   )   L2  G2  G  G1 1  2   G3  G4  cos(   )  1 L 2 L1    4 1 Where, G= rated lifting capacity G1= weight of fixed jib head and fixed jib pivot section＋weight of 6m fixed jib intermediate section ×(number of 6m fixed jib intermediate sections) + fixed jib anchoring rods G2= actual lifting capacity G3= weight of FA-frame and tilting-back support of fixed jib G4= weight of auxiliary load hook and other load handling devices L1= working radius (or main boom length ×cosα) L2= fixed jib length

ZCC800HWG.1 CRAWLER CRANE

2-27

Operator’s Manual for Crawler Crane

α= main boom angle o

o

β= fixed jib angle (10 or 30 )

Description of Crane Figure 2-13

Calculation of load

(6) The rated lifting capacity indicates the crane’s lifting capacity under different boom configurations when it is operated on firm and flat ground. (7) When tip boom is used, the lifting capacity on the tip boom is the same as that on the main boom within the same radius, but its max. lifting capacity should not exceed 7t. (8) Whether the tip boom is used or not, the lifting capacity on the main boom is the same. (9) Main boom and tip boom can not work at the same time when main boom is attached with tip boom. (10) The maximum in-service wind velocity should not exceed 9.8 m/s during crane operation. The maximum out-of-service wind velocity should not exceed 21 m/s when crane is only fitted with main boom. The maximum out-of-service wind velocity should not exceed 15 m/s when crane is fitted with main boom and fixed jib.

2-28

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

(11) Crane operation with main boom and fixed jib: The maximum lifting capacity on fixed jib (7 t) includes the weight of 8t auxiliary load hook and wire rope, which weigh 0.6t in total. Therefore, the maximum actual lifting capacity should not exceed 6.4 t. (12) When crane is traveling with load, 

70% of rated lifting capacity under corresponding working condition should not be exceeded. The boom should be located in the forward traveling direction.



The height of lifted load above the ground should not be more than 500 mm.

ZCC800HWG.1 CRAWLER CRANE

2-29

Description of Crane



Operator’s Manual for Crawler Crane

c)

Lifting capacity on S-2 boom Table 2-9

Lifting capacity on S-2 boom Main boom length (m) 37

Description of Crane

Fixed jib length (m) Radius (m) 6

12

18

Fixed jib angle (°)

2-30

10

30

10

30

10

30

9

26.9

26.7

26.7

26.4

26.5

26.1

10

23.1

23

22.9

22.7

22.7

22.4

12

17.7

17.6

17.5

17.4

17.4

17.1

14

14

13.9

13.9

13.7

13.7

13.5

16

11.4

11.3

11.3

11.1

11.1

10.9

18

9.5

9.5

9.4

9.3

9.2

9.1

20

7.9

7.9

7.8

7.7

7.7

7.5

22

6.6

6.6

6.5

6.4

6.4

6.3

24

5.5

5.5

5.4

5.3

5.3

5.2

26

4.7

4.7

4.6

4.6

4.5

4.4

28

3.9

3.9

3.8

3.8

3.7

3.6

30

3.2

3.2

3.1

3.1

3

3

32

2.7

2.7

2.6

2.6

2.5

2.5

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-10

Lifting capacity on S-2 boom Main boom length (m) 40 Fixed jib length (m)

Radius (m) 12

18

Description of Crane

6

Fixed jib angle (°) 10

30

10

30

10

30

10

22.3

22.2

22.1

21.9

22

21.6

12

17.5

17.4

17.4

17.2

17.2

16.9

14

14

13.9

13.9

13.7

13.7

13.5

16

11.3

11.3

11.2

11.1

11.1

10.9

18

9.4

9.4

9.3

9.2

9.2

9

20

7.9

7.9

7.8

7.7

7.7

7.5

22

7

7

6.9

6.8

6.8

6.7

24

5.9

5.9

5.8

5.8

5.7

5.6

26

5.1

5.1

5

5

4.9

4.8

28

4.3

4.3

4.2

4.2

4.1

4.1

30

3.8

3.8

3.7

3.7

3.6

3.6

32

3.3

3.3

3.2

3.2

3.1

3.1

34

2.6

2.6

2.5

2.5

2.4

2.4

36

2.6

2.5

2.4

2.4

2.3

2.3

ZCC800HWG.1 CRAWLER CRANE

2-31

Operator’s Manual for Crawler Crane

Table 2-11

Lifting capacity on S-2 boom Main boom length (m) 43 Fixed jib length (m)

Description of Crane

Radius (m) 6

12

18

Fixed jib angle (°)

2-32

10

30

10

30

10

30

10

21.7

21.6

21.5

21.3

21.4

21

12

17.1

17

17

16.8

16.8

16.5

14

13.7

13.7

13.6

13.4

13.5

13.2

16

11.2

11.2

11.1

11

11

10.8

18

9.2

9.2

9.1

9

9

8.8

20

7.8

7.8

7.7

7.6

7.6

7.5

22

6.8

6.8

6.7

6.6

6.6

6.5

24

5.7

5.7

5.6

5.6

5.5

5.4

26

5

5

4.9

4.9

4.8

4.7

28

4.2

4.2

4.1

4.1

4

4

30

3.5

3.5

3.4

3.4

3.3

3.3

32

3.3

3.2

3.2

3.1

3

3

34

2.7

2.6

2.6

2.5

2.5

2.4

36

2.4

2.3

2.3

2.2

2.2

2.1

38

1.8

1.8

1.7

1.6

1.6

1.5

40

1.6

1.6

1.5

1.4

1.4

1.3

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-12

Lifting capacity on S-2 boom Main boom length (m) 46 Fixed jib length (m)

6

12

Description of Crane

Radius (m) 18

Fixed jib angle (°) 10

30

10

30

10

30

10

21.1

21

21

20.7

20.8

20.5

12

16.7

16.6

16.6

16.4

16.4

16.1

14

13.5

13.4

13.4

13.2

13.3

13

16

11

11

10.9

10.8

10.8

10.6

18

9

9

8.9

8.8

8.8

8.6

20

7.7

7.7

7.6

7.5

7.5

7.4

22

6.6

6.6

6.5

6.5

6.4

6.3

24

5.6

5.6

5.5

5.5

5.4

5.3

26

5.1

5

4.9

4.9

4.8

4.7

28

4.2

4.1

4.1

4

3.9

3.9

30

3.7

3.6

3.6

3.5

3.5

3.4

32

3.2

3.1

3.1

3

3

2.9

34

2.6

2.5

2.5

2.4

2.4

2.3

36

2.3

2.2

2.2

2.1

2

2

38

1.8

1.8

1.7

1.7

1.6

1.5

40

1.6

1.6

1.5

1.5

1.4

1.4

ZCC800HWG.1 CRAWLER CRANE

2-33

Operator’s Manual for Crawler Crane

Table 2-13

Lifting capacity on S-2 boom Main boom length (m) 49 Fixed jib length (m)

Description of Crane

Radius (m) 6

12

18

Fixed jib angle (°)

2-34

10

30

10

30

10

30

12

16.3

16.2

16.2

16

16

15.7

14

13.3

13.2

13.2

13

13

12.8

16

10.8

10.8

10.7

10.6

10.6

10.4

18

8.8

8.8

8.7

8.6

8.6

8.4

20

7.5

7.5

7.4

7.3

7.3

7.2

22

6.5

6.5

6.4

6.4

6.3

6.2

24

5.6

5.5

5.4

5.4

5.3

5.2

26

4.8

4.7

4.7

4.6

4.6

4.5

28

4.2

4.1

4.1

4

4

3.9

30

3.7

3.6

3.6

3.5

3.5

3.4

32

3.1

3

3

2.9

2.9

2.8

34

2.6

2.5

2.5

2.4

2.4

2.3

36

2.1

2

2

1.9

1.9

1.8

38

1.8

1.8

1.7

1.7

1.6

1.6

40

1.3

1.3

1.2

1.2

1.1

1.1

42

1.1

1.1

1

1

0.9

0.8

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

d)

Lifting capacity on SF-2 boom Table 2-14

Lifting capacity on SF-2 boom Main boom length (m) 37

Description of Crane

Fixed jib length (m) Radius (m) 6

12

18

Fixed jib angle (°) 10

30

10

30

10

30

10

6

12

6

5.1

6.2

14

5.9

5.1

6.1

16

5.9

5.1

6.1

5.3

4.8

18

5.9

5

6.1

5.3

4.8

20

5.9

5

6.1

5.3

4.7

3.5

22

5.9

5

6.1

5.2

4.7

3.4

24

5.9

5

6.1

5.2

4.7

3.4

26

5.6

5

5.8

5.2

4.7

3.4

28

5

4.4

5.2

4.7

4.7

2.8

30

4.3

3.7

4.5

3.9

4.2

2.8

32

3.8

3.3

3.9

3.5

3.2

2.6

34

3.2

2.9

3.3

3.1

3.2

2.5

36

2.9

2.8

2.9

2.5

38

2.5

2.5

2.7

2.3

2.3

2.3

2.2

40

ZCC800HWG.1 CRAWLER CRANE

4.8

2-35

Operator’s Manual for Crawler Crane

Table 2-15

Lifting capacity on SF-2 boom Main boom length (m) 40 Fixed jib length (m)

Description of Crane

Radius (m) 6

12

18

Fixed jib angle (°) 10

10

30

10

30

10

6

12

6

5.1

6.2

14

5.9

5.1

6.1

16

5.9

5

6.1

5.3

4.8

18

5.9

5

6.1

5.3

4.7

20

5.9

5

6.1

5.2

4.7

3.5

22

5.9

5

6.1

5.2

4.7

3.4

24

5.9

5

6.1

5.2

4.7

3.4

26

5.3

5

5.2

4.6

4.7

3.3

28

4.4

4.4

4.9

3.9

4.2

3

30

4.1

3.9

4

3.3

4.2

3

32

3.3

3.2

3.3

3.1

3.2

2.8

34

2.9

2.8

2.9

3.1

3.1

2.8

36

2.5

2.4

2.6

2.6

2.9

2.5

2

2.2

2.1

2.3

2.3

1.7

1.8

1.7

1.7

1.4

1.6

1.5

38 40 42

2-36

30

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-16

Lifting capacity on SF-2 boom Main boom length (m) 43 Fixed jib length (m)

Radius (m) 12

18

Fixed jib angle (°) 10

30

10

30

10

30

12

5.9

14

5.9

5.1

6.1

16

5.9

5

6.1

5.3

4.7

18

5.9

5

6.1

5.3

4.7

20

5.9

5

6.1

5.2

4.7

3.5

22

5.9

5

6.1

5.2

4.7

3.4

24

5.9

5

6

5.2

4.7

3.4

26

5.2

4.4

5.3

5.2

4.7

3.3

28

4.4

3.6

4.5

4.5

4.6

3.3

30

3.7

3.2

3.8

3.8

4.1

3.3

32

3.1

3.1

3.2

3.2

3.6

3.3

34

2.9

2.9

3

3.1

3.1

2.7

36

2.5

2.5

2.7

2.7

2.7

2.7

38

2.2

2.2

2.3

2.5

2.5

2.5

40

2.1

2.1

2.2

2.3

42

1.7

1.7

1.8

1.9

1.5

1.6

1.7

44

ZCC800HWG.1 CRAWLER CRANE

2-37

Description of Crane

6

Operator’s Manual for Crawler Crane

Table 2-17

Lifting capacity on SF-2 boom Main boom length (m) 46 Fixed jib length (m)

Radius (m)

Description of Crane

6

12

18

Fixed jib angle (°) 10

10

30

10

30

12

5.9

14

5.9

5.1

6.1

16

5.9

5

6.1

18

5.9

5

6.1

5.3

20

5.9

5

6.1

5.2

4.7

22

5.9

5

6

5.2

4.7

3.4

24

5.4

5

6

5.2

4.7

3.4

26

4.9

4.7

4.9

4.8

4.6

3.3

28

3.9

3.8

4

4

4.1

3.3

30

3.6

3.5

3

3.6

3.9

3.3

32

2.9

3.2

3

3.1

3.5

3.1

34

2.9

2.6

3

2.8

2.9

2.7

36

2.4

2.4

2.5

2.6

2.6

2.5

38

2.1

2.1

2.2

2.3

2.3

2.4

40

1.8

1.8

1.9

2

2.1

2.2

1.5

1.5

1.6

1.6

1.7

1.5

1.5

1.6

42 44

2-38

30

ZCC800HWG.1 CRAWLER CRANE

Operator’s Operator’s Manual Manual for for Crawler Crawler Crane Crane

Table 2-18

Lifting capacity on SF-2 boom Main boom length (m) 49 Fixed jib length (m)

Radius (m) 12

Description of Crane

6

18

Fixed jib angle (°) 10

30

10

30

10

30

12

5.9

14

5.9

5.1

16

5.9

5

6.1

18

5.9

5

6.1

5.3

20

5.9

5

6

5.2

4.7

22

5.9

5

6

5.2

4.6

3.4

24

5.4

5

5.5

5.2

4.6

3.4

26

4.6

4.4

4.7

4.6

4.6

3.3

28

4

3.9

4

4.1

4

3.3

30

3.4

3.3

3.6

3.5

3.6

3.3

32

2.9

2.9

3

3.1

3.1

3

34

2.9

2.9

2.6

2.7

2.6

2.7

36

2.3

2.2

2.3

2.5

2.3

2.5

38

1.9

1.9

2

2.3

2.1

2.4

40

1.7

1.7

1.8

1.8

1.9

2.2

42

1.3

1.4

1.5

1.5

1.6

1.9

1.1

1.2

1.3

1.4

1.5

0.9

0.9

1

1

44 46

ZCC800HWG.1 CRAWLER CRANE

2-39

Operator’s履带起重机操作手册 Manual for Crawler Crane Chapter 3 Safety Guidelines 第三章 安全准则

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Chapter 3

Safety Guidelines

3.1 Operational planning In addition to a perfectly working crane and a well-trained crew, operational planning is an important precondition for safe and reliable crane operation. The crane operator must obtain or receive the necessary information (familiarize himself with the operating manual, basic knowledge about pneumatic, electrical and hydraulic drive, and notes for safe operation as well as operating environment) before starting the crane operation, in particular: a)

Clearly define the area of responsibility of all personnel concerned.

b)

Type of crane operation and required working mode.

c)

Distance between the lifting points and surrounding buildings.

d)

Influence of communal facilities (including the overhead high/low voltage lines and

e)

Space requirements at the work site.

f)

Movement restrictions due to surrounding structures (e.g. is there another crane nearby in working).

g)

Number, weight, dimensions, material of load(s) to be lifted.

h)

Required lifting height and slewing radius.

i)

Load-bearing capacity of soil or surface to be operated upon and its flatness.

j)

Height and widths of thoroughfares leading to the site.

k)

Other factors affecting the site (e.g. weather, live lines, etc.).

l)

Communication means adopted between signalman and crane operator.

m) Take appropriate measures to keep people and equipment unconcerned away from the working area. n)

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

Required boom configuration for crane operation

–

Hook blocks/load hook

CAUTION (1) A correct and complete operational planning is vital for safe and problem-free operation of the machine. The operation planner must plan a safe and reliable operational planning by obtaining and analyzing all necessary information about the operation and considering all the factors that may impair safety of the crane operation. (2) If the crane operator does not possess all necessary and required information, it may prove impossible to carry out the intended work and accidents may be the result!

ZCC800HWG.1 CRAWLER CRANE

3-1

Safety Guidelines

underground gas pipes).

Operator’s Manual for Crawler Crane

3.2 Safety technical notes 3.2.1 Safety instructions for crane operator The crane operator’s primary responsibility is to control, operate and adjust the crane in a manner that is safe for both himself and others. Therefore the crane operator should meet the following requirements. a)

The operator must be familiar with the operator’s manual for the crane, and know the working principle, structure performance and the safety devices’ function, as well as master the operation essentials and maintenance skills.

b)

The operator should inspect brake, load hook, wire rope and safety devices before operating the crane. Any irregularities detected during inspection should be removed immediately.

c)

The operator must focus his attention on his work during operation and is forbidden to chat with others. Generally speaking, the operator can only follow the signal sent out by

Safety Guidelines

appointed persons. For a stop signal, the operator should obey it all the time, no matter who gives it. He should refuse to accept signal which violates operation regulations. Stop the crane immediately if somebody is found climbing the crane. d)

Operator who is in low spirits or poor healthy is not allowed to operate the crane.

e)

Crane operator and signalman should be familiar with safety rules, signals and symbols. Prohibit driving after drinking.

f)

Be qualified with the work in hearing, eyesight and reaction ability; be strong enough to operate safely, and has the ability to estimate distance, height and clearance correctly.

g)

Be familiar with the usage of fire extinguisher and be well trained; know how to survive under emergent conditions.

h)

Make sure that only authorized personnel are allowed to operate the crane.

To make sure that the crane is kept in good working order, the crane operator should perform the following checks before operating the crane: a)

Check the daily record of work to ensure that all regular inspections, maintenance and repair work is performed.

b)

Check the hoisting limiter, boom angle indicator, tilting-back support and other safety equipment for functional work.

c)

Check the load-bearing parts carefully, such as wire rope (hoisting rope, derricking rope and anchoring rods etc.), boom, outriggers, hook and load handling devices.

d)

Check if there are some bolts, nuts and pins lost, and the components are cracked or damaged.

e)

Ensure that no modification has been made to the crane without permission, e.g., increase or decrease in counterweight plate and improper repair of boom frame.

3-2

f)

Check fuel lines and hydraulic oil lines for leakage.

g)

Check all control mechanisms for functional work after starting up the engine.

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

h)

Check all control devices for functional work.

i)

Check the brakes. Test the braking performance by lifting a load away from the ground and suspend it in the air for a moment.

j)

Check whether lubricating oil, grease or anti-freeze liquid is sufficient.

k)

Check for contamination.

The following improper operating errors should be avoided. Slewing too quickly.

b)

Quick braking of the load.

c)

Diagonal pulling of the load to be lifted which is still in contact with the ground.

d)

Loose wire rope formations.

e)

Overloading or improperly attaching the load.

f)

Driving (or slewing) too fast with a load, or lifting and loading on an uneven surface.

g)

Diagonal pulling the load, or sudden loosing of lifted load.

h)

Swinging of suspended load, crashing into bridges, roofs or high voltage wiring.

i)

Incorrect assembly or disassembly of booms.

3.2.2 Safety instructions for the rigger The rigger is responsible for ensuring that the load is slung or released safely and carefully. Therefore, he only uses suitable, undamaged lifting and slinging equipment to prevent the load from either slipping or falling. If no signalman is available, the rigger works directly with the crane operator. Qualifications for the rigger: a)

With crane operation certificate.

b)

Be qualified with the work in hearing, eyesight and reaction ability.

c)

Be strong enough to move hook or component.

d)

Be able to estimate the load, balance the load and judge the distance, height and clearance correctly.

e)

Be trained in the skill of handling load.

f)

Be able to choose proper lifting devices and components according to the loading condition.

g)

Be trained in hand signals for operation and familiar to use them.

h)

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

i)

Be capable of conducting the operation of crane to move the load safely.

j)

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

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Safety Guidelines

a)

Operator’s Manual for Crawler Crane

3.2.3 Safety instructions for the signalman The main job of signalman is to assist crane operator to carry out safe operation. Potential damage to property or personal injury could be avoided if the crane operator carries out the crane movement following the signals given out by appointed signalman. However, only one signalman may work with the crane operator at a time. Qualifications for signalman: a)

Familiar with the lifting task so as to cooperate with crane operator and other workers;

b)

Make sure that only authorized personnel are allowed to carry out the work;

c)

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

d)

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

e)

Be trained in hand signals for operating and familiar to use them;

f)

Use standard hand signals for crane operation. If necessary, use a radio device to send out correct and clear order;

Safety Guidelines

g)

Be capable of conducting the operating of crane to move the load safely;

h)

Position himself in a safe location from where he can see the whole process of operation and be seen clearly by the working personnel.

DANGER In order to assure yourself and other person’s interests, please operate the crane in accordance with specified regulations, and take precautions against possible dangers caused by improper operation.

3.2.4 Safety instructions for crane operating crew a)

Any unsafe operation must be corrected or any dangerous situations must be reported to supervisor.

b)

All the persons in the vicinity of the crane must observe the acoustic warning signals of the machine so as to ensure himself and others safety.

c)

All the workers must know about the content of the task and working sequence;

d)

Check whether dangerous situations occur during operation of the machine, and inform crane operator and signalman of the unsafe factors such as high-voltage power line, unauthorized persons and equipment, obstacles and poor ground conditions.

3.2.5 Points for attention during crane operation

CAUTION Observe the max. lifting capacity of the crane and working radius specified in lifting capacity charts.

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DANGER (1) The crane is not allowed to work at working radius which is not specified in load capacity charts. This case is also applicable to the condition that the load is not attached to the load hook. If not, there is a risk of accident. (2) Check that the number of wire rope reeving specified in load capacity charts matches with the maximum lifting capacity of the crane. If not, the wire rope may be broken and the accident may occur. (3) Slowly activating and stopping all crane movements can prevent load from swinging. If the wire rope on the winding drum is unwound to the last layer, an operator must check the drum to see if there are three windings of wire rope left on the drum. If less than three windings of wire rope remains on the drum, serious accident may occur. (4) Do use appropriate load hook whose lifting capacity matches the actual load to be

Safety Guidelines

lifted.

