ZCC800HWG - Operator Manual PDF

ZCC800H Crawler Crane
Operator’s Manual
Edition 1 04, 2017

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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 cause light or moderate injury.
Refers to a situation which, if you do not prevent, may cause property or

NOTICE equipment damage.
II
Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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 Description of Crane
2.1 Product model .................................................................................................................. 2-1

2.1.1 Product name plate and its position ..................................................................... 2-1
2.1.2 Engine type and its manufacturer......................................................................... 2-3
2.1.3 Intended use of the crane ..................................................................................... 2-3
2.1.4 Crane design calculation ...................................................................................... 2-3
2.2 Terminology ...................................................................................................................... 2-5
2.2.1 Boom configurations ............................................................................................. 2-5
2.2.2 Description of main components .......................................................................... 2-7
2.3 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
2.4 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
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
3.2.1 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
3.3 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 Load center of gravity ....................................................................................... 3-19
3.4 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
3.8.1 Counterweight .................................................................................................... 3-28
3.8.2 Hoisting winch and hoisting rope ........................................................................ 3-29
3.9 Crane operation with a load ............................................................................................ 3-30
3.9.1 Operating conditions ........................................................................................... 3-30
IV
Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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 Crane Operation
4.1 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
4.2 Instructions for digital display system ............................................................................. 4-15
4.2.1 Load moment limiter ........................................................................................... 4-15
4.2.2 Instrument panel ................................................................................................. 4-16
4.3 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
4.4 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
4.5 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
4.6 Rope reeving .................................................................................................................. 4-51
V
4.6.1 Hoisting rope guidance and reeving ................................................................... 4-51

4.6.2 Derricking rope reeving ...................................................................................... 4-57
Chapter 5 Assembly and Dismantling
5.1 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
5.2 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
5.6.1 Main boom configuration .................................................................................... 5-15
5.6.2 Main boom with fixed jib configuration ............................................................... 5-26
5.7 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
5.8 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
VI
Operator’s履带起重机操作手册
Manual for Crawler Crane
第一章安全操作说明
Chapter 1 Safety
Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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

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 to safety is marked with “ DANGER ”,
“ WARNING ”, “ 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
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
1.2 Note
Safety
a) 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.

1.6 Environmental safety

1.6.1 A regular service should be taken on the crane strictly in accordance
Safety
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:
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

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
1.8 Measured noise level
Safety
The condition of working site may affect the noise levels.
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.

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.

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
b) If your machine comes into contact with a live wire:

- Vacate the area
-
Safety
Warn others against approaching and touching the crane.
- Report the incident and have the live wire de-energized.
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.

1.13.4 Hydraulic equipment

a) Work on hydraulic system must be carried out by persons having special knowledge and
Safety
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.
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.

第二章 2起重机的描述
Chapter Description of Crane
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 Product name plate

Figure 2-2 Position of product name plate

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

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
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;
“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.

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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.
S-1 SF-1
Figure 2-3 Boom configurations

S-2 SF-2
Figure 2-4 Boom configurations
Table 2-1 Description of boom configurations
Configuration no. Description Parameters
S-1 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

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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.
1.1
1.2
1.4
1.3
1.5
Figure 2-5 Crane undercarriage

2.1
2.2
2.3
2.4 2.5 2.6 2.7 2.8
Figure 2-6 Slewing table

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3.1 3.2
3.7
3.3
3.6
3.4
3.5
Figure 2-7 Overview of slewing table from above

Table 2-2 Description of main components
No. Names of the components No Names of the components
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

Crawler carrier extending & retracting

1.5 3.2 Fuel tank
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.

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

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;
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).

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2.3.3 Overall dimensions

The overall dimensions of crane are shown in the figure 2-8.
Unit: mm
Figure 2-8 Overall dimensions of 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 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 125 (110, with free-fall
th m/min
4 rope layer) function)
Max. single rope Hoisting winch 2 (on the
th m/min 125
speed of winches 4 rope layer)
Derricking winch (on the
th m/min 93
4 rope layer)
Slewing speed rpm 0-2
Traveling speed km/h 0-1.67
Gradeability ％ 30
Ground pressure MPa 0.083
Overall dimensions (L×W×H) (with A-frame and
m 13.5×3.4×3.2
main boom pivot section)
Rated power / rotational
kW/r/min 199/2000
Engine (Weichai speed
power) Max. output torque /
N. m/r/min 1270/1200-1500
rotational speed
4200×5440×800
Distance between track center × crawler (crawler carrier extended)
mm
contact length × crawler width 2600×5440×800
(crawler carrier retracted)
Noise level outside the
operator’s cab during dB (A) ≤107
operation
Noise
Noise level in the
operator’s cab during dB (A) ≤79
operation

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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
Type 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
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
length (m)
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

“Main boom with Main boom/fixed jib

Rated lifting capacity (t) Rope reeving
fixed jib” length (m)
configuration 6-18 7 1
CAUTION
(1) If the crane is working with hoisting rope reeving less than the value listed in the
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 Parameters of wire rope

Description and Wire rope for Wire rope for
Derricking rope
intended use hoisting winch 1 hoisting winch 2
Rotation-resistance or
Yes Yes No
not
Type of rope 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

Direction and type of
Left-hand ordinary lay Left-hand ordinary lay Right-hand lang lay
lay
2 2 2
Tensile strength of rope 1960N/mm 1960N/mm 1910N/mm
c) 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.

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2.4.4 Lifting height

a) Lifting height on S boom
60
56
52
48
44
40
Lifting height (m)
36
32
28
24
20
16
12
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
Working radius (m)
Figure 2-9 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.

b) Lifting height on SF boom
68
64
60
56
52
48
44
40
Lifting height (m)
36
32
28
24
20
16
12
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
(3) For SF boom configuration, main boom = 37m-49m, fixed jib = 6m-18m, and fixed jib
angle = 10°.

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64
60
56
52
48
44
Lifting height (m)
40
36
32
28
24
20
16
12
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
(3) For SF boom configuration, main boom = 37m-49m, fixed jib = 6m-18m, and fixed jib
angle = 30°.

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

Table 2-7 Lifting capacity on S-1 boom
Main boom length (m)

Radius Radius
13 16 19 22 25 28 31 34 37
(m) (m)
4 80 4
5 68 66.8 5
6 52.3 52 51.8 51.7 6
7 42.3 42 41.9 41.7 40 39.5 7
8 35.5 35.2 35 34.8 34.6 33.97 33.8 33.5 8
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
14 17.2 17 16.9 16.6 16.2 16 15.8 15.5 14
16 14.37 14.2 13.9 13.6 13.4 13.1 12.9 16
18 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
24 7.7 7.65 7.6 7.5 24
26 6.8 6.75 6.7 26
28 6 5.9 28
30 5.5 5.4 30
32 4.2 32

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Radius (m) 40 43 46 49 52 55 58 Radius (m)
9 9
10 23.8 23.2 22.6 10
12 18.6 18.6 18.2 17.8 17.8 12
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
40 2.8 2.7 2.6 2.5 2.3 40
42 2.3 2.3 2.2 2 42
44 2 1.8 1.6 44
46 1.6 1.3 46
48 1.5 1 48
50 0.8 50
Note:
The lifting capacities highlighted in gray are determined by the strength.

b) Lifting capacity on SF-1 boom
Table 2-8 Lifting capacity on SF-1 boom
Main boom
37
length (m)
Fixed jib
6 12 18
length (m)
Fixed jib angle (°)
Radius (m) 10 30 10 30 10 30
10 7 6
12 7 6 7
14 7 6 7 5.5
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
40 3.2 3.2 3

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Main boom
40
length (m)
Fixed jib
6 12 18
length (m)
Radius (m) 10 30 10 30 10 30
10 7
12 7 6 7
14 7 6 7 5.5
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
38 3.1 3.2 3 3.2 3.1
40 2.7 2.7 2.6 2.5
42 2.4 2.5 2.3

Main boom
43
length (m)
Fixed jib
6 12 18
length (m)
Radius (m) 10 30 10 30 10 30
12 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 6.3 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
44 2.5 2.5 2.5

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Main boom
46
length (m)
Fixed jib
6 12 18
length (m)
Radius (m) 10 30 10 30 10 30
12 7
14 7 6 7
16 7 6 7 5.5
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
42 2.6 2.5 2.6 2.5 2.5
44 2.5 2.4 2.4

Main boom
49
length (m)
Fixed jib
6 12 18
length (m)
Radius (m) 10 30 10 30 10 30
12 7
14 7 6 7
16 7 6 7 5.5
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
44 2.2 2.2 2.3 2.3 2.3
46 1.9 1.9 1.9 1.8

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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.
+ Weight of load hook,
Rated lifting capacity = Actual load wire rope and other
load handling devices
Figure 2-12 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
 2 L1  4 1
L 
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

α= main boom angle

o o
β= fixed jib angle (10 or 30 )
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.