3.2.6 Safety signs There are safety signs affixed on the important components before the crane delivery. The safety signs affixed around the operator’s cab are shown in figure 3-1-figure3-11:

Figure 3-1

ZCC800HWG.1 CRAWLER CRANE

Emergency exit

Figure 3-2

Free-fall operation

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Operator’s Manual for Crawler Crane

Figure 3-3

Operation of slewing fixing pin

Safety Guidelines Figure 3-5

Figure 3-7

Unauthorized access prohibited

Figure 3-9

3-6

Read the manual

Free-fall operation

Figure 3-4

Points for attention before operation

Figure 3-6

Prohibit obliquely pulling the load

Figure 3-8

Figure 3-10

Safety sign

Drain port of air conditioning

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Figure 3-11

Pedals in operator’s cab

The safety signs affixed around the slewing table are shown in figure 3-12 – figure3-32:

Safety Guidelines

Figure 3-12

ZCC800HWG.1 CRAWLER CRANE

Hand signal for controlling crane operation

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Operator’s Manual for Crawler Crane

Figure 3-13

Safety Guidelines

Figure 3-15

3-8

Crush hazard

Access prohibited

Figure 3-17

Danger sign

Figure 3-19

Safety sign

Figure 3-14

Risk of falling

Figure 3-16

Warning overhead obstacles

Figure 3-18

Position of fire extinguisher

Figure 3-20

Safety sign

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Figure 3-21

Hydraulic oil tank

Figure 3-25

Figure 3-27

Danger sign

Battery master switch

ZCC800HWG.1 CRAWLER CRANE

Figure 3-22

Drain port

Safety Guidelines

Figure 3-23

Safety sign

Figure 3-24 Hydraulic oil level

Figure 3-26

Figure 3-28

Diesel oil tank

Operation of slewing fixing pin

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Operator’s Manual for Crawler Crane

Figure 3-29

Safety Guidelines

Figure 3-31

Risk of burn

Risk of falling

Figure 3-30

Figure 3-32

Safety sign

Naked flames prohibited

The safety signs affixed around the undercarriage are shown in figure 3-33 – figure 3-39:

Figure 3-33

Dragging / entanglement

Figure 3-35

Risk of falling

Figure 3-34

Figure 3-36

Lifting point

Unauthorized access prohibited

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Figure 3-37

Warning: Crushing / collisions

Keep away from moving parts

Safety Guidelines

Figure 3-39

Figure 3-38

Traveling direction

The safety signs affixed around the boom system are shown in figure 3-40- figure 3-42.

Figure 3-40

Danger: snagging /dragging

Figure 3-42

ZCC800HWG.1 CRAWLER CRANE

Figure 3-41

Safety sign

Lifting point

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Operator’s Manual for Crawler Crane

CAUTION (1) When the safety sign is damaged or illegible, please order it from appointed service supplier. (2) It is forbidden to cover or take off safety signs casually. (3) If the safety sign is covered with dust, clean it in time. (4) The operator’s cab should be equipped with an emergency hammer which can be used to smash the window in an emergency so that the operator can run away from the cab.

Safety Guidelines 3-12

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3.3 Slings 3.3.1 Slings introduction The predominant characteristics of a sling are determined by the components of that sling. For example, the strengths and the weaknesses of a wire rope are essentially the same as the strengths and the weaknesses of the wire rope from which it is made. Slings are generally one of the following six types: a)

Chain

b)

Wire rope

c)

Metal mesh

d)

Natural fiber rope

e)

Synthetic fiber rope

f)

Synthetic web

having its own particular advantages and disadvantages: a)

Chain

b)

Wire and mesh rope

c)

Fiber rope and fiber web rope

Factors that must be taken into consideration when choosing the best sling for the job include: a)

Size

b)

Weight

c)

Shape

d)

Temperature

e)

Sensitivity of the material to be moved

f)

Environmental conditions that the sling will be used

3.3.2 Sling identification tags All slings should be labeled with identification tags. The Information required to be on the identification tags is as follows: a)

Manufacturer’s name or trademark

b)

Diameter or size of the sling

c)

Material of the sling

d)

Rated load for the types of hitches used

e)

Lift angle the load rating is based

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Safety Guidelines

Usage and inspection procedures tend to place these slings into three groups with each type

Operator’s Manual for Crawler Crane

3.3.3 Angle of choke The angle used on the choke hitch will affect the sling capacity. Refer to figure 3-43 and table 3-1. Table 3-1

Angle of choke and lifting capacity

Angle of choke 90°- 120° 60°- 90° 30°- 60° 0°- 30°

Sling rated capacity (%) 87% 74% 62% 49%

Safety Guidelines Figure 3-43

Angle of choke

3.3.4 D/d ratio Depending on the hitch used, wire rope capacity will experience an efficiency loss when bent. To determine the D/d ratio, distinguish the diameter of the wire rope and the diameter of the load (see the following figure 3-44). A good rule to follow is to keep at least a 6:1 ratio which results in an 80% efficiency of the sling. A 1:1 ratio results in only a 50% efficiency of the sling and cannot be used.

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Table 3-2

D/d ratio

D/d ratio

Efficiency (%)

40

95

30

93

20

92

15

89

10

86

8

83

4

75

2

65

1

50

Safety Guidelines

Figure 3-44

D/d ratio

3.3.5 Load angle factor Increasing the number of sling legs on a load helps ensure better control of the load and helps distribute the weight of the load among more slings legs. Slings are at their greatest strength on a straight pull (refer to figure 3-45). By having the slings pull at an angle, added stress is placed on the sling. The capacity of a multiple leg sling is directly affected by the angle of the sling leg with the vertical. As the angle formed by the sling leg and the horizontal line decreases, the rated capacity of the sling also decreases (see the following figure 3-45).

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The smaller the angle between the sling leg and the horizontal is, the greater the stress on the sling leg and the smaller or lighter the load will be, which the sling can safely support. The smaller the angle is, the greater bending forces are imposed on the load will be. The capacity can be readily determined by multiplying the sling’s vertical capacity by the appropriate load angle factor.

Length (L)

Height (H)

Safety Guidelines Figure 3-45

Force on the sling

3.3.6 Load share For symmetrical loads with 2 legs: To calculate the load for each sling leg, use the following formula:

3-16

a)

Length(L) ÷Height(H) = Load angle factor

b)

Multiple the load angle factor by the load weight.

c)

Divide the answer by the number of legs.

d)

This equals the load share of each sling leg.

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3.3.7 Load angle factor chart When the load angle factor (LAF) has been determined, refer to the table 3-3 listing the corresponding sling angles measured in degrees. All safety standards recommend safe lifting angles to be 60°or more, and do not recommend angles lower than 45°. Table 3-3

Load angle factor

Sling angle

Load angle factor

90°

1.000

85°

1.004

80°

1.015

40°

1.555

75°

1.035

35°

1.742

70°

1.064

30°

2.000

65°

1.104

25°

2.364

60°

1.155

20°

2.924

55°

1.221

15°

3.861

50°

1.305

10°

5.750

45°

1.414

5°

11.49

The following angles are not recommended when lifting.

Safety Guidelines

3.3.8 Sling safety a)

Before making a lift, check to be certain that the sling is properly secured around the load and that the weight and balance of the load have been accurately determined. If the load is on the ground, do not allow the load to drag along the ground. This could damage the sling.

b)

Position the hook directly over the load and seat the sling squarely within the hook bowl. This gives the operator maximum lifting efficiency without stressing the sling.

c)

Make sure that the load is not lagged, clamped, or bolted to the floor.

d)

Guard against shock on the load by pulling the slack sling straight slowly.

e)

Apply power cautiously so as to prevent jerking at the beginning of the lift, and accelerate or decelerate slowly.

f)

Check the tension on the sling. Raise the load a few inches, stop, and check for proper balance and that all items are clear of the path of travel. Never allow anyone to ride on the hook or load.

g)

Keep all personnel informed while the load is being raised, moved, or lowered. The crane operator and rigger should watch the load at all times when it is in motion.

CAUTION Never allow anyone to ride on the hook or load.

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3.3.9 Sling safety guide a)

Sling must not be shortened with knots, or other makeshift devices.

b)

Sling legs cannot be kinked.

c)

Slings cannot be loaded in excess of their rated capacities.

d)

Slings used in a basket hitch can have the loads balanced to prevent slippage.

e)

Slings must be securely attached to their loads.

f)

Slings must be padded or protected from the sharp edges of their loads.

g)

Suspended loads must be kept clear of all obstructions.

h)

All employees must be kept clear of loads that is about to be lifted and of suspended loads.

i)

Hands or fingers cannot be placed between the sling and its load while the sling is being tightened around the load.

Safety Guidelines

j)

Do not impact on the load.

k)

A sling cannot be pulled under a load when the load is resting on the ground.

3.3.10 Taglines The safest method for a rigger to control a load suspended from a hook is with a tagline. (See the following figure) a)

Taglines are used to control load spin.

b)

Keep the tagline away from the center of gravity.

c)

Never wrap the tagline around your body or any limbs.

d)

The rigger shall stand at the back of the load and never stand directly underneath a load.

Figure 3-46

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Tagline

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3.3.11 Load center of gravity a)

The center of gravity of an object is the point at which the weight of the object acts as though it were concentrated. It is the point at which the object may be completely supported or balanced by a single force.

b)

The center of gravity of a regularly shaped object may be estimated fairly accurately by determining its approximate center.

c)

Finding the center of gravity of irregularly-shaped objects can be more difficult, but it is necessary. A load will always hang from its attachment point through the center of gravity. It is important to visualize this before making a lift.

d)

All loads to be lifted must be rigged above the center of gravity in order to prevent tipping and possible hazards to equipment and workers. The lifting force must always be located above the center of gravity and exert a straight vertical pull to prevent swinging of the load.

e)

In all crane lifts, the center of gravity must remain below the hook and below the point of

f)

A center of gravity above the hook is unstable and will cause the load to flip as the load will attempt to ‘find’ the center of gravity. Similarly, loads which are not balanced horizontally can slip from the rigging.

g)

The overall stability of the load is a combination of balance with respect to center of gravity, distribution of weight, and proper rigging practices.

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Safety Guidelines

attachment for any rigging.

Operator’s Manual for Crawler Crane

3.4 Requirements for operating site 3.4.1 Selecting an operating site It is very important to choose an appropriate location for crane operation in order to minimize safety risks. The operating site should be selected so that: a)

Crane movement can be carried out within the smallest possible radius.

b)

No obstacles hinder necessary movements in the working radius.

c)

The ground on the operating site is able to support expected loads.

DANGER The most essential requirement for safe crane operation is working on firm ground with the capacity to support your loads.

Safety Guidelines

3.4.2 Slopes and trenches The crane may not be set up too close to slopes or trenches. A safety distance must always be kept from them depending on the type of soil.

CAUTION Safety distance (refer to figure 3-47) is measured from the foot of the trench and it is: Soft or backfilled soil = 2× depth of trench (A2 = 2×T) Hard or grown soil = 1×depth of trench (Al = 1×T)

Figure 3-47

Slopes and trenches

DANGER If a safe distance is not maintained, the slope or trench must be firmly filled. Otherwise, there is a danger that the edge of the slope or trench will collapse.

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3.4.3 Permissible ground pressure Refer to table 3-4 for permissible ground pressure. Table 3-4

Permissible ground pressure Ground pressure

Soil type

[δ] MPa

A) Back-filled, not naturally compacted ground 1. Mud, peat, marshy land 2. Non-cohesive, sufficiently compactly layered soil

Fine to medium grained sand; From coarse-grained sand to gravel Loamy

apparently

3. Cohesive soil

undisturbed

0 0.15

0.2 0

Soft

0.04

Stiff

0.1

Semi-solid

0.2

Hard

0.4

Safety Guidelines

B) Natural soil,

0-0.1

In healthy, weatherproof condition and in a favorable 4. Rock with few

location

fissures

In cohesive layer order In massive or column-style shape

C) Artificially

1. Asphalt

compacted ground

1.0

1.5 3.0 0.5-1.5

Concrete group B I

5-25

Concrete group B II

35-55

2. Concrete

CAUTION If there is any doubt about the load-bearing capacity of the ground at the operating site, soil test should be carried out.

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3.4.4 Checking safety measures The safety condition of the crane should be checked thoroughly prior to operating the crane, including: a)

Check whether the ground provides adequate load-bearing capacity.

b)

Check whether there is sufficient safety clearance to slopes and trenches.

c)

Check whether the crane is adjusted to be horizontal.

d)

Check whether there are live electrical wires within the working range of the crane.

e)

Check whether there are obstacles which will hinder required crane operation.

CAUTION The crane operation belongs to dangerous operation; so much attention should be given to the working condition of the crane before and during crane operation.

Safety Guidelines

3.5 Working weather a)

At the job site, the ambient temperature should vary between -20℃ and 40℃, and the relative humidity should not be greater than 85%.

b)

The permitted wind velocity for the crane operation is at most 9.8m/s.

c)

The crane is fitted with main boom only, and the out-of-service wind velocity should not exceed 21m/s. The crane is fitted with main boom as well as jib, and the out-of service wind velocity should not exceed 15m/s. Under the above conditions, the entire boom must be placed on the ground.

WARNING (1) It is prohibited to work when ambient temperature is out of the normal range. (2) It is prohibited to work when out-of-service wind velocity is exceeded. (3) When the wind velocity reaches out-of service wind velocity range, stop working and place the boom on the ground.

3.6 Electromagnetic influences Strong electromagnetic fields are likely to be present if the construction site is close to a transmitter. In any case, before working with the crane near transmitters, contact Zoomlion representative. In addition, consult a high frequency specialist. a)

Every crane must be “totally” grounded. Check visually or with a simple tester to ensure that the ladder, cab and cable pulleys are grounded.

b)

All personnel working on the crane or with large metal objects must protect themselves from burns by wearing non-conductive gloves and clothing while working.

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c)

If one feels a little increase in temperature, there is no need to panic. This is because the respective workpiece, structural steel member or undercarriage becomes “hot”.

d)

The temperature of objects affected by high frequency radiation depends on their ‘size”. For example, cranes, undercarriage and coverings are “hotter”.

e)

Contact with other crane loads is not permitted when moving the crane. Since defects caused by burns may considerably reduce rope carrying capacity, any such occurrences must be reported immediately to the machinery supervisor so that the ropes can be inspected.

f)

An insulator is required at all times between the crane load hook and tackle. It is strictly prohibited to remove this insulator.

g)

The ropes are strictly prohibited from touching the above insulator.

h)

Crane with attached loads may not be touched by any unprotected parts of the body after the load has been lifted or put down. Do not work with a bare upper torso or in short pants.

j)

To minimize absorption of high frequency radiation, loads should be transported horizontally if possible.

k)

Loads must be grounded, or additional insulation used (rubber material between the tools used and gloves) when manual work is required.

l)

To avoid accidents, use a safety belt when working on components that are high off the ground.

m) Dealing with explosive matter (such as refueling) may only be carried out at least 6 m away from the place where sparks could form due to handling of large metal parts. Use only rubber hoses to refuel. n)

Any accidents and unexpected events must be reported immediately to the local project manager or the safety engineer.

CAUTION These electromagnetic fields can pose direct or indirect danger to persons or objects, for example: (1) Effect on human organs due to temperature increase. (2) Danger of burns or inflammation due to temperature increase. (3) Spark or electric arc formation.

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Safety Guidelines

i)

Operator’s Manual for Crawler Crane

3.7 Underground cables With special equipment, the crane can also be used for underground working. With underground working, it is possible to damage:

a)

Underground electric cables

b)

Gas pipes

c)

Telephone, TV, and data transmission cables

d)

Sewage pipes, district heating supply pipes, etc.

WARNING If a live underground cable is damaged, lives are at risk from electric shock. There is an extreme danger of explosion and fire in the vicinity of a damaged gas pipe.

3.7.1 Measures to be taken during operational planning Safety Guidelines

The construction company doing the work is responsible for gathering accurate information about possible underground cables within the working area of the equipment so that work can be done safely: Obtain the relevant information from the relevant utility companies. a)

Examine the "as completed" plans of: 1)

Utility companies (electricity, gas or water companies)

2)

Cable users (telephone companies, factories, transport companies)

3)

Building authorities.

b)

Only use the latest, up-to-date plans.

c)

If there are any changes or extensions to a project, initiate new inquiries.

d)

If in doubt, localize the underground cables around the site using a locating device via search slots or test digs.

e)

f)

The relevant utility companies, cable users and public authorities: 1)

Must be informed in good time about the start of the work.

2)

Must be asked for written approval for the civil engineering work to be done.

When several construction companies are involved, their activities must be coordinated. All companies must have the same up-to-date information on underground pipes, etc. on the construction site.

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3.7.2 Safety precautions and protective measures when operating the equipment near underground cables a)

Do not start work until you have obtained all the approvals from the utility companies and the cable users.

b)

The equipment operator must obtain all relevant information about the exact location of all underground cables before starting work. These plans must be readily accessible at the construction site.

c)

Operate the equipment with particular care near underground cables, all applicable national safety guidelines as well as the special guidelines and safety measures of the utility companies must be noted and obeyed.

d)

In the event of any unexpected encounters with underground cables or associated warning tapes and protective coverings, cease working with the equipment immediately and inform the appropriate superiors. It is prohibited to unearth underground cables with the machine. The underground cables may only be uncovered manually, using blunt tools.

f)

Secure, support, or prop up all exposed underground cables so that they cannot sway, slide, or become deformed.

g)

Stabilize the cable ducts and trenches and secure the edges to prevent caving in.

3.7.3 What is to be noted in connection with gas pipes? a)

Whenever the position of the gas pipe casing changes or the casing is damaged, report this to the appropriate gas company. The gas pipe can only be backfilled after inspection, repair, and approval by specialist personnel from the gas company.

b)

All devices of the gas supply network around the site must remain accessible (fittings, valve boxes, manhole covers, etc.). Existing markings and information signs must not be covered, rearranged or removed.

3.7.4 What happens if a gas pipe is damaged? The escaping gas: a)

Forms an inflammable gas-air mixture around the affected area.

b)

Can strike personnel or equipment if escaping from gas supply pipes under high pressure.

c)

Not only endangers personnel and equipment on the site, but also passers-by and residents in the neighboring houses.

A gas fire can develop in seconds and spread explosively. In a conventional supply pipe with a leak of 50 mm (2"), for example, the flames can be up to 10 m (33 ft) high if the gas is escaping at a pressure of 1 bar (14.5 psi). The machine and surrounding construction machinery will quickly be burnt out.

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Safety Guidelines

e)

Operator’s Manual for Crawler Crane

Even a minor change in position of the gas pipe can result in damage to other sensitive points of the gas network, for example connection points or house feeder pipes. Leaks and small leaks that are not immediately detectable are very dangerous if gas is allowed to escape over a lengthy period of time and penetrate along the gas pipe network into the surrounding buildings. An explosive gas-air mixture is formed considerably quicker in enclosed areas than in the open air. Every source of ignition, such as On /Off switches on electrical equipment or the turning on of a light, can trigger an explosion. Corrosion can cause leaks to form within 5 -10 years of minor damage to the casings of metal gas pipes.

3.7.5 What must the crane operator do if a gas pipe is damaged and gas escapes, or a leak is suspected?

Safety Guidelines

a)

Stop work immediately.

b)

Leave the crane after shutting down the engine and all additional fuel powered units.

c)

Alert all site personnel: avoid producing any sparks and maintain a strict no-smoking policy.

d)

Shut down all construction machinery and vehicle engines in the immediate vicinity.

e)

Clear the danger area and secure a wide area with barriers or cordons. Do not allow access by unauthorized personnel.

f)

g)

Inform the relevant gas company of the following: -

The extent of the damage

-

The exact location of the site

-

The exact circumstances of the accident

-

How long ago the accident occurred

-

A name and telephone number for a return call.

If there is the slightest suspicion that the gas is leaking into a building, alert the local occupants by knocking or calling. Do not ring the door bell or call them by telephone, as this may trigger an explosion.

h)

If gas can already smelt in the building, especially around the area where the gas pipe is known to enter the house; do not operate any electrical systems or equipment. Open all doors and windows widely for ventilation purposes and leave the building immediately.

i)

In the event of major damage, evacuate the occupiers of all the surrounding buildings with the cooperation of the police or fire brigade.

j)

k)

Building site personnel: -

Must assist all specialist personnel from the gas company during the repair work.

-

May therefore only leave the building site with the consent of the specialist personnel.

Work on the building site can only begin again if authorization has been given by the relevant gas company.

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

CAUTION Extinguishing a gas fire requires specialist knowledge. A gas fire that has already been extinguished can flare up again if more gas escape and break out in an unexpected spot. Precautions:

(1) Alert the local fire brigade to fight the fire. (2) Do not attempt to put out the fire before the fire brigade arrives unless lives are in danger or there is risk of major damage to property.

(3) If the gas fire is not causing any immediate danger, it is sometimes better, in certain circumstances, to let the gas burn. As soon as the gas company shuts off the gas pipe, the fire will extinguish itself.

Safety Guidelines

ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

3.8 Checking safety measures Before beginning any work, the crane operator must be convinced that the crane is in safe operating condition. All safety devices, such as load moment limiter, hoist limiter switches, brakes, limit switches, and boom angle indicator etc., are in good working order. a)

The load moment limiter must be set according to the current crane configuration.

b)

The lifting height of crane as given in the load capacity charts must be adhered to. The load given in the load capacity charts must not be exceeded.

c)

The crane operator must know the weight and dimensions of the load before operating the crane.

d)

Load handling devices, lifting equipment and hook block must be used in accordance with specified requirements.

e)

Make sure that the weight of load handling devices, lifting equipment and hook block are subtracted from the load given in the load capacity charts.

Safety Guidelines

Example: Table 3-5

Weight table Unit: ton(t)

Maximum permissible load according to the chart

27

Weight of the hook block

0.38

Weight of the slinging rope

0.04

Actual useful load of the crane

26.58

CAUTION In this case, the load to be lifted can not exceed 26.58t.

3.8.1 Counterweight The required counterweight must be installed prior to lifting operation and after the crawler carriers are extended to specific positions.

DANGER If the counterweight is not installed properly according to the lifting capacity table, the crane may topple over.

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

3.8.2 Hoisting winch and hoisting rope The lifting capacity of the crane is a function of the tension and pulling force of the hoisting rope and hoisting rope reeving. When working with a single cable, the crane can only lift as much of a load as the hoisting winch is able to pull. If the load to be lifted is heavier than the hoisting winch is capable of lifting, the hoisting rope must be reeved between the pulley on the boom head and the. The reevings is determined by the principle of hook block.

(As to detailed hoisting rope reeving, refer to Section 2.4.3 in

Chapter 2.) When reeving, ensure that the data given in the lifting capacity chart and operator’s manual are observed and adhered to. (For details, see Section 4.6 in Chapter 4.)

DANGER If the maximum tensile force is exceeded, the wire rope may snap or the winch motor

ZCC800HWG.1 CRAWLER CRANE

Safety Guidelines

may be damaged.