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(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.

c) Lifting capacity on S-2 boom
37
Fixed jib length (m)

Radius (m)
6 12 18
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

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40

Radius (m)
6 12 18
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

43

Radius (m)
6 12 18
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

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Crawler Crane
Crane
46

Radius (m)
6 12 18
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

49

Radius (m)
6 12 18
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

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d) Lifting capacity on SF-2 boom
37
Radius (m)
6 12 18
10 30 10 30 10 30
10 6
12 6 5.1 6.2
14 5.9 5.1 6.1 4.8
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
40 2.3 2.3 2.2

40

Radius (m)
6 12 18
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 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
38 2 2.2 2.1 2.3 2.3
40 1.7 1.8 1.7 1.7
42 1.4 1.6 1.5

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43

Radius (m)
6 12 18
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
44 1.5 1.6 1.7

46

Radius (m)
6 12 18
10 30 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
42 1.5 1.5 1.6 1.6 1.7
44 1.5 1.5 1.6

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49

Radius (m)
6 12 18
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
44 1.1 1.2 1.3 1.4 1.5
46 0.9 0.9 1 1

第三章安全准则
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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
underground gas pipes).
Safety Guidelines
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!

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.
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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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.
a) 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.
Safety Guidelines
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.

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;
g) Be capable of conducting the operating of crane to move the load safely;
Safety Guidelines
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
lifted.
Safety Guidelines
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 Emergency exit Figure 3-2 Free-fall operation

Figure 3-4 Points for attention before

Figure 3-3 Operation of slewing fixing pin
operation
Safety Guidelines
Figure 3-6 Prohibit obliquely pulling the

Figure 3-5 Read the manual
load
Figure 3-7 Unauthorized access prohibited Figure 3-8 Safety sign
Figure 3-9 Free-fall operation Figure 3-10 Drain port of air conditioning

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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 Hand signal for controlling crane operation

Figure 3-13 Crush hazard Figure 3-14 Risk of falling

Safety Guidelines
Figure 3-15 Access prohibited Figure 3-16 Warning overhead obstacles
Figure 3-17 Danger sign Figure 3-18 Position of fire extinguisher
Figure 3-19 Safety sign Figure 3-20 Safety sign

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Figure 3-21 Safety sign Figure 3-22 Drain port
Safety Guidelines
Figure 3-23 Hydraulic oil tank Figure 3-24 Hydraulic oil level
Figure 3-25 Danger sign Figure 3-26 Diesel oil tank
Figure 3-27 Battery master switch Figure 3-28 Operation of slewing fixing pin

Figure 3-29 Risk of burn Figure 3-30 Safety sign

Safety Guidelines
Figure 3-31 Risk of falling Figure 3-32 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 3-34 Lifting point
Figure 3-36 Unauthorized access

Figure 3-35 Risk of falling
prohibited

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Figure 3-37 Warning: Crushing / collisions Figure 3-38 Keep away from moving parts
Safety Guidelines
Figure 3-39 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 3-41 Safety sign
Figure 3-42 Lifting point

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

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

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 Sling rated capacity (%)
90°- 120° 87%
60°- 90° 74%
30°- 60° 62%
0°- 30° 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).

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:
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

The following angles are not recommended
90° 1.000
when lifting.
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
Safety Guidelines
60° 1.155 20° 2.924
55° 1.221 15° 3.861
50° 1.305 10° 5.750
45° 1.414 5° 11.49
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.

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.
j) Do not impact on the load.
k) A sling cannot be pulled under a load when the load is resting on the ground.
Safety Guidelines
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 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
attachment for any rigging.
Safety Guidelines
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.

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.
3.4.2 Slopes and trenches

Safety Guidelines
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 0-0.1
1. Mud, peat, marshy land 0
Fine to medium grained

2. Non-cohesive, 0.15
sand;
sufficiently compactly
From coarse-grained sand
layered soil 0.2
to gravel
Loamy 0
Safety Guidelines
Soft 0.04
B) Natural soil,
3. Cohesive soil Stiff 0.1
apparently
undisturbed Semi-solid 0.2
Hard 0.4
In healthy, weatherproof
condition and in a favorable 1.0
4. Rock with few location
fissures In cohesive layer order 1.5
In massive or column-style
3.0
shape
1. Asphalt 0.5-1.5
C) Artificially
compacted Concrete group B I 5-25
2. Concrete
ground
Concrete group B II 35-55
CAUTION
If there is any doubt about the load-bearing capacity of the ground at the operating site,
soil test should be carried out.

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.
3.5 Working weather

Safety Guidelines
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.
i) Do not work with a bare upper torso or in short pants.
Safety Guidelines
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.

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) 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.
f) 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.
Safety Guidelines
e) 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.

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?
a) Stop work immediately.
b) Leave the crane after shutting down the engine and all additional fuel powered units.
Safety Guidelines
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) 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.
g) 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) 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.
k) Work on the building site can only begin again if authorization has been given by the
relevant gas company.

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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

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
27
chart
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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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
may be damaged.
Safety Guidelines

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 3-48
c) 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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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
Wind force Effects of the wind in the inland
Beaufort Description Wind speed (m/s) Visible effects
0 Calm 0-0.2 No wind, smoke rises straight up

Wind direction is shown only by observing the trail of
1 Light air 0.4-1.4
smoke, not by the wind sock
Light Wind can be felt on the face, the leaves rustle, wind
2 1.6-3
breeze sock moves slightly
Gentle Leaves and thin twigs move. Wind extends a small
3 3.4-5.3
breeze breeze flag.
Moderate Swirls up dust and loose paper, moves twigs and thin
4 5.5-7.8
breeze branches
Fresh Small deciduous trees begin to sway, foam forms at
5 8-10.6
breeze sea.
Strong Thicker branches move; telephone lines begin to
6 10.8-13.7
breeze whistle, umbrellas are difficult to use
7 Stiff wind 13.9-17 Entire trees swaying; difficult to walk into wind
Gale force
8 17.2-20.6 Breaks twigs off trees, walking becomes difficult
wind
Minor damage to property(chimney tops and roofing
9 Gale 20.8-24.5
tile are blown off)
Severe
10 24.7-28.3 Trees are uprooted, significant damage to property
gale

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 3-50
Table 3-7 The safe clearance from high-voltage power lines

Safety Guidelines
Output voltage of
high-voltage V≤1 1< V ≤15 15 <V ≤40 40<V≤100 100<V≤200
power line (V, kV)
Safe clearance (m) 1.5 3 4 5 6
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) Only the crane without fault is allowed to work.

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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.
Safety Guidelines
Figure 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 3-52

d) It is forbidden to lift the load when someone stands on it. Refer to figure 3-53.
Safety Guidelines
Figure 3-53
e) Overloading operation and lifting staggered load is prohibited. Never pull load obliquely.
Refer to figure 3-54.
Figure 3-54

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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

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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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.
u) It is more dangerous that two cranes carry out lifting operations together. Therefore, a
Safety Guidelines
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.
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.
w) 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.

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.
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.
Safety Guidelines
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:
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.
Safety Guidelines
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.
h) 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.
i) 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:
1) Check the performance of electrical parts and load moment limiter.
2) Check the associated components for functional work.
j) 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.

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.

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
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 2
Signal Preparation Use main hoist
Arm stretched out over the head, palm Tap fist on the safety helmet; then use
Description
of the hand facing forwards. regular signals.
Safety Guidelines
Illustration
Ser. No. 3 4
Signal Use auxiliary hoist Hoist
Bend one hand and hold it upward, tap With forearm vertical, palm of the hand
Description the elbow with the other hand; then use facing forwards, move hand in small
regular signals. horizontal circle.
Illustration

Ser. No. 5 6
Signal Lower Raise load slowly
With arm extended downwards with a
With forearm vertical, palm of the hand
30°angle to the body，palm of the hand
Description 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
the forearm sideways horizontally, fingers pointing at the direction of rotation.
Description
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

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
Ser. No. 8 9
Signal Lower load slowly Indicate load lowering position
With arm extended downwards with a
30°angle to the body，palm of the hand Extend the fingers to point at the
Description
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

Ser. No. 11 12
Signal Raise boom Lower boom
With arm stretched sideways With arm stretched sideways
horizontally, thumb pointing upwards, horizontally, thumb pointing
Description
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
Bend one hand with thumb pointing
downwards; place other hand
Description upwards; place other hand motionless
motionless below hand moving up and
above hand moving up and down.
down.
Illustration

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
Ser. No. 15 16
Signal Stop Emergency stop
Arm extended, the palm facing Both arms extended, palms facing
Description downwards, move the arm back and downwards, move arms back and forth
forth horizontally. horizontally.
Illustration
Safety Guidelines
Ser. No. 17
Signal End of a movement
Description 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.

履带起重机操作手册
第四章起重机的操作
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.
9
1 2
Crane Operation
6
8
3 4 5
Figure 4-1 Operator’s cab assy.

Table 4-1 Components of the operator’s cab
Names of the
No. 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).
LCD screen of winch
2 Monitor the winch and crane tail in real time.
monitoring system
Control the freefall brake. Step the pedal down to release
3 Freefall pedal
the brake.
Travel gear pedal (with Control the movements of left travel gear and right travel
4
hand lever) gear.
5 Accelerator pedal Control the rotational speed of the engine.
Located at the rear side of the operator’s cab (see section

6 Air conditioning unit
4.3.3 for details).
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).
Control the movements of hoisting winches 1 and 2, and

9 Right control box
derricking winch (see section 4.1.3 for details).
Crane Operation

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.
3
2
4-7
4 5
Crane Operation
7 6
Figure 4-2 Left control box
4-3
Table 4-2 Components of left control box
Names of the
No. Description
components
Push control lever forwards, slew the superstructure to the

right.
1 Slewing control lever
Pull control lever backwards, slew the superstructure to
the left. (See Section 4.1.2.1 for details).
Push the lever forwards completely, the control system is