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Operator’s Manual for Crawler Crane

3.9 Crane operation with a load 3.9.1 Operating conditions a)

All components of the crane are in running-in state at the initial operating period. So, for the first 100 operating hours, the working load should not be too great and the working speed should not be too high. The maximum lifting load can not exceed 80% of its rated load. And the maximum working speed is forbidden.

b)

The ground on jobsite should be firm and flat and the gradient should not be greater than 1/100. The complete vehicle should be level and the supporting ground should not collapse during operating. If the ground is soft, a steel plate should be placed under the track pad. Refer to figure 3-48.

Safety Guidelines Figure c)

3-48

The permitted temperature range for crane’s operation is -20℃ – 40℃. Humidity should not exceed 85%; however, high humidity up to 100% is only permitted for a short period of time. The crane should be operated and supported on a ground lower than 1000m above seal level. Please consult the technician if there are special requirements for working temperature and altitude.

d)

The maximum in-service wind velocity should be not more than 9.8m/s during operation; the maximum out-of-service wind velocity should be no more than 21m/s when only main boom is assembled, and no more than 15m/s when fixed jib is assembled. Refer to figure 3-49.

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Figure

3-49

DANGER Before beginning any work, the crane operator must receive information on the expected wind velocity from the responsible meteorological authorities (refer to table

Safety Guidelines

3-6). If impermissible wind velocity is forecasted, lifting a load is prohibited. Table 3-6 Wind force Beaufort Description 0

Calm

1

Light air

2 3 4 5 6 7 8 9 10

Light breeze Gentle breeze Moderate breeze Fresh breeze Strong breeze Stiff wind Gale force wind Gale Severe gale

ZCC800HWG.1 CRAWLER CRANE

Wind force beaufort Effects of the wind in the inland

Wind speed (m/s) 0-0.2 0.4-1.4 1.6-3 3.4-5.3 5.5-7.8 8-10.6 10.8-13.7 13.9-17 17.2-20.6 20.8-24.5 24.7-28.3

Visible effects No wind, smoke rises straight up Wind direction is shown only by observing the trail of smoke, not by the wind sock Wind can be felt on the face, the leaves rustle, wind sock moves slightly Leaves and thin twigs move. Wind extends a small breeze flag. Swirls up dust and loose paper, moves twigs and thin branches Small deciduous trees begin to sway, foam forms at sea. Thicker branches move; telephone lines begin to whistle, umbrellas are difficult to use Entire trees swaying; difficult to walk into wind Breaks twigs off trees, walking becomes difficult Minor damage to property(chimney tops and roofing tile are blown off) Trees are uprooted, significant damage to property

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Operator’s Manual for Crawler Crane

e)

When the crane is working near the high-voltage power line, the safe clearance between any part of crane and overhead power line should comply with table 3-7. Refer to figure 3-50.

Figure

Safety Guidelines

Table 3-7

3-50

The safe clearance from high-voltage power lines

Output voltage of high-voltage

V≤1

1< V ≤15

15
40
100
1.5

3

4

5

6

power line (V, kV) Safe clearance (m)

CAUTION If, despite all precautions having been taken, a flashover occurs, carry out the following procedures: -

Keep calm!

-

Do not leave the crane cab.

-

Warn those people around the crane not to move and touch the crane.

-

Move the crane away from the danger area.

DANGER Not observing above points can lead to (fatal) accidents and damage! f)

3-32

Only the crane without fault is allowed to work.

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

3.9.2 Instructions for safe operation a)

No person is allowed to stand under boom when the crane is operated. Refer to figure 3-51.

3-51

b)

No person is allowed to stand on the slewing table during operation.

c)

It is forbidden to lift load over the people. Refer to figure 3-52.

Figure

ZCC800HWG.1 CRAWLER CRANE

Safety Guidelines

Figure

3-52

3-33

Operator’s Manual for Crawler Crane

d)

It is forbidden to lift the load when someone stands on it. Refer to figure 3-53.

Safety Guidelines

Figure e)

3-53

Overloading operation and lifting staggered load is prohibited. Never pull load obliquely. Refer to figure 3-54.

Figure

3-34

3-54

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

f)

It is forbidden to lift the load hidden in the ground or frozen on the ground. Otherwise, the crane may topple over, and the boom may be broken. Make sure the load to be lifted does not connect with other objects. Refer to figure 3-55.

Safety Guidelines

Figure 3-55 g)

The crane can travel with a load of 70% of the rated load. In this case, the ground should be firm and its gradient should not be more than 5/1000. The driving speed must be less than 0.5km/h. The boom frame must be located in the driving direction. The distance between the load and the ground should not be more than 50cm. The longer the boom, the slower the travelling speed. Lower the distance between the load and the ground as possible as you can. Refer to figure 3-56.

Figure 3-56

ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

h)

If the crane is operated in the vicinity of transmission systems (e.g. transmitters), strong electromagnetic field will be generated there, so measures should be taken to protect the crane against high frequency interference and all workers who stand on large metal plate should wear special isolating gloves and clothes to avoid being burnt.

i)

The brake of hoist mechanism is not allowed to be adjusted when the crane is lifting a load.

j)

Under any condition, there must be at least three windings of wire rope left on the hoisting drum.

k)

When a load is suspended in the air, the operator is not allowed to leave the cab. Refer to figure 3-57.

Safety Guidelines Figure 3-57 l)

Operation should be carried out stably and gently. Never operate control lever jerkily and carry out switchover operation abruptly.

m) When actual load reaches 90% of the rated one, the load moment limiter will sound an alarm, to which high attention should be given. n)

Getting on and off the crane should be careful to avoid casualty.

o)

It is prohibited to make any modifications to the crane without permission; otherwise you should take the consequences. It is prohibited for unauthorized person to repair and change the components.

p)

Stop the crane operation if one of the following conditions occurs: 1) The crane is overloaded or the weight of load is uncertain; 2) The load falls down due to bad binding or hanging; 3) No protective mat is added between the edges of load and wire rope; 4) In case of poor visibility and /or darkness, it is difficult to identify load or signal;

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5) There is defect or damage of configuration or components which will impair safe operation, for example, the brake and safety equipment fail, or the wire rope is damaged etc. q)

Anyone is not permitted to ride on the load hook, slings or load.

r)

Leave an ample space for stopping the crane; otherwise persons nearby may be hurt by crane counterweight due to narrow distance between counterweight and surrounding building.

s)

Keep the windows of crane operator’s cab clean to ensure good visibility; stop crane operation immediately in case of poor visibility; replace the broken window as soon as possible.

t)

Drive crane with great caution, in working site or not. Observe conditions surrounding the crane such as overhead power line, low-lying land, narrow clearance, restriction to bridge and road, uneven ground and gradient of road. If necessary, appoint a signalman to assist an operator to move the crane. Lock slewing mechanism during traveling. It is more dangerous that two cranes carry out lifting operations together. Therefore, a careful calculation must be made before commencing the work, and the following important requirements for this type of operation must be observed. 1) The load is not casually attached to the crane. It must be calculated carefully so that the actual lifting capacity of the crane can not exceed the rated lifting capacity. 2) Ensure that each lifting tackle can bear specified load weight which is calculated during design. 3) The crane operator, signalman and other worker must evaluate the operational planning together before operation. 4) Ensure that the crane can move properly in the whole process of operation.

v)

It’s very dangerous if you leave the crane without doing the following. Therefore, you must take the following measures prior to leaving the machine. 1)

Detach the load from the hook and set it down on the ground; if necessary, lower the boom frame.

w)

2)

Apply slewing brake or lock slewing mechanism.

3)

Apply parking brake.

4)

Lock traveling mechanism.

5)

Cut off power supply or switch off engine.

Do not wear loose clothing, scarves, open jackets or open shirt sleeves, and do not wear jewellery (rings, bracelets, earrings or similar). Otherwise, there is serious danger of injury from being pulled into moving machine parts.

x)

Do not stop crane near the bank which is possible to collapse or on low-lying land that may be washed away by water.

y)

Take away the key when machine remains idle. In this way, the unauthorized person can not start the machine without permission.

z)

Unqualified person is forbidden to repair the crane and change parts.

ZCC800HWG.1 CRAWLER CRANE

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Safety Guidelines

u)

Operator’s Manual for Crawler Crane

3.9.3 Preparation for crane operation Crane operator should perform the following checks before operating the crane: a)

Check the daily record of work to ensure that all regular inspections, maintenance and repair work are performed.

b)

Check the boom frame limiter, boom angle indicator, tilting-back support and other safety equipment for functional work.

c)

Check if the load-bearing parts such as wire rope (hoisting rope, derricking rope and sling etc.), boom, outriggers, hook and load handling devices are kept in good working order.

d)

Check if there are some bolts, nuts and pins lost, and the components are cracked or damaged.

e)

Ensure that no modification has been made to the crane without permission, e.g., increase or decrease in counterweight plate and improper repair of boom frame.

Safety Guidelines

f)

After starting up the engine, check if the values shown on instruments are normal.

g)

Check fuel lines and hydraulic oil lines for leakage.

h)

Check all control mechanisms for functional work.

i)

Check brakes and clutch. Test the braking performance by lifting a load away from the ground and suspend it in the air for a moment.

j)

Keep communication between the operator and rigger.

k)

Estimate the weight and dimensions of load to be lifted in advance.

l)

Crane operation can be carried out within minimum working radius. No obstacles hinder the necessary movements. The ground at the operating site is able to support expected loads.

m) Ensure that no obstacles are within working radius and the operator can see the load clearly from the cab. Check if the communication between operator and signalman is kept smooth so as to ensure safe crane operation. n)

Determine the load-bearing capacity of the ground to be operated upon. Ensure that the crane is supported properly and never operate the crane on the soft and uneven surface or on the ground of high water content or covered with frozen soil. If the crane is set up close to trenches, reinforce the trenches to avoid landslide. If the ground does not have adequate load-bearing capacity, the crane is liable to turn over. In this case, crosstie, steel plates should be padded underneath the crawler to distribute load so that the load-bearing capacity of the ground will not be exceeded; make sure that the crane is leveled.

3.9.4 Notes for crane operation a)

Estimate the weight and dimensions of load to be lifted in advance.

b)

Use load handling devices (wire rope or chain) correctly. Make the vertical line of hook pass through the center of gravity of the load.

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c)

If any part of the crawler crane or load handling devices comes in contact with high-voltage line, or an emergency occurs, the operator should stop the vehicle at once.

d)

The load capacities as given in the load lifting capacity chart must be adhered to. The loads given in the load lifting capacity chart must not be exceeded. Driving (or slewing) too fast with a load, setting up and loading on an uneven surface, and swinging of suspended load should be avoided.

e)

Diagonal pulling of the load to be lifted which is still in contact with the ground is prohibited.

f)

It should be avoided that the load or auxiliary lifting device collides with structural members of the crawler crane.

g)

If the crane gets caught in a thunderstorm during operation, the following measures should be taken at once: Stop work on the crane immediately.

2)

Always set down the load and boom frame on the ground.

3)

Apply brake or lock winch and slewing gear.

4)

Switch off the crane engine and cut off the power of load moment limiter and limit switch.

5) h)

i)

Ask all crane workers to leave.

If the crane is struck by thunderbolt, the following checks should be performed: 1)

Check whether there are burnt or damaged components.

2)

Check the performance of electrical parts and load moment limiter.

3)

Check the associated components for functional work.

If earthquake occurs when the crane is operated, the following measures should be taken immediately: 1)

Stop work on the crane immediately.

2)

Always set down the load and boom frame on the ground.

3)

Apply brake or lock winch and slewing gear.

4)

Switch off the crane engine and cut off the power of load moment limiter and limit switch.

5)

Ask all crane workers to leave.

After earthquake, the following checks should be performed prior to crane operation:

j)

1)

Check the performance of electrical parts and load moment limiter.

2)

Check the associated components for functional work.

If any part of the crawler crane or load handling device is in contact with high-voltage lines, the best way to guarantee the personal safety of the operator is to stay in the operator’s cab until the danger is obviated. If the operator must leave the crane, he’d better jump rather than climb down the cab.

k)

The operator’s cab should be equipped with an emergency hammer which can be used to smash the window in an emergency so that the operator can run away from the cab.

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Safety Guidelines

1)

Operator’s Manual for Crawler Crane

l)

The load moment limiter, once be triggered, should be kept in that state until the crane is not overloaded.

m) If the load moment limiter is not set to the actual configuration status of the crane, it can not fulfill its function as a safety device. n)

Examine if the angle indicators and the strain sensor are in function.

o)

The crane may topple over backwards if a load is suddenly freed since the tension created in the boom can cause it to jerk back violently.

p)

Make sure that the loads and working radius contained in the lifting capacity chart are not exceeded.

q)

When working in the vicinity of power cables, a sufficient safety clearance must be maintained, if the cables are not isolated by electricity engineers or the hazardous area is not fenced off.

r)

For all crane movements, the crane operator must always keep the load, as well as the crane hook or loading equipment when the crane is not loaded, in his field of vision. If this

Safety Guidelines

is not possible, the crane operator may only operate the crane according to instructions given to him by a signalman. These instructions may be given in the form of hand signals or over a wireless radio. Whatever method is used, precautions must be taken to eliminate the risk of misunderstanding.

3.9.5 Checks after operation a)

When crawler crane and auxiliary lifting device are in non-working condition, never park the vehicle near the embankment liable to collapse or low-lying land subject to be washed away by water.

b)

Set down the load on the ground, and if necessary low the boom frame to some extend; lock the slewing gear and traveling gear and apply the brake.

c)

Shut down the engine and cut off power.

d)

Check if there is leakage in someplace and repair it if necessary.

e)

Clean such components as movable parts and exposed part of the piston rod of cylinder.

f)

Check if bolts and nuts are fitted tightly. Any defects found should be eliminated at once. It is prohibited to operate the crane with fault.

g)

Record the operating conditions and abnormal symptoms.

h)

Check if the quantity of tools and accessories meet specified requirements.

i)

Lock the operator’s cab or safety devices.

j)

Take precaution measures against storm or lightning strikes.

k)

Take precaution measures against frostbite in winter.

CAUTION To avoid engine from freezing in winter, drain all cooling water when parking the vehicle, if no anti-freeze is added into the cooling water.

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3.10 Hand signals for controlling crane operations Refer to table 3-8 for hand signals for controlling crane operations. Table 3-8 Hand signals for controlling crane operations Ser. No.

1

Signal Description

2

Preparation

Use main hoist

Arm stretched out over the head, palm

Tap fist on the safety helmet; then use

of the hand facing forwards.

regular signals.

Safety Guidelines

Illustration

Ser. No.

3 Use auxiliary hoist

Hoist

Bend one hand and hold it upward, tap

With forearm vertical, palm of the hand

the elbow with the other hand; then use

facing forwards, move hand in small

regular signals.

horizontal circle.

Signal Description

4

Illustration

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Operator’s Manual for Crawler Crane

Ser. No.

5

6

Signal

Lower

Raise load slowly

With arm extended downwards with a Description

With forearm vertical, palm of the hand

30°angle to the body，palm of the hand

facing upwards, wave hand up

facing inwards, move hand in small

repeatedly.

horizontal circle.

Illustration

Safety Guidelines Ser. No.

7

Signal

Rotate Turn left: With right forearm vertical, the palm of the hand facing outwards, lower

Description

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

Illustration

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Ser. No.

8

9

Signal

Lower load slowly

Indicate load lowering position

With arm extended downwards with a Description

30°angle to the body，palm of the hand

Extend the fingers to point at the

facing downwards, wave hand down

position the load should fall on.

repeatedly.

Illustration

Safety Guidelines

Ser. No.

10

Signal

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

Description

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

Illustration

ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

Ser. No.

11

Signal

Description

12

Raise boom

Lower boom

With arm stretched sideways

With arm stretched sideways

horizontally, thumb pointing upwards,

horizontally, thumb pointing

the remaining fingers closed, wave

downwards, the remaining fingers

forearm up.

closed, wave forearm down.

Illustration

Safety Guidelines Ser. No.

13

14

Signal

Raise boom slowly

Lower boom slowly

Bend one hand with thumb pointing Description

upwards; place other hand motionless above hand moving up and down.

Bend one hand with thumb pointing downwards; place other hand motionless below hand moving up and down.

Illustration

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Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Ser. No.

15

16

Signal

Stop

Emergency stop

Description

Arm extended, the palm facing

Both arms extended, palms facing

downwards, move the arm back and

downwards, move arms back and forth

forth horizontally.

horizontally.

Illustration

17

Signal

End of a movement

Description

Safety Guidelines

Ser. No.

With fingers extended, cross both hands before the forehead.

Illustration

CAUTION (1) We recommend using the hand signals illustrated above. However, users can decide on their own hand signals depending on actual condition, as different countries and regions may differ in the expression of hand signals. (2) Hand signals must first be discussed, mutually agreed upon and clearly executed. Misunderstanding of hand signals may lead to serious accidents. (3) In any case, national traffic regulations must always be observed when abroad.

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Operator’s Manual for Crawler Crane 履带起重机操作手册 Chapter 4 Crane Operation 第四章 起重机的操作

Operator’s Manual for Crawler Crane

Chapter 4

Crane Operation

4.1 Operation and controlling instrument 4.1.1 Operator’s cab assy. Operator’s cab assy. is shown in the figure 4-1, and the components of operator’s cab are described in the table 4-1.

1

9 2

Crane Operation

6

7

8 3

4

5

Figure 4-1

ZCC800HWG.1 CRAWLER CRANE

Operator’s cab assy.

4-1

Operator’s Manual for Crawler Crane

Table 4-1 No.

Components of the operator’s cab

Names of the

Description

components

The upper part is the LCD screen of the load moment limiter 1

“Digital display” system

and the lower part is the instrument panel of the control system (see section 4.2 for details).

2

3

LCD screen of winch monitoring system Freefall pedal

Monitor the winch and crane tail in real time. Control the freefall brake. Step the pedal down to release the brake.

Travel gear pedal (with

Control the movements of left travel gear and right travel

hand lever)

gear.

5

Accelerator pedal

Control the rotational speed of the engine.

6

Air conditioning unit

7

Operator’s seat

It is adjustable (see section 4.3.1 for details).

8

Left control box

Control the slewing movements (see 4.1.2 for details).

9

Right control box

4

Located at the rear side of the operator’s cab (see section 4.3.3 for details).

Control the movements of hoisting winches 1 and 2, and derricking winch (see section 4.1.3 for details).

Crane Operation 4-2

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.1.2 Left control box Left control box is shown in the Figure 4-2, and its components are described in the Table 4-2.

1

3 2

4-7

5

7

6

Crane Operation

4

Figure 4-2

Left control box

4-3

Operator’s Manual for Crawler Crane

Table 4-2 Components of left control box No.

Names of the

Description

components

Push control lever forwards, slew the superstructure to the 1

Slewing control lever

right. Pull control lever backwards, slew the superstructure to the left. (See Section 4.1.2.1 for details).

2

Safety lever

Push the lever forwards completely, the control system is turned on. Otherwise, the power is cut off. Begin heating after you press it down and pull it up if no heating is needed.

3

Cigarette lighter

CAUTION Do not press it for more than 10 seconds, otherwise it will overheat.

CAUTION Crane Operation

Press down this button in an emergency to stop the 4

Emergency stop button

crane. As soon as this emergency stop button is pressed, the power supply of the crane will be cut off and the engine will be shut down. When over-hoisting warning is sent, it is used to bypass

5

Hoisting bypass switch

the crane movements “spool up hoisting winches” and “reel off derricking winch”. (for detailed operation, please refer to Section 4.1.4) When over-lowering warning is sent, it is used to bypass

6

Lowering bypass switch

the crane movement “reel off hoisting winches”. (for detailed operations, please refer to Section 4.1.4)

When overloading warning (100% < moment percentage 7

Derricking bypass switch

<110%) is sent, it is used to bypass the crane movement “spool up derricking winch”. (For detailed operation, please refer to Section 4.1.4)

4-4

Operator’s Manual for Crawler Crane

4.1.2.1 Slewing control lever The slewing control lever is shown in the Figure 4-3, and the components are described in the Table 4-3.

2

1

Crane Operation

Figure 4-3 Slewing control lever

Table 4-3 Components of slewing control lever No.

Names of the

Description

components

Push the switch leftwards to open the slewing brake cylinder, thus conducting slewing operation. 1

Slewing brake switch

Push the switch rightwards to close the slewing brake cylinder, thus stopping slewing operation. Control the warning horn

2

Horn switch

DANGER The horn can only be used in dangerous situation to ensure that it can warn all personnel around the crane.

4.1.3 Right control box 4-5

Operator’s Manual for Crawler Crane

Right control box is shown in the Figure 4-4, and its components are described in the Table 4-4.

1 2 3 4

5-11

6

7

11

10

9

8

Crane Operation

5

12

13

14

15

16

Figure 4-4

4-6

17

18

Right control box

19

20

21

22

Operator’s Manual for Crawler Crane

Table 4-4 Components of right control box No.

Names of the components

Description

Derricking winch control lever

Control the derricking winch. Push the control lever forwards, reel off derricking winch. Pull the control lever backwards, spool up derricking winch.

2

Hoisting winch 2 control lever

Control the hoisting winch 2. Push the control lever forwards, reel off hoisting winch 2. Pull the control lever backwards, spool up hoisting winch 2.

3

Hoisting winch 1 control lever

Control the hoisting winch 1. Push the control lever forwards, reel off hoisting winch 1; Pull the control lever backwards, spool up hoisting winch 1.

Ignition key switch

Insert the key into the ignition key switch and clockwise rotate it to the 2nd position to turn on the power, and then continue to rotate it to start the engine. CAUTION: (1) Before restarting the engine each time, first return the ignition key switch to original position and then rotate it to the 3rd position to start the engine. (2) The engine will be started after automatic preheating when it is cold. Moreover, delay start of the engine is normal.

5

Manual accelerator select switch

Accelerator control mode is changed into manual control after the switch is clockwise rotated. At this time, the accelerator is controlled by the knob (No. 17 in Figure 4-4). However, the accelerator pedal is invalid.

6

High-speed knob for hoisting winch 2

Control the high speed of hoisting winch 2. Counterclockwise rotate the knob, the high speed decreases. Clockwise rotate the knob, the high speed increases.

7

Spare

4

8

9

Engine shutdown switch

Press down this switch, the engine will be shut down. CAUTION: (1) After you shut down the engine, please keep the switch pressed down for more than 30 seconds, and then reset it again. Otherwise working hours of the engine this time cannot be saved. (2) Before the engine is ignited, the switch must be reset.

SetUp switch

In case of overloading (load moment below 110%) or main boom angle less than 30°, the dangerous crane movements are cut off by the system automatically. At this time, press down this switch, these cutoffs are bypassed, and the speed are reduced to 25% of the original one (see Section 4.1.4 for detailed usage of Setup switch). 4-7

Crane Operation

1

Operator’s Manual for Crawler Crane

Crane Operation

No.

Names of the components

10

High-speed knob for hoisting winch 1

Control the high speed of hoisting winch 1. Counterclockwise rotate the knob, the high speed decreases. Clockwise rotate the knob, the high speed increases.

11

Engine accelerator control knob

The engine speed can be adjusted via this knob under the manual accelerator mode. Clockwise rotate this knob, the engine speed increases.

12

Power switch

Control the controller power of the whole crane.

13

Inching speed switch

When the switch is pressed down, speed of all crane movements are reduced to 25% of the original one.

14

“Front windshield wiper on/off” switch

This switch is optional.

15

“Front washer on/off” switch

Switch on or off the front windshield wiper

16

Master lighting switch

Turn the switch to1st position: the LED on the switches of control panel will light up; 2nd position: master lighting switch

17

“Interior light on/off” switch

Switch on or off the interior light in operator’s cab

18

Free-fall switch

Press down this switch, the clutch of hoisting winch 1 is disengaged, then free-fall operation can be done. At this time, depress the free-fall pedal (No. 3 in Figure 4-1), the hook starts to lower down freely.

19

Derricking ratchet pawl switch

Control the derricking ratchet pawl. See Section 4.5.3 for detailed description.

20

Oil cooling switch

When oil temperature is too high, hydraulic oil is cooled by the switch.

21

Free swing button

This button is used to reduce the lateral force of the boom, thus protecting the boom against damage. CAUTION: Prevent vigorous swaying of the load brought by sudden stop of slewing motion.

22

Slewing alignment switch

When the ground is flat, it is suggested to turn on this switch. When the ground has a gradient, it is suggested to turn off this switch.

4-8

Description

Operator’s Manual for Crawler Crane

4.1.4 Safety control The safety control and bypass methods are listed in the tables 4-5 and 4-6. Table 4-5

Movement limitation and bypass method for safety warning

Warning

Limited

name

movements

Overloading (100%-110%) or minimum main boom angle

Bypass methods

Remarks

1．Turn bypass switch clockwise

1. Setup switch is active

until the icon

when pressed down once,

appears on

the screen of load moment limiter.

and it becomes invalid by

At this time, the limited movement

being pressed down again.

“raise main boom” is bypassed.

2. If overloading is

2．Press down “Setup” switch on

bypassed and the limited

right control panel, the icon

movements have been

Spool up

will appear on load moment limiter

performed, Setup switch

hoisting

if the load moment percent

requires to be pressed

winches 1 and

reaches 100%. At this time, turn

down again before bypass

2, raise and

“derricking bypass” switch

the overloading again.

lower main

clockwise and keep it there, then

3

boom

the limited movement “raise main

displayed after pressing

boom” is bypassed. However, the

down Setup switch when

icons

the crane is overloaded.

will

is

appear simultaneously on load

The icons

moment limiter if the load moment

are displayed

percent is less than 100%. At this

simultaneously after

time, the limited movement “raise

pressing down Setup

main boom” is bypassed.

switch when the main

Crane Operation

and

The icon

and

boom is less than the Spool up hoisting Overloading

winches 1 and

(above 110%)

2, raise and lower main boom

minimum angle. Release the bypass key switch

4. Bypass key switch is

when it is clockwise rotated. When

active by being rotated

there is

once, and it stops working

icon shown on the

load moment limiter, the limited

when it is rotated again,

movements are bypassed.

engine stops or power supply is off. Working time lasts 30 minutes once.

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Operator’s Manual for Crawler Crane

Warning

Limited

name

movements

Bypass methods

Remarks

1. The limited movements are bypassed when the icon

Spool up Over-winding/ over-hoisting

hoisting winches 1 and 2, lower main boom

appears on the load moment

1. Setup switch is active

limiter after clockwise rotating the

when pressed down once,

bypass key switch in electrical

and it becomes invalid by

control box for slewing table.

being pressed down again.

2．Press down “Setup” switch and

2. If overloading is

release it, when only the icon

bypassed and the limited

appears or both

and

appear simultaneously on

Crane Operation Over-lowering

hoisting winches 1 and 2

requires to be pressed

bypass switch clockwise and keep

down again before bypass

it there, the limited movements are

the overloading again.

bypassed when the icon

3

The icon

is

displayed after pressing

limiter.

down Setup switch when

1. The limited movements are

the crane is overloaded.

bypassed when there is

The icons

icon shown on the load moment

are displayed

limiter after clockwise rotating

simultaneously after

bypass key switch in electrical

pressing down Setup

control box for slewing table.

switch when the main

2．Press down “Setup” switch and

boom is less than the

release it, when only

minimum angle.

appears or both

icon and

and

4. Bypass key switch is

appear simultaneously on load

active by being

moment limiter, turn lowering

once, and it stops working

bypass switch clockwise and keep

when it is rotated again,

it there, the limited movements are

engine

bypassed when

supply is off. Working time

appears on

load moment limiter. Max. boom

Raise main

Bypassing the limited movement

angle (80°)

boom

is not allowed.

4-10

performed, Setup switch

load moment limiter, turn hoisting

appears on load moment

Reel off

movements have been

stops

or

rotated

power

lasts 30 minutes once.

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

CAUTION (1) The bypass key switch can bypass limitations of all other safety warning expect for the maximum boom angle, and the movement speed is reduced to 25% of the original one after being bypassed. (2) The action speed remains unchanged (except for bypass key switch release) when warning limitation is bypassed under no load angle. The action speed is reduced to 25% of the original one when warning limitation is bypassed under overload warning and in load angle. The action speed remains the same when warning limitation is bypassed under over-hoisting or over-lowering warning and in load angle. (3) “Bypassed” in the table refers to the temporary obtaining of the operation authority towards dangerous direction through the switch after safety warning is arisen and action is limited, not referring to safety warning removed. (4) All other switches are self-resetting switches except for the slew limit switch, and the bypass key switch and slew limit switch are installed in the electrical control box for slewing table (see section 4.1.4.1 for details).

Crane Operation

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4-11

Operator’s Manual for Crawler Crane

Table 4-6

Tricolor light alarm logic

Before bypass

Green

Yellow

light

light

○

Red light

Buzzer

√

√

√

√

○

○

○

○

√

○

Interrupted

○

√

√

√

○

Interrupted

○

Interrupted

○

√

√

√

○

Interrupted

○

√

○

√

√

√

○

Interrupted

○

√

○

√

√

√

○

○

Interrupted

√

○

√

○

Interrupted

0%< Moment percentage <90%

Overloading or minimum main boom angle

When After

load

bypass

angle

90%≤ Moment percentage ≤100% 100%< Moment percentage ≤110%

No load angle Before

Crane Operation

Over-winding

bypass After bypass Before

Over-lowering

bypass After bypass

Max. boom angle

Bypass

is

not allowed

When bypass key switch is active under any circumstance 90%≤ Moment percentage≤ 100%

4-12

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

CAUTION (1) “Bypass” in the table refers to the temporary obtaining the operation authority towards dangerous direction through the switch after safety warning is arisen and action is limited, not referring to safety warning removed. (2) “○” in table refers that the light is not on or the buzzer makes no sound, “√” refers that the light is on or the buzzer makes continuous sound, and “interrupted” refers that the light flickers or the buzzer makes interrupted sound.

DANGER All operation releasing safety warning limitation must be used under the circumstances of commissioning, repair conducted by the professionals or avoiding other accidents.

4.1.4.1 Electrical control box for the slewing table The electrical control box for slewing table is shown in the figure 4-5, and its components will be described in the table 4-7.

Crane Operation

1 Figure 4-5

ZCC800HWG.1 CRAWLER CRANE

2 Electrical control box for the slewing table

4-13

Operator’s Manual for Crawler Crane

Table 4-7 No.

Components of the electrical control box for slewing table

Names of the

Description

components

Clockwise rotate the switch to bypass all other limited crane movements except for maximum boom angle limitation when dangerous conditions occur. 1

Bypass key switch

DANGER Bypass key switch must be used under the circumstances of commissioning, repair conducted by professionals or avoiding other accidents.

2

Engine diagnosis socket

Interface for diagnosis by service men of the engine manufacturer.

Crane Operation 4-14

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.2 Instructions for digital display system The digital display system is shown in the figure 4-6, and it will be described in the table 4-8.

1

2

Figure 4-6

Table 4-8 No.

Digital display system

Description of digital display system Names of the components LCD screen of load moment limiter

2

Instrument panel

Crane Operation

1

4.2.1 Load moment limiter See instructions for the load moment limiter for detailed operation of load moment limiter.

WARNING In load moment limiter commissioning, safe operation rules of the crane must be followed and operation is conducted according to rated lifting capacity chart.

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Operator’s Manual for Crawler Crane

4.2.2 Instrument panel The instrument panel is used for real-time monitoring of the working condition of the crawler crane, which can show the engine speed, working time of the engine, water temperature, oil pressure, oil level and pump pressure etc. when abnormal conditions occur, the warning icon will flash in the screen. The instrument panel is shown in the figure 4-7, and the components of instrument panel will be described in the table 4-9.

1

2 3

4 5

Crane Operation

Figure 4-7

Table 4-9 No.

Instrument panel

Components of instrument panel

Names of the

Description

components

Display related parameters and various kinds of warning 1

Instrument assy.

indication of the engine (see Instrument assy. description for details).

2

3

4 5

4-16

Main pump (1) pressure gauge Main pump (2) pressure gauge Slewing pump pressure gauge Control pressure

Display the working circuit pressure of main pump I.

Display the working circuit pressure of main pump II.

Display the working circuit pressure of the slewing pump. Display the working circuit pressure of the control pump.

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

CAUTION When hoisting winch 1 or left travel gear is working, main pump I starts to work. When hoisting winch 2, derricking winch or right travel gear is working, main pump II starts to work. When slewing mechanism is working, the slewing pump starts to work.

4.2.2.1 Instrument assy. The instrument assy. is shown in the figure 4-8, and its components are described in the table 4-10. 1 2 3

8

14

9

2

3

4

components

Crane Operation

Table 4-10 Names of the

11 10

12

Figure 4-8

1

5 6 7

15

13

No.

4

Instrument assy.

Components of the Instrument assy.

Icon

Description

Oil pipeline clogging

When oil pipeline is clogged, this icon will flash.

Engine coolant

When engine coolant temperature is higher than

temperature

96℃, this icon will flash.

Power indication

When the power of crane is switched on, this icon will flash.

Engine speed and

Indicate the current engine speed and total working

working hours

hours of the engine.

5

Spare

6

Spare

7

Spare

ZCC800HWG.1 CRAWLER CRANE

4-17

Operator’s Manual for Crawler Crane

No.

8

Names of the components Engine oil pressure gauge

9

Voltmeter

10

Spare

11

Spare

12

Oil pressure

13

Fuel level

14

Water thermometer

15

Fuel gauge

Icon

Description

Indicate the current engine oil pressure Indicate the current voltage of the battery

When engine oil pressure is less than 0.06 MPa, this icon will flash. When fuel level is less than 10%, this icon will flash. Indicate the current engine coolant temperature. Indicate the fuel level of the fuel tank in percentage.

Crane Operation 4-18

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.3 Startup of the crane 4.3.1 Adjustment of crane operator’s seat The adjustment of crane operator’s seat is shown in the figures 4-9 – 4-13.

Figure 4-9

Vertical adjustment of headrest

Figure 4-10

Adjustment of armrest

The height of headrest is adjusted manually

The height of armrest can be adjusted by the

with proper strength.

adjusting knobs.

Crane Operation

Figure 4-11

Horizontal adjustment of the seat:

-

Pull the lever upwards;

-

Move the seat to required position;

-

Release the lever.

ZCC800HWG.1 CRAWLER CRANE

4-19

Operator’s Manual for Crawler Crane

Figure 4-12

Adjustment of the seat height

There are two levers to adjust the seat height. The left lever adjusts the height of the front part of the seat, and the right lever adjusts the height of the rear part of the seat. Pull the left lever upwards, the front part of the seat is raised up. Pull the right lever upwards, the rear part of the seat is raised up. After the seat is put in proper position, release the switch.

Crane Operation Figure 4-13

Adjustment of backrest

Pull the horizontal adjustment lever upwards, pull the backrest to proper position and release the lever.

4-20

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.3.2 Inspection before startup The following inspection must be conducted before the engine is started.

4.3.2.1 Filter and oil level inspection a)

Diesel engine oil level.

b)

Oil level of hydraulic oil tank of the crane hydraulic system.

c)

Oil filter on the hydraulic oil tank.

4.3.2.2 Fuel level inspection Inspect the fuel level on the fuel gauge in driver’s cab.

4.3.2.3 Coolant level inspection The coolant must be filled in the edge of the oil filling nozzle.

DANGER The coolant level must not be inspected before the engine is cooled down. In inspection, the engine must be cooled, or there is a risk of burning.

4.3.2.4 Inspection of overall status of the crane Before starting the crane, the driver must ensure that all the following conditions are met: Inspect the work log to ensure that all regular inspection, maintenance and repair work are done. b)

Inspect whether the boom over-wind protection device, angle indicator of the boom, tilting-back support and other safety devices are normal.

c)

Carefully inspect whether the heavy-bearing components, such as wire rope (hoisting rope, derricking rope and bracing cable etc.), boom, folding bracket, hook and lifting device, are in normal status.

d)

Inspect whether it lacks bolts, nuts and pins and whether components have cracks and damages.

e)

Make sure that there is no unauthorized rebuilding, such as counterweight increasing and decreasing, and incorrect boom repair.

f)

Inspect whether various instruments have normal indicated values when the engine is started.

g)

Inspect the leakage conditions of fuel and hydraulic oil.

h)

Test whether the various control mechanisms operate normally.

i)

Inspect the brake and the clutch, and lift the loads away from the ground slightly and suspend it for a moment to test the performance of the brake.

j)

Maintain exchanges between operators and hoisting workers.

k)

Estimate the loading conditions before lifting it.

ZCC800HWG.1 CRAWLER CRANE

4-21

Crane Operation

a)

Operator’s Manual for Crawler Crane

l)

The crane operation can be conducted within the minimum radius; there is no barrier within the necessary operation range, and the site ground shall bear the weight of various expected loads.

m) Make sure that the working area and the loading view is clear without barriers, inspect whether the communication system between the crane operator and signalman is unobstructed to ensure safe operation. n)

Verify the bearing capacity of the ground or working surface of other cranes, ensure that the crane has appropriate bearing to avoid operation on the floppy and instable ground, as well as the ground with high water content and part of frozen earth. When the crane operates next to the groove, the groove shall be reinforced or sloped to avoid collapse or landslide. If the ground cannot bear enough weight, the crane might be tipped over or collapsed, so there is a need to fill up with such things as sleepers, steel plate and concrete foundation under the crawler to distribute the loads without exceeding bearing capacity of the ground; the crane must be kept level.

DANGER Before operating the boom in any direction, ensure that there is no any other loose object on it, otherwise, the object will fall down to cause the injury to the people.

4.3.3 Turning on power and relevant preparations Crane Operation

a)

Turn on power supply Insert the key into the ignition key switch and clockwise turn it into the 2

nd

position to turn

on the power supply. Refer to figure 4-14.

Figure 4-14

4-22

Turning on power supply

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

b)

Air conditioning operation in operator’s cab The crane operator’s cab can be heated or cooled according to the expected temperature, and the control panel is located above the wallboard on the right side of the operator’s cab. Refer to figure 4-15.

Control panel of air conditioning

Off Air speed knob

Fresh air

Cooling/heating

switch

selector switch

Figure 4-15

On Ball valve switch

Control panel of the air conditioning

The air conditioning system mainly consists of compressor, condenser (including liquid reservoir), evaporator etc. driven by the engine. And the heating is achieved by utilizing the heat of engine circular water supplied by the evaporator fan. Cooling: Turn off the ball valve of hot water pipe at the lower rear part of the fuel tank. Rotate “cooling/heating” selector switch to “cooling” position. Rotate the wind speed knob to adjust the air volume and temperature in the cab. Heating: Turn on the ball valve of hot water pipe at the lower rear part of the fuel tank. Rotate “cooling/heating” selector switch to “heating” position. Rotate the wind speed knob to adjust the air volume and temperature in the cab.

CAUTION (1) Check the tension of the belt of the compressor regularly and adjust it in time. (2) Clean the surface of the cooling fin of the condenser to prevent the cooling effects from declining. (3) Run the air conditioning for about 10 minutes every month when it’s not used in winter to penetrate the cooling oil into the whole system to prevent leakage of refrigerant.

ZCC800HWG.1 CRAWLER CRANE

4-23

Crane Operation

When cooling performance is activated, its power is supplied by the compressor which is

Operator’s Manual for Crawler Crane

c)

Operation of the front/top windshield wiper In case of controlling the crane in rainy days, front windshield wiper can be started by pressing down the front windshield wiper switch on the upper right side of the control panel inside the operator’s cab; top windshield wiper switch is at the seat top inside the operator’s cab, and the top windshield wiper can be started by pressing down the switch. Refer to figure 4-16 for front windshield wiper.

Front windshield wiper switch

Water switch

Figure 4-16 d)

Working floodlight

Master lighting switch

Control panel in the operator’s cab

Horn Horn switch (No. 2 in Figure 4-3 of section 4.1.2.1) must be pressed down before the work

Crane Operation

is started to test whether the horn can sound. e)

Illumination When the crane works at night, turn the master lighting switch of control panel on the st

upper right side of the cab to the 1 position, the LED of instruments and switches will light up. After that, turn on the “working floodlight” switch, all the work floodlights will light up. Please refer to the figure 4-16. However, the interior light in the cab is not controlled by the master lighting switch. It is located on the top of operator’s seat. f)

Starting of the engine Insert the key into the ignition key switch, and continue to clockwise rotate it to start the engine. Refer to figure 4-17.

Figure 4-17

4-24

Starting of the engine

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

Check whether the engine works normally after starting of the engine. Refer to figure 4-18.

Engine coolant temperature

Figure 4-18

Engine speed

Engine oil pressure

Starting of the engine

1)

Check whether the engine speed is normal;

2)

Check whether the engine coolant temperature is normal;

3)

Check whether the engine oil pressure is normal.

CAUTION (1) Compared with routine conditions, it takes longer time to preheat the engine automatically in cold weather. This is a normal phenomenon. temperature.

(3) Do not use accelerator when starting engine. If the engine fails to start after approx. 5s, slowly depress the accelerator pedal all the way down. If the engine can not be started within 5-10s, give up the starting attempt and wait approx. 1 minute before trying again. If the engine still can not be started continuously for three times, stop starting engine at once and check it for fault. If the temperature of engine is high, do not depress accelerator pedal when starting engine to avoid black smoke discharging. After the engine starts, release ignition key switch at once to let it return to initial position, and check the parameters of engine at the same time.

ZCC800HWG.1 CRAWLER CRANE

4-25

Crane Operation

(2) The crane engine can only become full loaded when it achieves the running

Operator’s Manual for Crawler Crane

4.4 Safety device Before each crane operation, the operator must check whether all safety devices work normally.

WARNING The crane with safety device out of order is not allowed to be operated!

4.4.1 Emergency stop button As soon as this emergency stop button is pressed in an emergency, a)

The power supply of the machine is switched off and the diesel engine is shut down;

b)

All crane movements stop immediately.

The emergency stop button is shown in the figure 4-2.

DANGER Emergency stop button can only be used in real emergency rather than as operating shutdown device! If an emergency stop is triggered while a load is being lifted, there may be a risk of accident owing to swinging of load.

4.4.2 Battery master switch Battery master switch is located on the battery box at front right side of the slewing table. Set

Crane Operation

battery master switch in “OFF” position during long-time work breaks so as to prevent the electricity of battery from discharging excessively.

4.4.3 Flashing light Flashing light is installed on the top of operator’s cab and at the left rear side of the cab. When the power supply is connected via ignition key switch, the flashing light will flicker to warn people around that the crane is working. Refer to figure 4-19.

Flashing light

Figure 4-19

4-26

Position of flashing light

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.4.4 Load moment limiter See annex Instructions for Usage of Load Moment Limiter for specific operations. Load moment limiter is an electronic computer-centered measuring and control device, which can reflect basic real-time parameters of the crawler crane under various working conditions. It gives an early warning signal when the actual load reaches 90% of the rated one, and it gives a warning when the actual load reaches or exceeds the rated one and stops operation in all dangerous directions to make the boom operated towards safe directions, so as to prevent the crawler crane from causing accidents as tipping-over, breaking off the boom and personal injuries due to overload in construction and ensure that the crawler crane operates normally and safely. When the load moment limiter judges the crane as overload, it can give an auto-stop control signal which can cut off the actions of the crane toward dangerous directions through the electrical circuit of the crane itself and hydraulic control mechanism. When actual moment reaches 90–100% of the rated moment, yellow light on the moment limiter is on and the buzzer makes interrupted sounds. When the actual moment exceeds 100%, the red light and yellow light on the moment limiter are on simultaneously and the buzzer makes continuous sound to stop coiling and decoiling the cable of the derricking winch and actions of dangerous direction of the hook hoisting through PLC. See section 4.1.4 safety control for releasing methods of overload.

Overloading bypass operation must be used under the circumstances of commissioning, repair conducted by the professionals or avoiding other accidents.

4.4.5 Angle indicator Boom angle indicator is fitted on the lower rear end of main boom pivot section (i.e. on the right side of the crane operator’s cab). In this way, the operator, even in crane operator’s cab, can clearly read boom angle shown on the indicator. Refer to figure 4-20.