2 Safety lever
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
Press down this button in an emergency to stop the
Crane Operation
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

the crane movements “spool up hoisting winches” and
5 Hoisting bypass switch
“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

<110%) is sent, it is used to bypass the crane movement
7 Derricking bypass switch
“spool up derricking winch”. (For detailed operation, please
refer to Section 4.1.4)
4-4
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.
1 2
Crane Operation
Figure 4-3 Slewing control lever
Table 4-3 Components of slewing control lever
Names of the
No. 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
Right control box is shown in the Figure 4-4, and its components are described in the Table 4-4.
2
3
5-11
5 6 7 8
Crane Operation
11 10 9
12 13 14 15 16 17 18 19 20 21 22
Figure 4-4 Right control box
4-6
Table 4-4 Components of right control box
Names of the
No. Description
components
Control the derricking winch.
Derricking winch
1 Push the control lever forwards, reel off derricking winch.
control lever
Pull the control lever backwards, spool up derricking winch.
Control the hoisting winch 2.
Hoisting winch 2
2 Push the control lever forwards, reel off hoisting winch 2.
control lever
Pull the control lever backwards, spool up hoisting winch 2.
Control the hoisting winch 1.
Hoisting winch 1
3 Push the control lever forwards, reel off hoisting winch 1;
control lever
Pull the control lever backwards, spool up hoisting winch 1.
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
4 Ignition key switch
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.
Accelerator control mode is changed into manual control after
Crane Operation
Manual accelerator the switch is clockwise rotated. At this time, the accelerator is
5
select switch controlled by the knob (No. 17 in Figure 4-4). However, the
accelerator pedal is invalid.
Control the high speed of hoisting winch 2.
High-speed knob for
6 Counterclockwise rotate the knob, the high speed decreases.
hoisting winch 2
Clockwise rotate the knob, the high speed increases.
7 Spare
Press down this switch, the engine will be shut down.
CAUTION:
(1) After you shut down the engine, please keep the
Engine shutdown
8 switch pressed down for more than 30 seconds, and
switch
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.
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
9 SetUp switch
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
Names of the
No. Description
components
Control the high speed of hoisting winch 1.
High-speed knob for
10 Counterclockwise rotate the knob, the high speed decreases.
hoisting winch 1
Clockwise rotate the knob, the high speed increases.
The engine speed can be adjusted via this knob under the
Engine accelerator
11 manual accelerator mode. Clockwise rotate this knob, the
control knob
engine speed increases.
12 Power switch Control the controller power of the whole crane.
When the switch is pressed down, speed of all crane
13 Inching speed switch movements are reduced to 25% of the original one.
“Front windshield
14 This switch is optional.
wiper on/off” switch
“Front washer
15 Switch on or off the front windshield wiper
on/off” switch
Turn the switch to1st position: the LED on the switches of
16 Master lighting switch
control panel will light up; 2nd position: master lighting switch
“Interior light on/off”
17 Switch on or off the interior light in operator’s cab
switch
Press down this switch, the clutch of hoisting winch 1 is
disengaged, then free-fall operation can be done. At this time,
18 Free-fall switch
depress the free-fall pedal (No. 3 in Figure 4-1), the hook starts
to lower down freely.
Crane Operation
Derricking ratchet Control the derricking ratchet pawl. See Section 4.5.3 for
19
pawl switch detailed description.
When oil temperature is too high, hydraulic oil is cooled by the
20 Oil cooling switch
switch.
This button is used to reduce the lateral force of the boom, thus
protecting the boom against damage.
21 Free swing button CAUTION:
Prevent vigorous swaying of the load brought by sudden
stop of slewing motion.
When the ground is flat, it is suggested to turn on this switch.

Slewing alignment
22 When the ground has a gradient, it is suggested to turn off this
switch
switch.
4-8
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
Bypass methods Remarks
name movements
1．Turn bypass switch clockwise 1. Setup switch is active
until the icon appears on when pressed down once,
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
Overloading
hoisting if the load moment percent requires to be pressed
(100%-110%)
winches 1 and reaches 100%. At this time, turn down again before bypass
or minimum
2, raise and “derricking bypass” switch the overloading again.
main boom
lower main clockwise and keep it there, then 3 The icon is
angle
boom the limited movement “raise main displayed after pressing
boom” is bypassed. However, the down Setup switch when
icons and will the crane is overloaded.
Crane Operation
appear simultaneously on load The icons and
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
boom is less than the
minimum angle.
Spool up
Release the bypass key switch 4. Bypass key switch is
hoisting
when it is clockwise rotated. When active by being rotated
Overloading winches 1 and
there is icon shown on the once, and it stops working
(above 110%) 2, raise and
load moment limiter, the limited when it is rotated again,
lower main
movements are bypassed. engine stops or power
boom
supply is off. Working time
lasts 30 minutes once.