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4-27

Crane Operation

DANGER

Operator’s Manual for Crawler Crane

Figure 4-20

Position of Angle indicator

4.4.6 Lowering limiter Crane Operation

In order to prevent wire rope from being wound in the opposite direction after it is unwound completely, the lowering limit switch fitted on the hoisting winch is triggered when there are only three windings of wire rope left on the drums. Under this condition, the buzzer will sound, the tricolor light will send out yellow and red warning continuously, and the warning icon on the screen will flash. At this time, the movement of “reel off winch” is switched off, and only the movement of “spool up winch” can be carried out. The lowering bypass method refers to section 4.1.4. The position of lowering limiter is shown in the figure 4-21.

Figure 4-21

4-28

Lowering limiter

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

WARNING The lowering bypass switch or bypass key switch can only be allowed to use under the circumstance of commissioning, repair or avoiding other incidents.

4.4.7 Hoisting limiter Hoisting limiter installation is to prevent hook pulley block from running into boom head. Before each use of the crane, the switch must be checked by operating the hook pulley to the hoisting limiter weight. When hoisting limiter is triggered, the hook cannot be lifted and the boom cannot be lowered. If the load hook comes into contact with the hoisting limit switch weight during its upward movement, the hoisting limit switch is triggered. Under this condition, the buzzer will sound, and the crane movements “lift the hook” and “lower the boom” are switched off. The hoisting bypass method refers to section 4.1.4. The position of hoisting limiter is shown in the figure 4-22.

Crane Operation

Figure 4 - 22

Hoisting limiter

DANGER The hoisting bypass switch or bypass key switch can only be used when one observer carefully observes the distance between hook pulley and boom head. The observer must directly contact with the crane operator, and the hook must be lifted with great caution and at the lowest possible speed.

WARNING The hoisting bypass switch or bypass key switch can only be used under the circumstance of commissioning, repair or avoiding other incidents.

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Operator’s Manual for Crawler Crane

4.4.8 Derricking limiter It is used to detect main boom angle in real time according to the data collected by angle sensors. Once detected angle exceeds safe angle range, an alarm will be sent out and dangerous movements will be switched off so as to ensure safe crane operation. a)

Crane operation with main boom The maximum main boom angle is 80°. When main boom angle reaches 78°, the crane will give a sound alarm, while main boom can still be raised. However, when main boom angle reaches 80°, the crane movement “Raise main boom” will be automatically cut off, and the crane will give an alarm. At this time, it is only allowed to lower main boom, and any bypass method is invalid at the moment.

b)

Crane operation with fixed jib The requirements for main boom angle under this boom configuration are the same as that under “Main boom” configuration. The fixed jib can be fitted in the angle of either 10°or 30° to main boom.

4.4.9 Anemometer The anemometer fitted on the main boom or fixed jib head can detect the wind speed on the top of the boom in real time. The permitted wind velocity for the crane operation is at most 9.8m/s. The crane is fitted with

Crane Operation

main boom only, and the out-of-service wind velocity should not exceed 21m/s. The crane is fitted with main boom as well as jib, and the out-of service wind velocity should not exceed 15m/s. Under the above conditions, the entire boom must be placed on the ground. Please pay attention to the data detected by anemometer on the boom top in the load moment limiter in real time.

CAUTION The permitted wind velocity for the crane operation is at most 9.8m/s. The crane is fitted with main boom only, and the out-of-service wind velocity should not exceed 21m/s. The crane is fitted with main boom as well as jib, and the out-of service wind velocity should not exceed 15m/s. Under the above conditions, the entire boom must be placed on the ground.

4.4.10 Crane inclinometer The mechanical inclinometer is installed on the front of the crawler crane which can measure the inclination of the crane.

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4.5 Operation of crane 4.5.1 Operation of travel gear a)

Components of the travel gear The travel gear consists of drive sprocket, driven sprocket, track carrier roller, track roller and track pad, crawler carrier, travelling motor and travelling reducer etc. (refer to figure 4-23 and table 4-11). Both right crawler carrier and left crawler carrier are fitted with an independent traveling reducer. The hydraulic oil in traveling motor is supplied by superstructure main pump through main valve and central revolving joint.

1

2

3

4

Figure 4-23

5

6

7

8

Components of travel gear

No.

Description

1

Drive sprocket

2

Track carrier roller

3

Track roller

4

Track pad

5

Track carrier roller

6

Crawler carrier

7

Track carrier plate

8

Driven sprocket

ZCC800HWG.1 CRAWLER CRANE

Crane Operation

Table 4-11 Components of travel gear

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Operator’s Manual for Crawler Crane

b)

Operation of the travel gear The traveling movements are controlled by left and right travel gear pedals or left and right hand levers. The movements “left crawler forwards” and “left crawler backwards” are controlled by left travel gear pedal or left hand lever, and the movements “right crawler forwards” and “right crawler backwards” are controlled by right travel gear pedal or right hand lever. The crane can carry out such movements as traveling straight ahead/backwards, steering during traveling and turning on spot. Refer to figure 4-24. Before travelling, the travelling alarm installed at the bottom of the operator’s cab will send a sound warning. Right crawler forwards Left crawler forwards

Right crawler backwards Left crawler backwards

Crane Operation Figure 4-24

Operation of travel gear

DANGER During crane operation, make sure that there is no obstruction or person within the danger zone. Send an audible signal before every crane operation.

CAUTION At any time, slowly and carefully operate the control lever. This will not only prolong the service life of the crane, but also will help avoid accidents.

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Operator’s Manual for Crawler Crane

c)

Traveling on level road 1)

Traveling straight ahead Depress two travel gear pedals forwards at the same time (Or push two hand levers forwards at the same time.)

2)

Traveling straight backwards Depress two travel gear pedals backwards at the same time (Or push two hand levers backwards at the same time.)

3)

Turning to left with a crawler Depress right travel gear pedal forwards (Or push right hand lever forwards.) Refer to figure 4-25.

4)

Turning to right with a crawler Depress left travel gear pedal forwards (Or push left hand lever forwards.) Refer to figure 4-26.

Crane Operation

Figure 4-25 5)

Turning to left with a crawler

Figure 4-26

Turning to right with a crawler

Differential steering to left Depress right travel gear pedal or push right hand lever forwards heavily, while depressing left travel gear pedal or pushing left hand lever forwards slightly to make the speed of right crawler faster than that of left crawler. Refer to figure 4-27.

6)

Differential steering to right Depress left travel gear pedal or push left hand lever forwards heavily, while depressing right travel gear pedal or pushing right hand lever forwards slightly to make the speed of left crawler faster than that of right crawler. Refer to figure 4-28.

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Operator’s Manual for Crawler Crane

Figure 4-27

Differential steering to left

Figure 4-28

Differential steering to right

CAUTION The operator is allowed to operate the hand lever in a stepless manner so that the crawlers on both sides will move forward at different speeds, so as to change the

Crane Operation

turning radius in a stepless manner. 7)

Turning to right on the spot Depress right travel gear pedal backwards or push right hand lever backwards heavily, then right crawler will move backwards. Push left travel gear pedal or left hand lever forwards heavily, then left crawler will move forwards. Refer to figure 4-29.

8)

Turning to left on the spot Depress left travel gear pedal backwards or push left hand lever backwards heavily, then left crawler will move backwards. Push right travel gear pedal or right hand lever forwards heavily, then right crawler will move forwards.

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Operator’s Manual for Crawler Crane

Figure 4-29

Turning on the spot

(1) If there is a need to stop travelling or turning, just return the travel gear pedal (or hand lever) to the neutral position and the travelling brake will be activated automatically. No other operations are needed. (2) When crawler crane is travelling with a load, the boom is right in front of the crane and the crane is only allowed to move forward. The maximum allowed lifting capacity during travelling shall not exceed 70% of the rated lifting capacity. (3) When traveling crawler crane for a long distance, make sure that the travelling motor is at the rear of the basic machine. d)

Traveling on a slope When the crane is traveling on slope, the drive sprocket is behind the driven sprocket and the slewing control lever is placed in neutral (zero) position. When the crawler crane is climbing a slope, keep the engine speed within medium speed range, and shorten the boom as much as possible. When crane is traveling on a slope with maximum permissible gradient, it can only be fitted with basic boom. Refer to figure 4-30.

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4-35

Crane Operation

CAUTION

Operator’s Manual for Crawler Crane

Figure 4-30 1)

Traveling on a slope

Prerequisite for travelling on a slope The gradeability of crane is restricted by the following conditions: -

The position of the center of gravity of the complete crane.

-

Friction coefficient between the road surface and the track pad.

-

Shift between the horizontal direction and the inclined direction.

-

A maximum gradient of 30%.

Crane Operation

CAUTION To travel the crawler crane uphill, the following conditions must be observed: (1) The ground must be able to bear the possible pressure. (2) The friction coefficient between roadway and track pad must be large enough to take on any drive forces which will occur. Slippery ground can cause the crane to slip sideways and to move into an impermissible side incline position. There is a danger of accidents! (3) The slewing table must be aligned parallel to the crawler carriers and must be secured by slewing fixing pin to prevent it from turning. (4) The maximum allowed wind velocity is 9 m/s. (5) Side incline is not permitted! (6) Drive slowly. Great care must be taken to every acceleration and deceleration action. (7) The transfer from the horizontal to the incline and from the incline to the horizontal must be made very evenly, which means there may be no edges over which the crane tips. The change of gradient must be continuous.

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Operator’s Manual for Crawler Crane

2)

Steering on a slope If crawler crane needs to turn on the slope, the top and bottom of the slope shall be graded or provided with a bearing plate so as to form a gentle slope curve (see the following figure), which can prevent crane’s center of gravity from deviating and load from concentrating on a section of crawler when crawler crane is traveling over undulations.

Remove the undulation Gentle slope

Figure 4-31

Treatment of slope

CAUTION When crawler crane is traveling from the horizontal ground to the slope, if its center of gravity deviates backwards, stop the crane to adjust the center of gravity.

For the sake of safety, demount the counterweight and boom when the crane is traveling on a slope with permissible maximum gradient, and the operator does not know about the ground condition. The crane can only travel with suspended load, providing that the following precautions are taken: (1) The ground surface must be flat and level (no gradient). (2) The subsoil must be capable of bearing the crane’s maximum service weight and the weight of suspended load. (3) Only minimum traveling speed is permitted and the boom should be in the direction of travel. (4) Jerky crane movements must be avoided. (5) The suspended load must be lashed to prevent it from swinging. (6) Steering of crawler is not needed.

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Crane Operation

WARNING

Operator’s Manual for Crawler Crane

4.5.2 Operation of hoisting winches a)

Components of hoisting winch The hoisting winch consists of hydraulic motor, winch reducer, normally closed brake, lowering limiter, hoisting limiter, wire rope, main and auxiliary load hooks etc.. The lifting speed of load can be changed by adjusting the inclination angle of control lever. The angle can vary from -26.5 to 26.5. The bigger the inclination angle is, the quicker the lifting (or lowering) speed is. Operate the control lever forwards or backwards to limit position, which can be maintained here through a mechanism on the control lever. When there is a need to stop operation, push the control lever to the neutral position with a little force to stop it.

b)

Operation of hoisting winch The crane is fitted with two hoisting winches: hoisting winch 1 and hoisting winch 2. The structure of hoisting winch 1 is the same as that of hoisting winch 2 with different length of wire rope, but their positions and functions are different. Hoisting winch 1 is required for crane operation with main boom, and hoisting winch 2 is required for crane operation with main boom and fixed jib, or crane operation with main boom and tip boom. The control lever of hoisting winches can refer to figure 4-32.

Crane Operation

1: Hoisting winch1control lever 2: Hoisting winch 2 control lever 3: Derricking winch control lever

3 2 1

Seat

1 Figure 4-32

4-38

2

3

Control levers of hoisting winches

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

1)

Operation of hoisting winch 1 Push control lever (1) forwards – reel off hoisting winch 1 to lower the load hook; Push control lever (1) backwards – spool up hoisting winch 1 to lift the load hook.

2)

Operation of hoisting winch 2 Push control lever (2) forwards – reel off hoisting winch 2 to lower the load hook; Push control lever (2) backwards – spool up hoisting winch 2 to lift the load hook.

3)

High-speed operation of hoisting winches Both hoisting winches 1 and 2 have high-speed load lifting and lowering functions. It’s possible to lift or lower main hook or auxiliary hook at higher speed by adjusting the high-speed knob of the hoisting winch 1 or hoisting winch 2 (See No.6 and No.16 in figure 4-4).

4)

Inching speed function Hoisting winches 1 and 2 provide inching speed functions. After pressing the inching speed switch (see No.8 in figure 4-4), the hoisting winches will move at a speed 25% of the normal speed.

WARNING (1) The high-speed knobs of hoisting winch 1 and hoisting winch 2 are only used when single rope force is not more than 30% of rated one. Otherwise, the knobs must be placed in neutral position. 1500rpm. (3) The hoisting winches have good inching speed function. In inching-speed operating condition, the engine should run at fixing speed. Never change rotational speed of the engine arbitrarily, otherwise the unstable hoisting speed and vibration of lifted load will occur. (4) Under any conditions, there must be at least three windings of wire rope left on the winding drum. (5) During simultaneous operation of hoisting winches 1 and 2, the sum of their single rope forces must be less than 6t, otherwise, they may not work normally. (6) When system sounds the alarm, the operator should operate crane towards safe directions. If it is necessary to operate crane towards dangerous directions, the operator can refer to Section 4.1.4 “safety control”. Any operation to bypass the switch-off is only carried out by specialist personnel in commissioning and maintenance conditions or it is carried out to avoid other accidents.

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Crane Operation

(2) When operating the crane using inching speed function, keep engine speed about

Operator’s Manual for Crawler Crane

CAUTION (1) Choose proper rope reeving in accordance with boom length. (2) If the hook swings due to twisting of the wire rope, put down the load. It’s only allowed to hoist after the wire rope is totally untied. (3) When a load is lifted away off the ground, it should first be suspended in the air for a moment. Do not lift the load until the operator confirms that there is no safety hazard. Do not pull the load by changing the boom angle if the load is still in contact with the ground. Only lift the load by operating hoisting winch. (4) Do not change control lever between “lift hook” and “lower hook” jerkily, vice versa. The operator must return the control lever to neutral position and ensure that the winding drum has stopped before changing control lever from “lift hook” to “lower hook”. Otherwise, the machine components will be damaged. (5) If the main boom length is extended in “main boom” configuration, the lifting height of the crane will increase accordingly, which will therefore make the wire rope not be long enough. Such problem can be solved by changing the rope reeving of the wire rope. Before changing the rope reeving, fit a hoisting limit switch weight; (6) When the crane is overloaded, or wire rope on hoisting winch 1 or 2 is excessively

Crane Operation

wound / unwound, dangerous movements will be switched off automatically and alarms will be given out. c)

Free-fall operation As to hoisting winch 1, the free fall function is available as an option. The hoisting winch 1 with free-fall function consists of hydraulic motor, winch reducer, winding drum, brake drum, normally closed brake, outside band brake, hoisting limiter, and wire rope as well as load hook. The outside band brake mainly consists of brake cylinder, brake spring, connecting-rod mechanism, brake band, adjustment device, water-proof cover and etc. Refer to figure 4-33 and table 4-12.

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Operator’s Manual for Crawler Crane

5 1

2

3

4

6

Figure 4-33

Winch with outside band brake

Table 4-12 Names of the

Instructions

components

Prevent the rain water from entering the friction surface 1

Water-proof cover

between brake strap and brake drum to affect brake performance.

2

Adjustment device 1

3

Brake strap

4

Brake cylinder

5

Adjustment device 2

Adjust the distance between the brake strap and brake drum. Make friction with brake drum, and achieve braking effects through the resistance Release the brake effects of band brake. Adjust the distance between brake strap and brake drum after wear and tear of brake strap. The brake is normally closed, that is, the brake spring is

6

Brake spring and

compressed all the time. The connecting-rod connects the

connecting-rod

front and rear brake straps to cooperate with the brake cylinder to release the braking effects.

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Crane Operation

No.

Components of band brake

Operator’s Manual for Crawler Crane

The free-fall operation is shown as follows: (1) Stop the movement of hoisting winch, and the outside band brake at this time is normally closed. (2) Switch on free-fall switch (No. 9 in figure 4-4) on the right control box to open the reducer clutch and observe the pressure of control circuit in hydraulic system (no. 5 pressure gauge in figure 4-7) to check whether it achieves the required pressure. (3) Depress free-fall pedal (No. 3 in figure 4-1) with left foot, activate the brake through brake cylinder, then the winch is reeled off quickly under the influence of pulling force of load hook. (4) Slowly release the free-fall pedal after the load hook is lowered in a proper position, so that the brake is activated under the function of brake spring to reduce the lowering speed of the winch until it stops. (5) Switch off the free-fall switch on right control box after making sure that the winch is static. The free-fall operation is finished.

DANGER (1) It’s prohibited to use free-fall function if it is not in main boom configuration. (2) It’s prohibited to switch on free-fall switch if hoisting winch control lever is operated to perform regular movements. (3) Never reset any free-fall switch before the free-fall operation is finished (when the

Crane Operation

drum is completely static, an operation is finished). (4) The free-fall operation is only allowed when the crane is working without load or with a light load. (5) Calculate the length of the wire rope before free-fall operation and make sure that at least 3 windings of wire rope left on the winding drum.

CAUTION (1) The brake strap is a component liable to wear and tear. When the abrasion thickness of friction lining reaches 2 – 4mm, change it in time. (2) The braking torque of brake can be controlled by adjusting the tensioning of spring of band brake. (3) Each braking procedure must be carried out with maximum care and sensitivity. Release the foot pedal slowly and stably.

4.5.3 Derricking mechanism a)

Derricking mechanism components Through changing the length of wire rope reeved between derricking pulley blocks (includes derricking crown block and derricking traveling block), the derricking mechanism, via main boom derricking winch, can adjust boom angle so as to change the working

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Operator’s Manual for Crawler Crane

radius. We can use A-frame and boom frame to carry out derricking movement. During derricking, the derricking crown block is located at the top of A-frame, while the derricking traveling block is on the other end of anchoring rod, so the boom angle can be changed with the variation in the length of wire rope between the derricking pulley blocks. The derricking mechanism consists of derricking winch reducer, winding drum, motor, brake, derricking rope, ratchet wheel mechanism, A-frame assy. and derricking pulley block as well as main boom anchoring rods. Refer to figure 4-34 and table 4-13.

7 1

Crane Operation

6 2 3 5 4

Figure 4-34

ZCC800HWG.1 CRAWLER CRANE

Derricking mechanism components

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Operator’s Manual for Crawler Crane

Table 4-13 Derricking mechanism components

b)

No.

Names of the components

1

Derricking traveling block

2

Derricking crown block

3

A-frame assy.

4

Derricking rope

5

Main boom tilting-back support

6

Main boom assy.

7

Main boom anchoring rods

Operation of derricking mechanism Refer to No.3 in figure 4-32 for the position of the derricking winch control lever. The derricking speed can be changed by adjusting the inclination angle of control lever. The angle can vary from -26.5 to 26.5. The bigger the inclination angle is, the quicker the raising(lowering) speed is. Operate the control lever forwards or backwards to limit position, which can be maintained here through mechanism on the control lever. When there is a need to stop operation, push the control lever to the neutral position with a little force to stop it. Push control lever (3) forwards – reel off derricking winch to lower the boom; Push control lever (3) backwards – spool up hoisting winch to raise the boom.

c)

Functions and definitions of derricking winch for various boom configurations

Crane Operation

1)

“Main boom” configuration Main boom angle can be changed from 0 to 80.

2) Main boom with fixed jib configuration The fixed jib can be assembled in the angle of 10 or 30 to main boom. Note: The angle must be set in advance. It can not be changed during operation. d)

Ratchet pawl mechanism The main boom derricking winch drum is fitted with brake, ratchet wheel mechanism and ratchet pawl mechanism, which can lock main boom derricking winch using ratchet pawl so as to make boom stop at any position in case the crane does not work for a long time. The ratchet pawl can be turned on or turned off by derricking ratchet pawl switch on right control box. Refer to figure 4-35 and table 4-14.

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Operator’s Manual for Crawler Crane

2

3

1

4

7 Figure 4-35

Table 4-14 No.

Ratchet pawl mechanism

Components of ratchet pawl mechanism

Names of the components

Instructions

6 On the right control box, used to control movements

1

2 ratchet switch Derricking

2

On the right of derricking drum

3

Ratchet3 wheel Ratchet pawl

4

Ratchet pawl cylinder

Open or close by ratchet pawl

of ratchet pawl cylinder

Open or close by ratchet pawl cylinder

When pressure oil passes through the brake valve, press ratchet switch and hold it until ratchet the ratchet pawl can be disengaged from ratchet wheel all the time even though the ratchet switch is released. If derricking mechanism does not work for a long time, the brake must be actuated and the brake valve should not be electrified. At this time, press derricking ratchet switch and hold it until ratchet pawl engages with ratchet wheel teeth.

CAUTION (1) Derricking operation should be performed stably. When the crane is lifting a load, jerky operation will bring great impact on the crane. (2) When the crane is lifting a load, the operator should not derrick boom towards dangerous directions. Otherwise, the crane may topple over. (3) Raise boom a little when using derricking mechanism, then disengage the ratchet pawl from ratchet wheel using correct method. (4) Do not operate the derricking mechanism before the ratchet pawl is disengaged from ratchet wheel completely. (5) Only when the ratchet pawl engages with the ratchet tooth using ratchet wheel cylinder, can the operator press derricking ratchet switch to lock derricking winch.

ZCC800HWG.1 CRAWLER CRANE

4-45

Crane Operation

pawl is disengaged from ratchet wheel completely. Once ratchet wheel mechanism is activated,

Operator’s Manual for Crawler Crane

(6) If ratchet pawl is not disengaged from ratchet wheel completely, the operator must only spool up the derricking winch.