Warning Limited
Bypass methods Remarks
name movements
1. The limited movements are
bypassed when the icon
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.
Spool up
2．Press down “Setup” switch and 2. If overloading is
hoisting
Over-winding/ release it, when only the icon bypassed and the limited
winches 1 and
over-hoisting appears or both and movements have been
2, lower main
appear simultaneously on performed, Setup switch
boom
load moment limiter, turn hoisting 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
appears on load moment displayed after pressing
limiter. down Setup switch when
1. The limited movements are the crane is overloaded.
bypassed when there is The icons and
Crane Operation
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
Reel off
2．Press down “Setup” switch and boom is less than the
hoisting
Over-lowering release it, when only icon minimum angle.
winches 1 and
appears or both and 4. Bypass key switch is
2
appear simultaneously on load active by being rotated
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 stops or power
bypassed when appears on supply is off. Working time
load moment limiter. lasts 30 minutes once.
Max. boom Raise main Bypassing the limited movement
angle (80°) boom is not allowed.

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

Table 4-6 Tricolor light alarm logic
Green Yellow
Red light Buzzer
light light
Before
○ √ √ √
bypass
0%<
Moment
√ ○ ○ ○
percentage
<90%
Overloading
90%≤
or minimum When
Moment
main boom After load ○ √ ○ Interrupted
percentage
angle bypass angle
≤100%
100%<
Moment
○ √ √ √
percentage
≤110%
No load angle ○ Interrupted ○ Interrupted
Before
○ √ √ √
bypass
Over-winding
Crane Operation
After
○ Interrupted ○ √
bypass
Before
○ √ √ √
bypass
Over-lowering
After
○ Interrupted ○ √
bypass
Max. Bypass is
○ √ √ √
boom angle not allowed
When bypass
key switch is
active under ○ ○ Interrupted √
any
circumstance
90%≤
Moment
○ √ ○ Interrupted
percentage≤
100%

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 2
Figure 4-5 Electrical control box for the slewing table

Table 4-7 Components of the electrical control box for slewing table
Names of the
No. 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.
Engine diagnosis
2 Interface for diagnosis by service men of the engine manufacturer.
socket
Crane Operation

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.
Figure 4-6 Digital display system
Table 4-8 Description of digital display system
No. Names of the components

1 LCD screen of load moment limiter
2 Instrument panel
Crane Operation
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.

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.
2
3
4
5
Crane Operation
Figure 4-7 Instrument panel
Table 4-9 Components of instrument panel
Names of the
No. Description
components
Display related parameters and various kinds of warning
1 Instrument assy. indication of the engine (see Instrument assy. description for
details).
Main pump (1)
2 Display the working circuit pressure of main pump I.
pressure gauge
Main pump (2)
3 Display the working circuit pressure of main pump II.
pressure gauge
Slewing pump pressure
4 Display the working circuit pressure of the slewing pump.
gauge
5 Control pressure Display the working circuit pressure of the control pump.

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 4 5 6 7
15 8
14 9
13 12 11 10
Crane Operation
Figure 4-8 Instrument assy.
Table 4-10 Components of the Instrument assy.
Names of the
No. Icon Description
components
1 Oil pipeline clogging When oil pipeline is clogged, this icon will flash.
Engine coolant When engine coolant temperature is higher than

2
temperature 96℃, this icon will flash.
When the power of crane is switched on, this icon

3 Power indication
will flash.
Engine speed and Indicate the current engine speed and total working
4
working hours hours of the engine.
5 Spare
6 Spare
7 Spare

Names of the
No. Icon Description
components
Engine oil pressure
8 Indicate the current engine oil pressure
gauge
9 Voltmeter Indicate the current voltage of the battery
10 Spare
11 Spare
When engine oil pressure is less than 0.06 MPa,

12 Oil pressure
this icon will flash.
When fuel level is less than 10%, this icon will

13 Fuel level
flash.
14 Water thermometer Indicate the current engine coolant temperature.
Indicate the fuel level of the fuel tank in

15 Fuel gauge
percentage.
Crane Operation

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.

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.

4.3.2 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:
a) Inspect the work log to ensure that all regular inspection, maintenance and repair work are
Crane Operation
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.

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

a) Turn on power supply
Crane Operation
nd
Insert the key into the ignition key switch and clockwise turn it into the 2 position to turn
on the power supply. Refer to figure 4-14.
Figure 4-14 Turning on power supply

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.
Control panel of air conditioning
Off On
Air speed knob Fresh air Cooling/heating
Ball valve switch
switch selector switch
Figure 4-15 Control panel of the air conditioning
The air conditioning system mainly consists of compressor, condenser (including liquid
reservoir), evaporator etc.
Crane Operation
When cooling performance is activated, its power is supplied by the compressor which is
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.