4.5.4 Operation of slewing mechanism a)

Components of slewing mechanism The slewing mechanism consists of piston hydraulic motor, planetary gear reducer, slewing brake valve, built-in brake, drive gear and slewing ring, etc. The superstructure can carry out 360°continuous rotation via the slewing ring which is driven by drive gear. Pinion gear of slewing reducer and large gear of slewing ring are meshed internally. The slewing speed can be adjusted by changing the inclination angle of control lever (No.1 in figure 4-2). An independent closed piston pump is applied to hydraulic system to supply oil. The slewing valve is load sensing proportional valve, which can adjust the slewing speed accurately.

b)

Operation of slewing mechanism Slewing operation can be achieved by controlling the slewing control lever (No. 1 in figure 4-2) on left control box in the operator’s cab. Put “Slewing brake switch” (No.1 in figure 4-3) in “ON” position before slewing operation, then slewing movement will be performed. If the switch is in “OFF” position, the slewing mechanism won’t work. Slew to right: put “Slewing brake switch” in “ON” position and push the control lever

Crane Operation

forwards. Slew to left: put “Slewing brake switch” in “ON” position and pull the control lever backwards. The slewing control lever adjustment range can vary from -26.5 to 26.5. The bigger the inclination angle is, the quicker the slewing speed is. After the slewing control lever is returned to neutral position, the slewing movement will stop.

CAUTION (1) If the crane is equipped with a slewing alarm (available as an optional function), an audible and optical signal will be sent out at the rear part of the slewing table when slewing. (2) A warning signal must be sent before the crane slewing. (3) Too fast slewing speed increases the risk of accidents. (4) Ensure that there are no obstacles in the crane slewing radius before slewing operation, otherwise, accidents may occur. (5) Longer boom - slower slewing speed; Heavier load - slower slewing speed;

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Operator’s Manual for Crawler Crane

(6) Inspect the levelness of the ground in the slewing range before slewing operation in crane lifting process. (7) It’s prohibited to use “Swing brake cylinder switch” as a switch to stop slewing operation. Push the control lever to neutral position slowly to stop slewing operation. c)

Fixing device for slewing table Procedure for fixation of slewing table: -

slew slewing table to front position

-

pull out slewing fixing pin

-

rotate the fixing pin for 180°

-

insert the fixing pin.

The sleeve of fixing device has upper position and lower position. When the fixing pin is inserted into lower position, slewing mechanism is locked; when it is inserted into upper position, the locked slewing mechanism is unlocked. Refer to figure 4-36.

Fixing device for slewing table

Crane Operation

Figure 4-36

7

CAUTION Put the fixing pin on upper position before crane operation; put it in lower position 6 work for after operation, and when the crane is in transport condition or it does not a long time. d)

Swing free3running If the load hook is not positioned vertically over the load’s center of gravity before lifting operation, the operator can open “Swing free running” switch (No. 8 in figure 4-2) to decrease the side force of the crane boom or press the “Swing free running” button when operating hoisting control lever. At this moment, the boom will enforce the slewing table, under the influence of side force of wire rope, to rotate toward the direction of load’s center of gravity till the hoisting wire rope is vertical. In this way, the boom can be protected against damage due to side force. When the hoisting wire rope is vertical, stop the above operation.

ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

CAUTION (1) When carrying out the movement “Swing free running”, operate control lever to lift hook at the same time. In this way, load hook will be pulled vertical to boom. (2) Operate stably when the crane is working. Jerky slewing movement stopping or changing direction may lead to accidents. (3) When the operator has to leave the machine in traveling, the crane does not work for a long time or other reasons, never rely solely on the slewing brake to lock the slewing mechanism. Even though the slewing brake is applied, the superstructure may still slew, because it is not a positioning lock. (4) Activating slewing brake switch to lock slewing mechanism abruptly should be avoided, since it may cause damage to the crane.

4.5.5 Simultaneous operation The following simultaneous operations are available such as simultaneous operation of slewing mechanism and derricking mechanism, simultaneous operation of slewing mechanism and hoisting winch 1, simultaneous operation of slewing mechanism and hoisting winch 2, simultaneous operation of slewing mechanism and travel gear, simultaneous operation of derricking mechanism and hoisting winch 1, simultaneous operation of slewing mechanism and hoisting winch 2. To achieve simultaneous movement, the operator only operates the relevant control lever of

Crane Operation

working mechanism. For the sake of safety, it’s suggested to operate at most two movements.

CAUTION (1) Jerky operation of control lever is not permitted during simultaneous operation or single operations. (2) It is prohibited to carry out simultaneous operation at high speed. (3) It is prohibited to carry out simultaneous operation with three or more than three movements.

4.5.6 Crawler carrier extending & retracting mechanism Crawler carrier extending & retracting mechanism consists of folding brackets, crawler carrier extending & retracting cylinder, crawler carrier, horizontal anchoring rods and inserting pin etc. The crawler carrier is connected to undercarriage central section through folding brackets. The extending and retracting of crawler carrier is achieved by the crawler carrier extending & retracting cylinder. The working mechanism is located at the front of the undercarriage central section, refer to figure 4-37.

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Operator’s Manual for Crawler Crane

Crawler carrier extending & retracting cylinder

Crawler carrier

Undercarriage central section

Horizontal anchoring rods

Indicating sign Undercarriage control lever

Figure 4-37

Procedure for extending and retracting crawler carrier 1)

Check the surrounding after the crane has reached jobsite to determine whether it is proper to extend the crawler carrier.

2)

Pull out four limit pin spindles between horizontal anchoring rods and the undercarriage central section to make sure the right and left crawler carriers can be 6 extended.

3)

Pull out the undercarriage control lever at the front of the undercarriage central section (refer to figure 4-37) manually. Make the horizontal cylinder work through changing the pressure oil circuit via direction change valve in the undercarriage central section.

4)

Operate the travel gear pedal (No. 4 in figurer 4-1) and extend and retract the crawler carrier through pressure oil in hydraulic system driving the cylinder.

5)

After the left and right crawler carrier has extended to required position, insert the limit pin spindle connecting the horizontal anchoring rods and undercarriage central section to make sure the crawler carrier and undercarriage central section are locked relatively.

6)

Push the pin spindle internally at the front of the undercarriage central section to make sure the travel motor is working.

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Crane Operation

a)

Crawler carrier extending & retracting mechanism

Operator’s Manual for Crawler Crane

The retracting of crawler carrier is similar with the above process, but the travel gear pedal direction should be carried out in reverse direction.

WARNING (1) In any cases, crawler carrier must be extended and retracted by more than two operators. During operation, one operator moves control lever, and the other checks whether the crawler carrier have extended/retracted to proper position. (2) Insert the limit pin spindles between the horizontal anchoring rods and crawler carrier of undercarriage central section after the crawler carrier extending & retracting cylinder is extended / retracted completely. (3) It is forbidden to extend/ retract crawler carrier when the crane is equipped with boom, counterweight or when it is lifting a load. (4) The engine speed must be controlled within middle-low speed (about 1000 - 1500 rpm) when crawler carriers are extended/retracted. (5) The extending or retracting of crawler carrier should be carried out on firm and flat ground. Much attention should be given to the level state of the machine during operation. (6) Do not lift a load until two crawler carriers are extended completely!

Crane Operation 4-50

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

4.6 Rope reeving 4.6.1 Hoisting rope guidance and reeving a)

Preparation 1)

Choose proper load hook according to operational planning and actual conditions.

2)

Choose a correct rope reeving in accordance with boom length shown in the table 2-5 of chapter 2.

b)

3)

The boom is placed straight ahead of the crane.

4)

An assistant is present to guide the hoisting rope.

Assembly procedure 1)

Place required hook block under the pulley block on the boom head with the help of an auxiliary crane.

2)

Remove the retaining springs, rope guard tube and rope lock from the pulley block on the boom head.

3)

Remove the retaining springs, rope guard tube and rope lock from the hook block.

4)

Start the crane and operate hoisting winch to unwind the hoisting rope, and then guide the hoisting rope to the boom head, finally reeve it between the pulley block and hook block.

5) c)

Reinsert the retaining springs and rope guard tubes.

Number of rope pulleys and available rope reeving 80t load hook, 6 rope pulleys, rope reeving: 12, 10,8;

2)

50t load hook, 3 rope pulleys, rope reeving: 7, 6, 5;

3)

30t load hook, 2 rope pulleys, rope reeving: 4, 3;

4)

16t load hook, 1 rope pulley, rope reeving: 2;

5)

8t load hook, without rope pulley, rope reeving:1

Crane Operation

1)

Rope reeving for different load hook is shown in the figures 4-38 to 4-42.

WARNING When the assistant guides the hoisting rope to the pulley block on the boom head, the crane operator must operate the hoisting winch. This procedure must be done in such a manner that the rope does not slacken up on the winding drum.

DANGER (1) Complete the assembly operation on a safe area! If it is unavoidable that the rope must be hand-guided over the boom to the pulley block on the boom head, proceed with great caution when walking on the boom. (2) There is a great danger of causing a serious accident if the crane function is not operated properly and the person guiding the rope slips on the boom.

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Operator’s Manual for Crawler Crane

Rope reeving: 10

Rope reeving: 12

Crane Operation 7

6 2 3 Rope reeving: 8 Figure 4-38

4-52

Reeving 80t load hook

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

Rope reeving: 7

Rope reeving: 6

Crane Operation

6 2 3 Rope reeving: 5 Figure 4-39

ZCC800HWG.1 CRAWLER CRANE

Reeving 50t load hook

4-53

Operator’s Manual for Crawler Crane

Rope reeving: 3

Rope reeving: 4 Figure 4-40

Reeving 30t load hook

Crane Operation

7

6 2 3

Rope reeving: 2 Figure 4-41

4-54

Reeving 16t load hook

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

Rope reeving: 1 Figure 4-42 d)

Reeving 8t load hook

Fixation of hoisting rope end point Step 1

Step 2

Step 3

Step 4

Crane Operation

7

Rope thimble

Rope lock

6 2 Rope end point

3

Rope clamp

6 Figure 4-43

ZCC800HWG.1 CRAWLER CRANE

Fixation of hoisting rope end point

4-55

Operator’s Manual for Crawler Crane

The rope end point must be fixed in accordance with the following steps: 1)

Step 1: insert wire rope into rope lock according to the direction as shown in the figure, and reserve a certain length of rope;

2)

Step 2: put wire rope around rope thimble and then insert them together into rope lock again;

3)

Step 3: pull down wire rope and rope end point, or knock rope lock upwards, to make wire rope fixed between rope lock and rope thimble closely;

4)

Step 4: fix wire rope with two rope clamps which match with rope diameter.

DANGER The pin spindle, which is used to connect rope lock and boom frame, must be inserted outwards from inside, and it must be secured at the outside with retaining pin, thus avoiding friction between hoisting rope and pin spindle (or retaining pin). e)

Attachment of hoisting limit switch weight Pin spindle and retaining pin

Rope lock and rope thimble Boom head

Rope clamp

Crane Operation

7

Chain and shackle Auxiliary load hook

6

2 3

Main load hook

Weight

Hoisting rope

Figure 4-44

4-56

Installation of hoisting limit switch weight

ZCC800HWG.1 CRAWLER CRANE

Operator’s Manual for Crawler Crane

Procedure for attaching hoisting limit switch weight as shown in the figure 4-44: -

Fix the weight ring at the outside of hoisting rope;

-

Insert the weight plate upwards from the bottom of weight ring until the mounting hole appears;

-

Remove the bolt of shackle at one end of chain, then pass the chain into the mounting hole, finally secure the chain with shackle;

-

Connect the other end of chain with the hoisting limit switch.

DANGER Risk of injury to feet! The hoisting limit switch weight consists of weight ring and weight plate. When detaching or attaching the weight, make sure that both parts remain inserted in each other and that weight does not fall down. Accident hazard! Incorrect rope reeving or incorrect number of reevings can lead to accidents. Make sure that the reeving process has been done properly and that the overload protection has been correctly set.

4.6.2 Derricking rope reeving As to derricking rope reeving, please refer to figure 4-45 and table 4-15.

Crane Operation

2 1

4, 5, 6

7

3

Figure 4-45

ZCC800HWG.1 CRAWLER CRANE

Derricking rope reeving

4-57

Operator’s Manual for Crawler Crane

Table 4-15

Parts used for derricking rope reeving

No.

Names of the parts

Remarks

1

Pin spindle

2

Retaining spring

3

Washer

4

Rope lock

5

Rope thimble

block. The method refers to fixation of hoisting rope

6

Rope clamp

end point.

7

Derricking rope

Connect derricking rope end and derricking crown block Secure pin spindle (1) Install between pin spindle and rope lock to avoid friction between them. Connect derricking rope end and derricking crown

The detailed parameters are shown in the table 2-6 of chapter 2.

CAUTION (1) When wire rope is wound onto the drum, it may lash out like a whip. Therefore, ensure that there is no loose rope on the winch. (2) Incorrect fixation of wire rope end point will decrease the performance of wire rope, even damage the wire rope.

Crane Operation 4-58

ZCC800HWG.1 CRAWLER CRANE

Operator’s履带起重机操作手册 Manual for Crawler Crane 第五章 安装说明and Dismantling Chapter 5 Assembly

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Chapter 5 Assembly and Dismantling 5.1 Safety-technical notes 5.1.1 Notes on assembly a)

Make sure that the crane complies with operating requirements. Then check the positions of A-frame, anchoring rod, FA-frame and assembly sequence of boom intermediate sections one by one according to combination mode of boom.

b)

Reeve the hoisting rope between the rope pulleys on the boom head and hook block in accordance with the corresponding hoisting rope reeving.

c)

Extend the crawler carrier to the required position, and assemble counterweight according to relevant requirements.

d)

Safe assembly platform must be used during crane assembly. Otherwise, there is a risk of falling down.

e)

Remove obstacles away from the ground on the site before assembling and dismantling. In addition, the ground on the site should be cordoned off to prevent access by unauthorized person.

f)

Choose a flat ground to raise the boom. The assembly of the boom must be carried out in front or at the rear side of the crane.

g)

Assemble the fixed jib strictly in accordance with the maximum permissible boom length.

h)

Do not use chains, hook or wire ropes to directly touch the chord member or web member of the boom. Instead, fix them to the hoisting pile of the boom sections by using protection pads or fiber woven sling before the lifting and installation work.

i)

Lattice components which are not in contact with the ground during assembly & disassembly must be supported by appropriate and stable objects.

j)

Make sure that no one is standing beneath the lattice boom when the lattice boom is pinned or unpinned.

Assembly and Dismantling

DANGER Before operating the slewing mechanism, pull out the slewing fixing pin.

5.1.2 Checking safety measures a)

Clearly define the duty and area of responsibility of all personnel concerned.

b)

Check whether the crane is adjusted to be horizontal.

c)

Check whether there is sufficient safety clearance to slopes and trenches.

d)

Check the voltage of electrical cables in vicinity of the working area. Make sure that there is enough distance between the crane and live-wire so that any components of the crane will not come into contact with the live-wire when crane movement is carried out.

ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

e)

Check whether an appropriate operating site has been selected so that the crane movements can be performed within maximum and minimum working radiuses.

f)

Check whether there are obstacles which will hinder required crane operation.

g)

Check whether sufficient load bearing capacity is available at the work site.

h)

Know clearly about the type of crane operation and operating mode.

i)

Check the distance between the lifting points and surrounding buildings.

j)

Influence of communal facilities on crane operation (including the overhead high/low voltage lines and underground gas pipes).

k)

Movement restrictions due to surrounding structures (e.g. is there another crane nearby in working).

l)

Number, weight, dimensions, material of load(s) to be lifted.

m) Required lifting height and slewing radius. n)

Heights and widths of thoroughfares leading to the site.

o)

Check the communication ways adopted by signalman and crane operator.

p)

Take appropriate measures to keep people and equipment unconcerned away from the danger area of the crane.

CAUTION To master the actual condition of lifting operation accurately and ensure safe operation, the safety measures mentioned above should be checked and a proper operational planning should be carried out.

5.1.3 Checking wire rope, load hook, rope pulley and anchoring rod a)

Checking wire rope The wire rope must be checked by an expert before assembly and checks must be performed at regular intervals in order to detect possible damage or wear and tear at an early stage.

Assembly and Dismantling

The wire rope must be removed immediately and replace it with a new one if any of the following damage is detected: (For details, please refer to the relevant chapter of Maintenance Manual.) 1)

Broken wires more than 10% of total wires of outer rope strand in one lay (which is the moving distance of rope strand when it rotates around the rope core a circle), or broken wire more than 20% of total wires of outer rope strand in five lays.

2)

Broken wires more than 5% of total wires of outer rope strand mainly in one strand, or in one position of rope.

3)

Broken wires or corrosive wires in the rope strands.

4)

Reduction from nominal rope diameter of 7%, or wire wear on the outer rope layer up to 4% of wire diameter.

5)

5-2

Broken strands.

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

6)

Deformation of wire rope such as kink, basket formation and birdcage.

7)

Other damage caused by overheating, improper connection and increase of permanent elongation.

The replaced rope must comply with the original rope’s specifications, including the elongation rate of rope length and diameter. The lowering limit switch must be readjusted if a new hoisting rope is used. Worn rope pulley must be repaired or changed prior to fitting a new hoisting rope. If this is not done, the new hoisting rope will be damaged. b)

Checking load hook 1)

Check load hook for deformation, e.g., at the hook jaw.

2)

Check all bolts and screws, and ensure all cotter pins are complete and open.

3)

Check whether the rotary connection of load hook moves easily, and ensure that the clearance is not too large.

4)

Check easy rotation of load hook. Rotate load hook by hand. If it is stiff, it indicates that the bearing is damaged.

5)

Check safety catch for completeness and functional work.

6)

Check load hook for corrosion and wear.

7)

For detailed information about inspection and maintenance for load hook, please refer to Maintenance Manual.

c)

Checking rope pulley 1)

Check rope pulley for damage and cracks.

2)

If rope pulleys are hit during crane operation (for example on buildings) or if they are subjected to other stress, they must be checked extensively.

3)

Check rope groove for wear. When rope groove has been worn down more than 1/4 of rope diameter, replace the pulley.

4)

Check the pulley of hoisting rope for damage or cracks. If any damage or cracks are found, replace the pulley immediately. If this is not observed, there is great danger of causing a serious accident! Check rope pulley for tight fit. Loose and shaken rope pulley indicates that the bearing or bearing bush is damaged. At this time, replace the pulley in time.

6)

For detailed information about inspection and maintenance for rope pulley, please refer to Maintenance Manual.

d)

Checking anchoring rod 1)

The anchoring rods must be secured firmly during transportation, and they must be placed flatly on the supports to avoid bending and deformation.

2)

Check anchoring rods for cracks, wear and corrosion.

3)

Check anchoring rods regularly.

4)

For detailed information about inspection and maintenance for anchoring rods, please refer to Maintenance Manual.

ZCC800HWG.1 CRAWLER CRANE

5-3

Assembly and Dismantling

5)

Operator’s Manual for Crawler Crane

5.1.4 Raising and lowering boom Before raising and lowering a boom combination, ensure that the following prerequisites are met: a)

The crane is properly supported and leveled.

b)

The counterweight plates have been attached on slewing table according to requirements.

c)

All limit switches have been correctly set and are fully operational.

d)

Main boom and fixed jib have been attached in accordance with Operating Plan and Operator’s Manual.

e)

All pinned connections have been secured.

f)

The hoisting rope has been correctly placed in the rope pulleys and it is prevented from jumping out of the rope groove via rope guard tubes.

g)

Ensure that wire rope end is firmly fastened by the rope clamps, and wire rope properly falls down on the web members of boom during boom raising and lowering.

h)

There are no loose components on main boom and fixed jib.

i)

In winter, main boom, fixed jib and associated parts (including limit switches, winding drums, warning light on the boom head etc.) must be kept free of ice and snow.

CAUTION Incorrectly fitted or faulty limit switches and falling parts (bolts, retaining spring, ice etc.) can cause injury.

Assembly and Dismantling 5-4

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.2 Unloading and assembly of basic machine According to relevant transport requirements and actual conditions, this crawler crane will be divided into several parts for transport. The basic machine mainly includes main boom pivot section (it may be removed from basic machine depending on the actual conditions), undercarriage central section, slewing table, left and right crawler carriers, A-frame, derricking pulley block and so on. The transport weight of basic machine is about 42t.

5.2.1 Unloading of basic machine 5.2.1.1 Checks before operation a)

Jobsite: -

The ground on the jobsite must be firm and flat. If necessary, the steel plates must be padded.

b)

The jobsite must be large enough for trailer traveling and auxiliary crane operation.

Check the operating procedure and safety regulations All operators must be familiar with operating procedure and safety regulations and clear about their areas of responsibility before operation.

c)

Check basic machine before operation.

5.2.1.2 Unloading of basic machine After the basic machine reaches the jobsite, remove fixing devices and the package. The removal of slewing fixing device is shown in the section 4.5.4 of chapter 4.

Assembly and Dismantling

Figure 5-1

ZCC800HWG.1 CRAWLER CRANE

Unloading of basic machine

5-5

Operator’s Manual for Crawler Crane

Slew the superstructure for 180°, move the basic machine down off the low-loader. At this time, the speed of left travel gear should be kept the same as that of right travel gear as possible as you can so as to prevent basic machine from overturning on the low-loader. Please see the figure 5-1. The basic machine can also be lifted off the low-loader by the use of an auxiliary crane.

5.2.2 Assembly of basic machine

Assembly and Dismantling Figure 5-2

5-6

Assembly of A-frame on the basic machine

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

As shown in the figure 5-2, spool up derricking winch until the locking pin for main boom tilting-back support can be inserted into the pin hole. At this time, main boom is raised to 65° position. Remove the pin spindle between A-frame rear anchoring rods and slewing table, and continue to spool up derricking winch to raise main boom. When A-frame rear anchoring rods are vertical, insert the pin spindle to connect the upper anchoring rod and lower anchoring rod. Continue to spool up derricking winch until A-frame rear anchoring rods can be aligned with the pin hole at the rear side of slewing table. Insert the pin spindle and secure it with retaining pin. After A-frame is assembled on the basic machine, remove the locking pin from main boom tilting-back support.

CAUTION The locking pin for main boom tilting-back support can only be inserted when assembling A-frame. It must not be inserted in working position of main boom tilting-back support.

DANGER (1) Before transportation, retract the crawler carrier, lay down A-frame onto slewing table and place main boom pivot section flatly, and finally lock the slewing mechanism by slewing fixing pin. (2) When drive the basic machine off or onto to the low-loader, a steel plate (with an inclination less than or equal to 8° to the ground) should be used to connect the low-loader and the ground. At this time, main boom pivot section must be kept at 30°position in order to protect the crane against overturning. (3) The slewing fixing pin must be unpinned prior to operating the slewing mechanism. Otherwise, the slewing fixing device and slewing reducer may be damaged.

Assembly and Dismantling

ZCC800HWG.1 CRAWLER CRANE

5-7

Operator’s Manual for Crawler Crane

5.3 Assembly of rear counterweight The crane counterweight, weighting 27t in total, consists of a 2.7t counterweight base plate, four 3.825t counterweight plates and two 4.5t central counterweight plates. During working, all counterweight plates must be fixed on the tail end of slewing table. Before assembly of counterweight, ensure that the crawler carriers are extended completely. In addition, for the purpose of crane stability, it is suggested that the boom sections are connected well prior to assembly of counterweight. Procedure for assembly of counterweight (refer to figure 5-3): -

Unload the counterweight plates with the help of auxiliary crane from the transport vehicle, and then put them on the ground.

-

Pile the counterweight plates one by one on the required position of slewing table.

-

Secure the counterweight plates with locking bolts and nuts.

The dismantling of counterweight is carried out exactly in reverse order of assembly.

Assembly and Dismantling Figure 5-3

5-8

Assembly of rear counterweight

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

WARNING (1) During assembly of counterweight, observe correct assembly sequence, and distinguish the front counterweight plate from the rear one. (2) Do not assemble and dismantle the counterweight before the crawler carriers are extended to specified position. Generally speaking, the distance between track centre will reach 4.2m when the crawler carriers have been extended completely. (3) In any conditions, the assembly and dismantling of counterweight must be done by more than two persons.

Assembly and Dismantling

ZCC800HWG.1 CRAWLER CRANE

5-9

Operator’s Manual for Crawler Crane

5.4 Installation of undercarriage wedge block 5.4.1 Description of undercarriage wedge block The undercarriage wedge block is mainly used to fill up the clearance between undercarriage central section and crawler carriers. Its structure is shown in the figure 5-4. Due to different manufacturing errors, the thickness of wedge block varies. Before the crane leaves the factory, proper wedge blocks have been outfitted according to the actual clearance, and they are fixed at both front and rear of the undercarriage central section. The position of wedge block for storage is shown in the figure 5-5.

Figure 5-4

Structure of undercarrigage wedge block

Storage position

6

Assembly and Dismantling 6 Storage position

Figure 5-5

5-10

Storage position of undercarriage wedge block

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

CAUTION During transportation, the wedge blocks must be fixed in the proper positions of undercarriage central section for their installation. Both front and rear of undercarriage central section are outfitted with two wedge blocks. They are not interchanged at will.

5.4.2 Installation of undercarriage wedge block 5.4.2.1 Status of basic machine during installation of undercarriage wedge block a)

Basic machine is fitted with main boom pivot section and rear counterweight, and center of gravity of superstructure approaches the rear side of slewing table at this time.

b)

Crawler carriers have been extended completely and the distance between track centre reaches 4.2m at this time.

c)

The ground is flat without obvious gradient.

During operation, the wedge blocks are installed between undercarriage central section and crawler carriers to adjust the clearances. The installation position of wedge block is shown in the figure 5-6.

Storage position

Installation

6

Figure 5-6

Storage and installation positions of undercarriage wedge block

ZCC800HWG.1 CRAWLER CRANE

5-11

Assembly and Dismantling

position

Operator’s Manual for Crawler Crane

5.4.2.2 Installation of undercarriage wedge block Installation principle: exert pressure on the installation position of wedge block by use of crane superstructure weight to maximize the clearance as possible as you can, and then install undercarriage wedge block. Taking the installation of undercarriage wedge block at left rear side of undercarriage central section as example, show the installation procedure: a)

Confirm that the basic machine satisfies the installation requirements mentioned above.

b)

Slew the superstructure until its central axis passes the wedge block at the left rear side of undercarriage central section. Please see the figure 5-7.

Figure 5-7 c)

Installation of left rear wedge block

The left rear side of undercarriage central section is pressed down to the limit position by 6 the weight of superstructure, so the clearance between upper part of undercarriage central section and crawler carrier reaches the maximum. At this time, install the corresponding wedge block and secure it with bolts. Please see the figure 5-8.

Assembly and Dismantling Figure 5-8

5-12

Installation of left rear wedge block

6 CRAWLER CRANE ZCC800HWG.1

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

d)

Slew the superstructure to the right rear side of undercarriage central section, and then install the wedge block in this position in the same way. Please see the figure 5-9.

6

Figure 5-9

e)

Installation of right rear wedge block

Slew the superstructure a circle to install four wedge blocks. When removing the wedge block, it must be taken off from the installation position and secure the corresponding position behind the wedge block with bolts.

Assembly and Dismantling

ZCC800HWG.1 CRAWLER CRANE

5-13

Operator’s Manual for Crawler Crane

5.5 Available boom configurations Available boom configurations for ZCC800H crawler crane is shown in the figure 5-10. They will be described in the table 5-1. Table 5-1 Configuration no.

Available boom configurations for ZCC800H crawler crane

Description

Parameters

Remarks Main boom is fitted with tip

S-1

Main boom

Main boom: 13m-58m

boom, and the load can be attached onto main boom or tip boom.

SF-1

S-2

SF-2

Main boom with

Main boom: 37m-49m

The load is attached onto fixed

fixed jib

Fixed jib: 6m-18m

jib.

Main boom with

Main boom: 37m-49m

fixed jib

Fixed jib: 6m-18m

Main boom with

Main boom: 37m-49m

fixed jib

Fixed jib: 6m-18m

Both main boom and fixed jib are fitted with a load hook, but only main boom lifts the load. Both main boom and fixed jib are fitted with a load hook, but only fixed jib lifts the load.

Assembly and Dismantling 6 S-1

SF-1 Figure 5-10

5-14

S-2

SF-2

Available boom configurations

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.6 Boom configurations and anchoring rods combination 5.6.1 Main boom configuration 5.6.1.1 Components of main boom Main boom, whose length varies from 13m to 58m, is comprised of basic boom and main boom intermediate sections. The basic boom is 13m long, including main boom pivot section, main boom head and tip boom. There are three kinds of main boom intermediate section: 3m main boom intermediate section, 6m main boom intermediate section and 9m main boom intermediate section. The connecting parts of main boom are shown in the figure 5-11, and they will be described in the table 5-2. The assembly of main boom is shown in the figure 5-11, and they will be described in the table 5-3.

7, 8, 9 6, 4 G12

5, 4 3, 4 G15 G10

6

Assembly and Dismantling

G14 1, 2

G13

G11

Figure 5-11

ZCC800HWG.1 CRAWLER CRANE

Assembly of main boom

5-15

Operator’s Manual for Crawler Crane

Table 5-2 No.

1

2

Names of the parts

Pin spindle

Retaining spring (D40,45)

Connecting parts of main boom

ID code

00663000100001031

006340000001

Assembly and Dismantling

3

Pin spindle

00663020100001010

4

Retaining pin

00663300100001230

5

Pin spindle

00663000100001162

6

Pin spindle

00663020100001040

5-16

Illustration

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-2 No.

Names of the

Connecting parts of main boom ID code

parts

7

Rope lock

1090100448

8

Rope thimble

1090100455

9

Rope clamp

1090100022

Table 5-3 Code

Illustration

24 (GB5976-1986)

Description of main boom components

Names of the components

ID code

Length

Weight

Tip boom

00663050100600001

1m

0.13t

G11

Main boom pivot section

00663050100200000

6.5m

0.95t

G12

Main boom head

00663050100400001

6.5m

1.2t

00663050100800000

3m

0.26t

00663050101000000

6m

0.44t

00663050101200000

9m

0.63t

G13

G14

G15

3m main boom intermediate section 6m main boom intermediate section 9m main boom intermediate section

When different length of main boom is required, the crane operator only needs to disconnect main boom pivot section from main boom head, and then install main boom intermediate sections between them. In this way, main boom can be assembled to required length. The assembly of main boom is shown in the table 5-4.

ZCC800HWG.1 CRAWLER CRANE

5-17

Assembly and Dismantling

G10

Operator’s Manual for Crawler Crane

Table 5-4

Assembly of main boom

Main boom

Assembly sequence of

Main boom

Assembly sequence of main

length

main boom sections

length

boom sections

13m

G11+G12

37m

G11+G14+G15×2+G12

16m

G11+G13+G12

40m

G11+ G13+G14+G15×2+G12

19m

G11+G14+G12

43m

G11+G13+G15×3+G12

22m

G11+G13+G14+G12

46m

G11+G14+G15×3+G12

25m

G11+G13+G15+G12

49m

G11+ G13+G14+G15×3+G12

28m

G11+G14+G15+G12

52m

G11+G13+G15×4+G12

31m

G11+G13+G14+G15+G12

55m

G11+G14+G15×4+G12

34m

G11+G13+G15×2+G12

58m

G11+G13+G14+G15×4+G12

DANGER Principle for assembling main boom: when connecting main boom intermediate sections to main boom pivot section, always bolt the shortest intermediate section first. Main boom of different length can be assembled according to the following figures: G10 G10 G12

G10 G12

G10 G12

G15 G12

G13

Assembly and Dismantling

G11

13m

G11

16m Figure 5-12

5-18

G14

G11

19m

G11

22m

Assembly of main boom

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

G10 G10 G12

G10 G12

G10 G12

G15

G12 G15 G15

G15

G15 G14 G14

G13

G13

过

G11

G13 G11

G11

卷开 25m

关和

28m

31m

重锤

34m G10

太 G10

阳能 G10

报警 G10

G12 G12

灯 风 G12

G15

速传

G12

G15

感器 G15

G11

G15

G15 G15

Assembly and Dismantling

G15 G15

G15

6

G15 G15 G14

G11

37m

G11

G11

40m Figure 5-13

ZCC800HWG.1 CRAWLER CRANE

G14

G13

43m

G11

46m

Assembly of main boom

5-19

Operator’s Manual for Crawler Crane

G10 G10 G12

G10 G12

G10 G12

G15

G12 G15 G15

G15

G15 G15 G15 G15

G15 G15 G15

G15

G15 G15 G15 G14

G15

G14

G13 G11

49m

G13

G11

52m Figure 5-14

G11

55m

G11

58m

Assembly of main boom

Assembly and Dismantling

5.6.1.2 Combination of main boom anchoring rods Principle for determining the length of main boom anchoring rods: When basic boom is 13m long, the length of anchoring rods must be 6.22m. When main boom length increases by 3m, two 0.3m-long double-anchoring rods and two 2.7m-long single-anchoring rods must be added accordingly. When main boom length increases by 6m, two 0.3m-long double-anchoring rods and two 5.7m-long single-anchoring rods must be added accordingly. When main boom length increases by 9m, four 0.3m-long double-anchoring rods, two 2.7m-long single-anchoring rods and two 5.7m-long single-anchoring rods must be added accordingly. 6

5-20

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

a)

The components of main boom anchoring rods are shown in the figure 5-15, and they will be described in the table 5-5. The unit in the following figure is given in mm.

To main boom head

1, 2

3

4

5

6

Assembly and Dismantling

7

Figure 5-15

ZCC800HWG.1 CRAWLER CRANE

Combination of main boom anchoring rods

5-21

Operator’s Manual for Crawler Crane

Table 5-5 No.

Names of the components

Components of main boom anchoring rods ID code

1

Pin spindle

00663005400201022

2

Retaining pin

00663065400201010

3

4

5

Assembly and Dismantling

6

7

5-22

Double-anchoring rod

Single-anchoring rod

Reducing anchoring rod

Single-anchoring rod

Single-anchoring rod

Illustration

00663025400210000

00660515400001030

00663055400210000

00663025400201020

00663025400201010

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

b)

The combination of main boom anchoring rods for different main boom length is shown in the following figures. The unit in the following figures is given in mm.

Assembly and Dismantling

13m

Figure 5-16

16m

19m

22m

25m

Combination of main boom anchoring rods for different main boom length

ZCC800HWG.1 CRAWLER CRANE

5-23

Operator’s Manual for Crawler Crane

Assembly and Dismantling 28m Figure 5-17

5-24

31m

34m

37m

40m

43m

Combination of main boom anchoring rods for different main boom length

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Assembly and Dismantling

46m Figure 5-18

49m

52m

55m

58m

Combination of main boom anchoring rods for different main boom length

ZCC800HWG.1 CRAWLER CRANE

5-25

Operator’s Manual for Crawler Crane

5.6.2 Main boom with fixed jib configuration 5.6.2.1 Components of main boom with fixed jib Main boom with fixed jib configuration are composed of main boom and fixed jib. Main boom length varies from 37m to 49m and fixed jib length varies from 6m to 18m. Fixed jib consists of fixed jib pivot section (G31), fixed jib head (G32) and fixed jib intermediate section (G33). Both fixed jib pivot section and fixed jib head are 3m long, while fixed jib intermediate section is 6m long. The fixed jib can be mounted in the angle of either 10°or 30° to main boom. When different length of fixed jib is required, the operator only needs to disconnect fixed jib pivot section from fixed jib head, and then install fixed jib intermediate sections between them. In this way, the fixed jib can be assembled to required length. Main boom sections in this boom configuration are bolted together in the same way as that in main boom configuration. The connecting parts of fixed jib are shown in the figure 5-19, and they will be described in the table 5-6. The assembly of main boom is shown in the figure 5-19, and they will be described in the tables 5-7 and 5-8.

Fixed jib front anchoring rods G32

G37

G34 G74

Fixed jib rear anchoring rods

G75

G31 1, 2 3, 4, 5, 6

Assembly and Dismantling Figure 5-19

5-26

Assembly of fixed jib

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-6 No.

1

Names of the

Connecting parts of fixed jib

ID code

parts

Pin spindle

Illustration

00663000200001022

Retaining 2

spring

006340000029

(D30,32,35)

GB/T5783-2000

3

Bolt

1040000108

4

Washer

1040300054

GB/T93-1987

006340000019

PD0406

5

6

Retaining plate

60

Pin spindle

00663050200001010

Table 5-7

Description of fixed jib components

Names of the components

ID code

Length

Weight

G31

Fixed jib pivot section

00663020200200000

3m

0.18t

G32

Fixed jib head

00663050200400000

3m

0.21t

00663020200600000

6m

0.17t

00663027800000000

3m

0.26t

00663003100600001

1.6m-2.8m

0.05t

00663050101200000

1.5m-2.33m

0.04t

G34 G37 G74 G75

6m fixed jib intermediate section FA-frame Front tilting-back support of fixed jib Rear tilting-back support of fixed jib

ZCC800HWG.1 CRAWLER CRANE

5-27

Assembly and Dismantling

Code

(ISO4017-1999)

Operator’s Manual for Crawler Crane

Table 5-8

Assembly of fixed jib

Fixed jib

Assembly sequence of fixed

Fixed jib

Assembly sequence of fixed

length

jib sections

length

jib sections

6m

G31+G32

18m

12m

G31+G34+G32

G31+G34×2+G32

The assembly of fixed jib of different length is shown in the figure 5-20.

G32

G34 G32 G74 G34 G37

G34

G32 G31

G31

G31

G75

Figure 5-20

Assembly of fixed jib

Assembly and Dismantling 5-28

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.6.2.2 Combination of fixed jib anchoring rods a)

Combination of fixed jib rear anchoring rods When fixed jib is mounted in the angle of 10º to main boom, fixed jib rear anchoring rods is 7.16m long. When fixed jib is mounted in the angle of 30º to main boom, fixed jib rear anchoring rods is 8.06m long. At this time, two 0.3m-long double-anchoring rods (part 3 in the figure 5-21) and two 0.6m-long single-anchoring rods (part 6 in the figure 5-21) are added correspondingly. The components of fixed jib rear anchoring rods are shown in the figure 5-21, and they will be described in the table 5-9. The unit in the following figure is given in mm. To FA-frame 1, 2 3

4 5, 6 7

8

9

3

Assembly and Dismantling

10

11

Figure 5-21

ZCC800HWG.1 CRAWLER CRANE

Combination of fixed jib rear anchoring rods

5-29

Operator’s Manual for Crawler Crane

Table 5-9 No.

Names of the components

Components of fixed jib rear anchoring rods ID code

1

Pin spindle

00663025400401010

2

Retaining pin

00663065400201010

3

4

Double-anchoring rod

Reducing anchoring rod

00663025400410000

00663025400420000

Assembly and Dismantling

5

Pin

1040500173

6

Pin spindle

00663015410401050

7

Reducing piece

00663025400401050

5-30

Illustration

GB/T91-2000/6.3×80

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-9 No.

8

9

10

11

Names of the components Double-anchoring rod

Coupling link

Single-anchoring rod

Single-anchoring rod

Components of fixed jib rear anchoring rods ID code

Illustration

00663025400430000

00663025400440000

00663025400401030

00663025400401040

Assembly and Dismantling

ZCC800HWG.1 CRAWLER CRANE

5-31

Operator’s Manual for Crawler Crane

b)

Combination of fixed jib front anchoring rods When fixed jib is 6m long, fixed jib front anchoring rods is 6.34m. When fixed jib increases by 6m, two 0.3m-long double-anchoring rods (part 3 in the figure 5-22) and two 5.46m-long single-anchoring rods (part 4 in the figure 5-22) are added correspondingly. The components of fixed jib front anchoring rods are shown in the figure 5-22, and they will be described in the table 5-10. The unit in the following figure is given in mm.

1, 2 3

4

3

5

Assembly and Dismantling To FA-frame

Figure 5-22

5-32

Combination of fixed jib front anchoring rods

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-10 No.

Names of the components

Components of fixed jib front anchoring rods ID code

1

Pin spindle

00663025400401010

2

Retaining pin

00663065400201010

3

4

5

Double-anchoring rod

Plate

Single-anchoring rod

Illustration

00663025400410000

00663025400601010

00663025400601030

Assembly and Dismantling

ZCC800HWG.1 CRAWLER CRANE

5-33

Operator’s Manual for Crawler Crane

The combination of fixed jib front anchoring rods of different length is shown in the figure 5-23.

6m

Figure 5-23

12m

18m

Combination of fixed jib front anchoring rods

Assembly and Dismantling 5-34

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.7 Assembly and dismantling of main boom 5.7.1 Preparation for assembly a)

Choose an appropriate boom combination and corresponding anchoring rod combination in accordance with operational planning and lifting capacity charts.

b)

Choose appropriate load hook and rope reeving in accordance with rope reeving plan and working requirements.

c)

Assemble counterweight according to relevant requirements.

d)

Make sure that an auxiliary crane is available and operating personnel get full prepared for the operation.

CAUTION (1) For assembly work on the crane, a safe assembly working platform should be used. Improvisations are prohibited. Otherwise, there is a danger of falling down. (2) It is prohibited to use any other boom configurations and anchoring rod combination that have not been stipulated in the Operator’s Manual. (3) When connecting main boom intermediate sections to main boom pivot section, always bolt the shorter intermediate sections first. (4) If the boom head is lifted by an auxiliary crane, at least two pieces of lifting chain with a breaking force ≥5t should be used. (5) Do not stand on the lattice boom when it is assembled. (6) Do not stand beneath the boom when it is being pinned or unpinned. (7) Do not put squared timbers or pad blocks under the middle position of main chord and web members. Otherwise, the boom sections will be damaged.

5.7.2 Assembly of main boom After unloading the basic machine and fitting the counterweight plate, assemble such

5.7.2.1 Attachment of main boom sections a)

Preassemble main boom sections according to section 5.6.1. For detailed operation, refer to the following methods: -

Bolt main boom intermediate sections of 3m, 6m or 9m to each other in the following sequence: Position two intermediate sections to be bolted in such a way that the connection holes in one intermediate section are precisely aligned with those in another intermediate section (see the figure 5-24). Join them with pin spindles (1) and secure the pin spindle with retaining springs (2). Note: the other connecting holes are joined in the same way.

ZCC800HWG.1 CRAWLER CRANE

5-35

Assembly and Dismantling

components as boom sections and anchoring rods according to working requirements.

Operator’s Manual for Crawler Crane

9m main boom intermediate section

6m main boom intermediate section 3m main boom intermediate section

Retaining spring 2

Pin spindle 1

Figure 5-24 -

Connecting main boom intermediate sections

Bolt main boom head with assembled intermediate section in the following sequence: Position the assembled intermediate section in such a way that the upper connecting holes in it are aligned with those in the boom head. Join the upper connecting holes with pin spindles and secure them with retaining springs. Join the lower connecting holes in the same way. Insert two pin spindles into upper connecting holes

Assembly and Dismantling

Main boom intermediate section Main boom head

Figure 5-25

5-36

Connecting main boom intermediate section to main boom head

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

b)

Slowly drive the basic machine with main boom pivot section attached to the preassembled main boom. Adjust derricking winch in such a way that the upper connecting holes in main boom pivot section are aligned with those connecting holes in adjacent main boom intermediate section. Join the upper connecting holes with pin spindles (1) and secure properly with retaining springs (2) on two sides. Operate derricking winch to adjust the derricking rope (or lift the main boom intermediate section with the help of an auxiliary crane) until the lower connecting holes in main boom pivot section are aligned with those connecting holes in adjacent main boom intermediate section. Join the lower connecting holes with pin spindles (1) and secure properly with retaining springs (2) on two sides. Detach the anchoring rod of derricking pulley block from the main boom pivot section. Refer to figure 5-26.

First insert pin spindles into upper connecting holes, and then into lower connecting holes.

Figure 5-26

Connecting assembled main boom intermediate section to pivot section

The following parts are used during assembly of main boom.

No.

1

2

Names of the parts

Pin spindle

Retaining spring (D40,45)

ZCC800HWG.1 CRAWLER CRANE

Parts used for assembly of main boom ID code

Assembly and Dismantling

Table 5-11

Illustration

00663000100001031

006340000001

5-37

Operator’s Manual for Crawler Crane

WARNING (1) The connecting pin must always be fitted from outside inwards during assembly. And they must be greased. (2) It is prohibited to put hand or fingers into the connecting hole during assembly. (3) Do not stand beneath or in the boom when it is being pinned or unpinned. Do not climb up the boom, and stand or walk on the boom. (4) Utilize a ladder or other similar tools to carry out assembly operation.