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 Working floodlight Master lighting switch
Figure 4-16 Control panel in the operator’s cab
d) Horn
Horn switch (No. 2 in Figure 4-3 of section 4.1.2.1) must be pressed down before the work
is started to test whether the horn can sound.
Crane Operation
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 Starting of the engine

Check whether the engine works normally after starting of the engine. Refer to figure 4-18.
Engine coolant temperature Engine speed Engine oil pressure
Figure 4-18 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.
Crane Operation
(2) The crane engine can only become full loaded when it achieves the running
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.

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 Position of flashing light

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.
Crane Operation
DANGER
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.

Figure 4-20 Position of Angle indicator
4.4.6 Lowering limiter

In order to prevent wire rope from being wound in the opposite direction after it is unwound
Crane Operation
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 Lowering limiter

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.

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
main boom only, and the out-of-service wind velocity should not exceed 21m/s. The crane is
Crane Operation
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.

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 5 6 7 8
Figure 4-23 Components of travel gear
Table 4-11 Components of travel gear
Crane Operation
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

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.

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 Turning to left with a crawler Figure 4-26 Turning to right with a crawler
5) 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.

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.

Figure 4-29 Turning on the spot
Crane Operation
CAUTION
(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.

Figure 4-30 Traveling on a slope
1) 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.

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.
WARNING
Crane Operation
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.

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 2 3
Figure 4-32 Control levers of hoisting winches

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

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
wound / unwound, dangerous movements will be switched off automatically and
Crane Operation
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.

Figure 4-33 Winch with outside band brake
Table 4-12 Components of band brake
Names of the
Crane Operation
No. 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.
Adjust the distance between the brake strap and brake
2 Adjustment device 1
drum.
Make friction with brake drum, and achieve braking effects
3 Brake strap
through the resistance
4 Brake cylinder Release the brake effects of band brake.
Adjust the distance between brake strap and brake drum

5 Adjustment device 2
after wear and tear of brake strap.
The brake is normally closed, that is, the brake spring is
Brake spring and compressed all the time. The connecting-rod connects the
6
connecting-rod front and rear brake straps to cooperate with the brake
cylinder to release the braking effects.

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
drum is completely static, an operation is finished).
Crane Operation
(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

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.
Crane Operation
6
2
Figure 4-34 Derricking mechanism components

Table 4-13 Derricking mechanism components
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
b) 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.

3
1
7
Figure 4-35 Ratchet pawl mechanism
Table 4-14 Components of ratchet pawl mechanism
No. Names of the components Instructions

6
On the right control box, used to control movements
1 2 ratchet switch
Derricking
of ratchet pawl cylinder
2 Ratchet3 wheel On the right of derricking drum
3 Ratchet pawl Open or close by ratchet pawl cylinder
4 Ratchet pawl cylinder Open or close by ratchet pawl
When pressure oil passes through the brake valve, press ratchet switch and hold it until ratchet
pawl is disengaged from ratchet wheel completely. Once ratchet wheel mechanism is activated,
Crane Operation
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.

(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;

(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.
Crane Operation
Figure 4-36 Fixing device for slewing table
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.

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

Crawler carrier
extending &
retracting
cylinder
Crawler
carrier
Undercarriage
central section
Horizontal anchoring rods
Indicating sign
Undercarriage
control lever
Figure 4-37 Crawler carrier extending & retracting mechanism
Crane Operation
a) 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.

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

4.6 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.
3) The boom is placed straight ahead of the crane.
4) An assistant is present to guide the hoisting rope.
b) 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) Reinsert the retaining springs and rope guard tubes.
c) Number of rope pulleys and available rope reeving
Crane Operation
1) 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
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.

Rope reeving: 12 Rope reeving: 10

Crane Operation
6
2
Rope reeving: 8
Figure 4-38 Reeving 80t load hook

Crane Operation
6
2
Rope reeving: 5


Crane Operation
6
2
Rope reeving: 2

Rope reeving: 1
d) 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 Fixation of hoisting rope end point

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
Chain and shackle

Auxiliary
load hook
6
2
Main load
3 hook
Weight
Hoisting rope
Figure 4-44 Installation of hoisting limit switch weight

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 Derricking rope reeving

Table 4-15 Parts used for derricking rope reeving
No. Names of the parts Remarks

Connect derricking rope end and derricking crown
1 Pin spindle
block
2 Retaining spring Secure pin spindle (1)
Install between pin spindle and rope lock to avoid
3 Washer
friction between them.
4 Rope lock Connect derricking rope end and derricking crown
5 Rope thimble block. The method refers to fixation of hoisting rope
6 Rope clamp end point.
The detailed parameters are shown in the table 2-6
7 Derricking rope
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

第五章
Chapter 安装说明and Dismantling
5 Assembly
Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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. Dismantling
Assembly and
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.