5.7.2.2 Assemble main boom anchoring rods and reeve in hoisting rope a)

According to the principle for combination of main boom anchoring rods, connect main boom anchoring rods from main boom head in turn, and secure them with pin spindles and retaining pins (For detailed operation, refer to section 5.6.1.2 “Combination of main boom anchoring rods”). Detach single anchoring rods of derricking traveling block from connecting holes in main boom pivot section, and then connect single anchoring rods of derricking traveling block to main boom double anchoring rods. See the figure 5-27.

First insert the pin spindles into upper connecting holes, and then insert the pin spindles into lower connecting holes

Assembly and Dismantling

Figure 5-27 Connecting main boom pivot section to assembled main boom intermediate section b)

Operate hoisting winch 1 control lever to reel off hoisting winch 1, and pull the hoisting rope manually to main boom head, then reserve a certain length of rope for load hook reeving. See the figure 5-28.

5-38

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Figure 5-28 c)

Rope reeving

Pull derricking winch control lever backwards to spool up derricking winch until main boom head is raised by the derricking rope to a proper position a little higher than the load hook. See the figure 5-29.

Figure 5-29 d)

Rope reeving

Position the load hook directly under main boom head, and then reeve the hoisting rope between hook block and rope pulley on main boom head in accordance with rope reeving plan, finally secure the rope end point with rope lock and rope thimble. See the figure 5-30.

Assembly and Dismantling

Figure 5-30

Rope reeving

CAUTION The worker who guides wire rope to main boom head should take great care to prevent himself against falling down when walking on the boom frame. Otherwise, serious accident may occur.

ZCC800HWG.1 CRAWLER CRANE

5-39

Operator’s Manual for Crawler Crane

5.7.3 Electrical connection to main boom 5.7.3.1 Wire layout of main boom The electrical elements of main boom are shown in the figure 5-31.

Cable drum assy.

Wind speed sensor Solar lamp

Hoisting limit switch and weight

Figure 5-31

Electrical elements of main boom

Unplug the cable plug of main boom cable drum, pull the cable plug along the main boom, fix every section with rope clamps, and then insert it into the corresponding socket on the main boom junction box. Establish the electrical connection from the junction box on the boom head to the associated electrical elements respectively. See the figure 5-32.

To cable plug

A view Hoisting Anemometer limit for H1

To fixed jib junction box

Assembly and Dismantling Hoisting limit for H2 A view

Figure 5-32

5-40

Wire layout of main boom junction box

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.7.3.2 Function check Insert the ignition key into the key hole, and then turn it clockwise to the first position to switch on the power. After that, perform the following checks. a)

Check anemometer One person rotates the vane of anemometer quickly by hand, and the other checks whether there is the wind speed value shown on the screen in the cab.

b)

Check warning light on the boom head The warning light is a kind of solar lamp. Switch on the solar lamp control switch, and cover the solar lamp with a cover with weak transparency to check whether the warning light glows.

c)

Check hoisting limit switch for H1 Support and hold the hoisting limit switch weight for H1 to ensure that the switch is triggered, and then check whether the icon “upper limit switch on H1” on the screen will flash and the buzzer will sound.

d)

Check hoisting limit switch for H3 Support and hold the hoisting limit switch weight for H3 to ensure that the switch is triggered, and then check that the icon “upper limit switch on H3” on the screen will flash and the buzzer will sound.

5.7.4 Raising main boom 5.7.4.1 Prerequisites a)

The crane is properly supported and leveled.

b)

The counterweight plates have been attached.

c)

Select appropriate boom configurations according to the load to be lifted and the load capacity charts as well as lifting height. Ensure that boom sections have been connected and secured. All limit switches have been correctly fitted and are fully operational.

e)

All pinned connections have been secured.

f)

The hoisting rope is properly placed in the rope pulleys, and is secured with rope guard tubes against jumping out from rope groove.

g)

No person is present in the danger zone.

h)

There are no loose parts on main boom.

i)

In winter, main boom and associated components (limit switches, cable drums, warning light on boom head, anemometer etc.) must be kept free of ice and snow.

DANGER Faulty limit switches and falling parts can cause injuries.

ZCC800HWG.1 CRAWLER CRANE

5-41

Assembly and Dismantling

d)

Operator’s Manual for Crawler Crane

5.7.4.2 Raising main boom -

Set “main boom” configuration in the load moment limiter.

-

Pull derricking winch control lever backwards to spool up derricking winch so that main boom anchoring rods is tensioned gradually.

-

Continue to wind derricking rope to raise main boom.

-

When main boom is raised to required working position, return the derricking winch control lever to neutral position to stop the movement. (see the figure 5-33)

During boom-raising process, the operator must unwind the hoisting rope properly to ensure that the load hook is placed in a proper position.

Assembly and Dismantling Figure 5-33

5-42

Raising main boom

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

CAUTION (1) Main boom angle can be changed between 0°to 80°. When main boom is raised to 78° position, acoustic warning will be given, but main boom can still be raised. However, when main boom is raised to 80°position, the movement of raising boom will be switched off automatically along with alarm being sent out. At this time, only lowering the boom is permitted. (2) Always monitor the wire rope in the process of raising main boom to make sure that the wire rope is kept in the rope groove all the time. (3) Ensure that the load hook is still in contact with the ground before the boom angle reaches 30°. (4) The boom-raising movement should be performed slowly and stably. And during the operation, the crane operator must observe the data shown on the screen, while other workers should pay attention to environmental changes. (5) Standing beneath the boom frame is prohibited. (6) Working radius stipulated in the lifting capacity charts should be adhered to, even if no load is attached on the load hook! Non-observance of it is likely to cause the crane turn over.

5.7.5 Lowering and dismantling main boom 5.7.5.1 Lowering main boom -

Push derricking winch control lever forwards to reel off derricking winch, and main boom will be lowered gradually.

-

Make load hook come into contact with the ground first.

-

Continue to reel off derricking winch until main boom head is lowered on the ground.

-

Move derricking winch control lever to the neutral position to stop operation.

(1) During boom-lowering process, reel off hoisting winches 1 and 2 to prevent the load hook against collision with main boom head. (2) It is prohibited to stand within an area where the crane movement is carried out. (3) The boom-raising movement should be performed slowly and stably. And during the operation, the crane operator must observe the data shown on the screen, while other workers should pay attention to environmental changes.

ZCC800HWG.1 CRAWLER CRANE

5-43

Assembly and Dismantling

CAUTION

Operator’s Manual for Crawler Crane

5.7.5.2 Dismantling boom sections and anchoring rods a)

After lowering the anchoring rods down on the nylon supports on the relevant boom sections, dismantle the anchoring rod connecting spindle and then secure each anchoring rod on the boom frame with pin spindles for transportation.

b)

Separate boom sections using an auxiliary crane.

c)

Lower A-frame onto the slewing table.

CAUTION (1) Dismantling of boom sections and anchoring rods is carried out in the reverse order to assembly. (2) Warnings and safety precautions for assembly must be followed during dismantling operation.

Assembly and Dismantling 5-44

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.8 Assembly and dismantling of main boom with fixed jib 5.8.1 Preparation for assembly a)

The crane is properly supported and leveled.

b)

Main boom has been installed.

c)

The counterweight plates have been assembled.

d)

An auxiliary crane as well as an assembly working platform is available.

e)

The safe load indicator system of load moment limiter is set according to the data given in the lifting capacity charts.

f)

Choose appropriate boom configuration and relevant anchoring rod combinations according to operational planning.

DANGER (1) For assembly work on the crane, a safe assembly working platform should be used. Improvisations are prohibited. Otherwise, there is a danger of falling down. (2) Do not stand beneath the boom when it is being pinned or unpinned.

5.8.2 Assembly of fixed jib During transportation, fixed jib pivot section (G31), FA-frame (G37), front tilting-back support of fixed jib (G74) and rear tilting-back support of fixed jib (G75) are assembled together. See the following figure. G37

G75

Assembly and Dismantling

G74 G31

Figure 5-34

ZCC800HWG.1 CRAWLER CRANE

Fixed jib pivot section assy.

5-45

Operator’s Manual for Crawler Crane

Procedure for assembly of fixed jib: -

Assemble required main boom sections (for the details, see Section 5.7).

-

Lift fixed jib pivot section assy. with the help of an auxiliary crane until it is aligned with main boom head. Then connect fixed jib pivot section assy. to main boom head with pin spindles (6) and secure them with locking plates (5), washers (4) and bolts (3). See the figure 5-35.

6 5 4

3

Assembly and Dismantling

Figure 5-35 -

Assembly of fixed jib

According to actual conditions, choose appropriate number of 6m fixed jib intermediate sections and assemble them together. All fixed jib intermediate sections are connected with double tapered pins (1), secured on both sides with retaining springs (2) as follows:

5-46

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

G32

G34 1

2

G31

Figure 5-36

Assembly of fixed jib

The parts mentioned in the figures 5-35 and 5-36 are described in the table 5-6. -

Connect main boom anchoring rods according to the length of assembled main boom (for the details, see the section 5.6.1). Pre-assemble some fixed jib rear anchoring rods to FA-frame according to required fixed jib angle (for the details, see the section 5.6.2). Connect fixed jib front anchoring rods according to the length of assembled fixed jib (for the details, see Section 5.6.2).

-

Lift FA-frame backwards using an auxiliary crane until the fixed jib front anchoring rods is tensioned. spindle (7) and secure the pin spindle with pin (8). Put one end of rear tilting-back support of fixed jib (G75) on main boom head temporarily. Connect fixed jib rear anchoring rods to main boom head in accordance with fixed jib angle. See the figure 5-37.

ZCC800HWG.1 CRAWLER CRANE

5-47

Assembly and Dismantling

Joint one end of front tilting-back support of fixed jib (G74) to fixed jib pivot section with pin

Operator’s Manual for Crawler Crane

7, 8

Figure 5-37 -

Assembly of fixed jib

Push hoisting winch 2 control lever forwards to unwind the hoisting rope, and then pull the rope forwards onto the rope pulley at the fixed jib head via the rope pulley on the FA-frame, reserve a certain length of rope for reeving load hook.

-

Pull derricking winch control lever backwards to spool up derricking winch. When main boom is raised to a proper position, connect rear tilting-back support of fixed jib (G75) to main boom head with pin spindle (9) and secure the pin spindle with pin (10). Adjust the mounting position of pin spindle on the tilting-back support (G75) to allow the length of tilting-back support to proper position and tension the fixed jib rear anchoring rods. Please see the figure 5-38 and the table 5-11.

Assembly and Dismantling 9, 10

Figure 5-38

5-48

Assembly of fixed jib

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-11 No.

1

Names of the parts

Pin spindle

Connecting parts of fixed jib

ID code

Illustration

00663000200001022

Retaining 2

spring

006340000029

(D30,32,35)

GB/T5783-2000

3

Bolt

1040000108

4

Washer

1040300054

GB/T93-1987

006340000019

PD0406

5

Retaining plate 60

Pin spindle

00663050200001010

7

Pin spindle

00663308000001020

8

Pin - 5×50

1040500057

9

Pin spindle

00663003100401010

10

Retaining pin

00663604100001050

ZCC800HWG.1 CRAWLER CRANE

Assembly and Dismantling

6

(ISO4017-1999)

GB/T91-2000

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Operator’s Manual for Crawler Crane

CAUTION (1) Check whether the spring is fitted correctly in outer pipe when assembling front tilting-back support of fixed jib. If it is not fitted correctly, the tilting-back support is out of function and the fixed jib may be tilted backwards. (2) Make sure that the hoisting rope near the boom head is not exposed to crushing force during rope reeving and raising main boom. (3) Ensure that the running wheel on fixed jib head is always rolling on the ground before fixed jib is lifted away from the ground. (4) Take great care to connect rear titling-back support of fixed jib to main boom head after raising main boom to a proper position. (5) Install rear tilting-back support of fixed jib, otherwise, fixed jib may be damaged. -

Pull derricking winch control lever backwards to spool up derricking winch and lift main boom with fixed jib from the ground until fixed jib head is raised by the derricking rope to a proper position a little higher than the load hook. Position auxiliary load hook directly under fixed jib head, and then reeve the hoisting rope between pulley blocks of load hook and fixed jib head, finally secure the rope end point with rope lock and rope thimble. Please see the figure 5-39.

Assembly and Dismantling

Figure 5-39

5-50

Installation of load hook

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.8.3 Electrical connection to fixed jib 5.8.3.1 Wire layout of fixed jib The electrical elements of fixed jib are shown in the figure 5-40.

Junction box on fixed

Solar lamp

jib head

Wind speed sensor

Hoisting limit switch and weight

Figure 5-40

Electrical elements of fixed jib

After assembly of main boom and fixed jib, pull the 16-core plug of main boom junction box along fixed jib pivot section and fixed jib intermediate sections to fixed jib head, and then connect it to the socket of junction box. The cable must be fixed with rope clamps on the boom frame. After that, establish electrical connection between junction box on fixed jib head and electrical elements of fixed jib as shown in the figure 5-41. If fixed jib is not used, wind the cable with 16-core plug onto the cable drum of main boom head, and then insert the plug into the corresponding socket to prevent water from entering the cable. Dismantle such electrical elements as warning light on the boom head, wind speed sensor and hoisting limit switch, and then install them on corresponding positions on fixed jib head.

Assembly and Dismantling

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Operator’s Manual for Crawler Crane

To the plug of main

A view

boom junction box

Hoisting limit for H2

Anemometer

A view

Figure 5-41

Wire layout of fixed jib junction box

5.8.3.2 Function check Insert the ignition key into the key hole, and then turn it clockwise to the first position to switch on the power. After that, perform the following checks. a)

Check anemometer Rotate the vane of anemometer to check whether the wind speed shown on the screen in the cab is normal.

Assembly and Dismantling

b)

Check warning light on boom head The warning light is a kind of solar lamp. Switch on the solar lamp control switch, and cover the solar lamp with a cover with weak transparency to check whether the warning light glows.

c)

Check hoisting limit switch for H2 Support and hold the hoisting limit switch weight for H2 to ensure that the switch is triggered, and then check whether the icon “upper limit switch on H2” on the screen will flash and the buzzer will sound.

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ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.8.4 Raising main boom with fixed jib 5.8.4.1 Prerequisites a)

The crane is properly supported and leveled.

b)

The counterweight plates have been attached in accordance with the requirements.

c)

Select appropriate boom configurations according to the load to be lifted and the load capacity charts as well as lifting height. Ensure that boom sections have been connected and secured.

d)

All limit switches have been correctly fitted and are fully operational.

e)

All pinned connections have been secured.

f)

The hoisting rope is properly placed in the rope pulleys, and is secured with rope guard tubes against jumping out from rope groove.

g)

No person is present in the danger zone.

h)

There are no loose parts on main boom or fixed jib.

i)

In winter, main boom, fixed jib and associated components (limit switches, cable drums, warning light on boom head, anemometer etc.) must be kept free of ice and snow.

DANGER Faulty limit switches and falling parts can cause accidents.

5.8.4.2 Raising main boom with fixed jib -

Set “main boom with fixed jib” configuration in the load moment limiter.

-

Pull derricking winch control lever backwards to spool up derricking winch so that main boom anchoring rods is tensioned gradually.

-

Continue to wind derricking rope to raise main boom until it reaches required position. At this time, fixed jib rear anchoring rods is tightened. Continue to wind derricking rope until fixed jib is lifted off the ground.

-

When fixed jib is raised to required working position, return the derricking winch control lever to neutral position to stop the movement. (see the figure 5-42)

During boom-raising process, the operator must unwind the hoisting rope properly to ensure that the load hook is placed in a proper position.

ZCC800HWG.1 CRAWLER CRANE

5-53

Assembly and Dismantling

-

Operator’s Manual for Crawler Crane

Figure 5-42

Raising main boom with fixed jib

Assembly and Dismantling

CAUTION (1) When raising and lowering 58m main boom or 49m main boom with fixed jib, the boom must be positioned straight ahead of the crawler crane (i.e. the drive sprocket is at the back of the crane). (2) Before raising the boom, a certain length of hoisting rope should be unwound to guarantee that the load hook is still in contact with the ground before the boom angle has reached 30°. Before lowering the boom, a certain length of hoisting rope should be unwound to ensure that the load hook is lowered down on the ground once the boom angle is less than 30°. (3) The boom should be raised or lowered stably at even speed.

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ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.8.5 Lowering and dismantling main boom with fixed jib 5.8.5.1 Lowering main boom with fixed jib -

Push derricking winch control lever forwards to unwind derricking rope, thus allowing the running wheel of fixed jib head to come into contact with the ground. Unpin the pin spindle as shown in the figure 5-43 to disconnect the rear tilting-back support of fixed jib from main boom head.

Unpin the pin spindle

Figure 5-43 -

Lowering main boom with fixed jib

Continue to reel off derricking winch so as to make fixed jib head roll forwards on the running wheel until the entire boom gets into contact with the ground. Move derricking winch control lever to neutral position to stop the movement.

-

Push hoisting winch 2 control lever backwards to wind the hoisting rope onto the drum and secure it.

-

Tilt FA-frame forwards to an appropriate position with the help of an auxiliary crane,

-

Dismember fixed jib sections one by one, leaving fixed jib pivot section assembled.

-

Detach fixed jib pivot section assy. from main boom head.

Assembly and Dismantling

dismantling fixed jib rear anchoring rods and then fixed jib front anchoring rods.

CAUTION (1) The boom-lowering movement should be performed slowly and stably. And during the operation, the crane operator must observe the data shown on the screen, while other workers should pay attention to environmental changes. (2) It is prohibited to stand within an area where the crane movement is carried out. (3) To prevent the wire rope from being damaged due to crush, it should be guided by a person. (4) After winding hoisting rope on the drum, fix rope end point well. ZCC800HWG.1 CRAWLER CRANE

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Operator’s Manual for Crawler Crane

5.9 Assembly and dismantling of tip boom The mounting parts of tip boom are shown in the figure 5-44, and they will be described in the table 5-12.

1

2

1

3

No.

Names of the parts

Figure 5-44

Mounting parts of tip boom

Table 5-12

Mounting parts of tip boom

ID code

Assembly and Dismantling

1

Retaining pin

00663300100001230

2

Pin spindle

00663000100001162

3

Pin spindle

00663020100001010

5-56

Illustration

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Procedure for assembly of tip boom: -

Align upper connecting holes in tip boom with those holes in main boom head, insert pin spindles (part 2) and then secure them with retaining pins (part 1).

-

Align lower connecting holes in tip boom with those holes in main boom head, insert pin spindles (part 3) and then secure them with retaining pins (part 1).

The dismantling of tip boom is carried out exactly in reverse order.

CAUTION The operator must raise and lower main boom with tip boom slowly, otherwise, the jerky operation may bright about the impacts on the tip boom, thus causing damage.

Assembly and Dismantling

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Operator’s Manual for Crawler Crane

5.10 Transport dimensions and weights of main components The following table shows the transport dimensions and weights of main components of ZCC800H crawler crane. Table 5-13 Names of the components

Basic machine

Transport dimensions and weights of main components Dimensions (mm)

Weight

Qty.

41.5t

1

2.7t

1

3.825t

2

3.825t

2

4.5t

2

Counterweight base plate

Counterweight plate

Assembly and Dismantling

Counterweight plate

Counterweight plate

5-58

Remarks

Width: 3400mm

Height: 705mm

Height: 620mm

Height: 620mm

Height: 620mm

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

Table 5-13 Names of the components

80t load hook

50t load hook

30t load hook

16t load hook

Dimensions (mm)

Weight

Qty.

1.25t

1

0.92t

1

0.61t

1

0.5t

1

0.27t

1

1.2t

1

Main boom head

ZCC800HWG.1 CRAWLER CRANE

Remarks

Width: 650mm

Width: 582mm

Width: 504mm

Width: 504mm

Width: 350mm

Width: 1700mm

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Assembly and Dismantling

8t load hook

Transport dimensions and weights of main components

Operator’s Manual for Crawler Crane

Table 5-13 Names of the components

Transport dimensions and weights of main components Dimensions (mm)

Weight

Qty.

0.3t

1

0.44t

1

0.63t

4

0.7t

1

0.17t

2

0.21t

1

Remarks

3m main boom intermediate

Width: 1700mm

section 6m main boom intermediate

Width: 1700mm

section 9m main boom intermediate

Width: 1700mm

section Fixed jib pivot section + FA-frame + front and rear tilting-back

Width: 740mm

supports of fixed jib 6m fixed jib intermediate section

Assembly and Dismantling

Fixed jib head

5-60

Width: 560mm

Width: 560mm

ZCC800HWG.1 CRAWLER CRANE

Operator’s Crane Operator’s Manual Manual for for Crawler Crawler Crane

5.11 Transport means and points for attention 5.11.1 Transport means and relevant notes a)

After being dismembered, the crawler crane can be transported by a low-loader, train or by other transport equipment for a long distance. During transportation, the crane is fixed by rope, with its doors and windows locked up. If necessary, take preventive measures against rain. The crawler crane should be dismembered and transported in accordance with the permissible load carrying capacity of transport vehicle, the weight, dimensions of dismantled parts which are shown in previous figures, and the local traffic laws and regulations. The transport vehicle is forbidden to be overloaded.

b)

During transportation, all component parts should be fixed to prevent them from jostling and sliding.

c)

The rear anchoring rods of A-frame must be secured on the rear end of slewing table.

d)

To understand the detailed transport means, please consult our company.

5.11.2 Other requirements If the crane is not put into use for a long time (over 6 months), take the following protective measures. a)

Wipe off the dust and oil dirt to keep the crane clean.

b)

Retract all the piston rods of the cylinders completely.

c)

Put the battery in a dry and ventilating place and charge it periodically.

d)

Grease the surfaces of all exposed components to prevent them from corroding.

e)

Clean the wire ropes and grease them again with ZG-3 graphite calcium base grease.

f)

Store the crane in a garage. If the crane is placed in the open air, it must be covered up with water-proof cloth to prevent it from corroding, and in winter antifreeze measure should be taken.

g)

Start the crane once a month and run all mechanisms without load to check whether they

h)

Assign a person responsible for the completeness of the crane so that it can be put into operation at any time.

CAUTION The crane that has been stored for a long time should be inspected completely before starting.

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Assembly and Dismantling

are in good condition.