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.
The wire rope must be removed immediately and replace it with a new one if any of the
Dismantling
Assembly and
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) Broken strands.

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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!
Dismantling
Assembly and
5) 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.

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.
Dismantling
Assembly and

Operator’s
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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.
- The jobsite must be large enough for trailer traveling and auxiliary crane operation.
b) 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.
Dismantling
Assembly and
Figure 5-1 Unloading of basic machine

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

Dismantling
Assembly and
Figure 5-2 Assembly of A-frame on the basic machine

Operator’s
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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.
Dismantling
Assembly and

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.
Dismantling
Assembly and
Figure 5-3 Assembly of rear counterweight

Operator’s
Operator’s Manual
Manual for
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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.
Dismantling
Assembly and

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
Dismantling
Assembly and
Storage position
Figure 5-5 Storage position of undercarriage wedge block

Operator’s
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Manual for
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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
position
Dismantling
Assembly and
Figure 5-6 Storage and installation positions of undercarriage wedge block

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 Installation of left rear wedge block
c) 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.
Dismantling
Assembly and
Figure 5-8 Installation of left rear wedge block
5-12 6 CRAWLER CRANE

ZCC800HWG.1
Operator’s
Operator’s Manual
Manual for
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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.
Figure 5-9 Installation of right rear wedge block
e) 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.
Dismantling
Assembly and

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 Available boom configurations for ZCC800H crawler crane
Configuration
Description Parameters Remarks
no.
Main boom is fitted with tip
boom, and the load can be
S-1 Main boom Main boom: 13m-58m
attached onto main boom or tip
boom.
Main boom with Main boom: 37m-49m The load is attached onto fixed
SF-1
fixed jib Fixed jib: 6m-18m jib.
Both main boom and fixed jib are
Main boom with Main boom: 37m-49m
S-2 fitted with a load hook, but only
fixed jib Fixed jib: 6m-18m
main boom lifts the load.
Both main boom and fixed jib are
Main boom with Main boom: 37m-49m
SF-2 fitted with a load hook, but only
fixed jib Fixed jib: 6m-18m
fixed jib lifts the load.
Dismantling
Assembly and
S-1 SF-1 S-2 SF-2
Figure 5-10 Available boom configurations

Operator’s
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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
Dismantling
Assembly and
G14
1, 2
G13
G11
Figure 5-11 Assembly of main boom

Table 5-2 Connecting parts of main boom
Names of the
No. ID code Illustration
parts
1 Pin spindle 00663000100001031
Retaining spring
2 006340000001
(D40,45)
3 Pin spindle 00663020100001010
4 Retaining pin 00663300100001230

Dismantling
Assembly and
5 Pin spindle 00663000100001162
6 Pin spindle 00663020100001040

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Table 5-2 Connecting parts of main boom
Names of the
parts
7 Rope lock 1090100448
8 Rope thimble 1090100455
9 Rope clamp 1090100022 24 (GB5976-1986)
Table 5-3 Description of main boom components
Code Names of the components ID code Length Weight
G10 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
3m main boom intermediate

G13 00663050100800000 3m 0.26t
section
G14 00663050101000000 6m 0.44t
section
Dismantling
Assembly and

G15 00663050101200000 9m 0.63t
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.

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
G10 G12
G12
G10
G12
G15
G12 G13 G14
Dismantling
Assembly and
G11 G11 G11 G11
13m 16m 19m 22m

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G10
G10
G10 G12
G10 G12
G12
G15
G12
G15
G15
G15 G15
G14
G14
G13 G13 G13
G11 过 G11 G11

卷开
关和
25m 28m 31m 34m
重锤
G10
太
G10
阳能
G10
报警 G12
G10 灯 G12
风 G12
速传 G15
G12
感器 G15
G11 G15
G15 G15
G15
G15
Dismantling
Assembly and
G15
G15
G15 6
G15
G14 G14
G13
G11 G11 G11 G11
37m 40m 43m 46m

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
G13 G14
G13
G11 G11 G11 G11
49m 52m 55m 58m

Dismantling
Assembly and
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

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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
Dismantling
Assembly and
Figure 5-15 Combination of main boom anchoring rods

Table 5-5 Components of main boom anchoring rods
Names of the
components
1 Pin spindle 00663005400201022
2 Retaining pin 00663065400201010
Double-anchoring
3 00663025400210000
rod
Single-anchoring
4 00660515400001030
rod
Reducing
5 00663055400210000
anchoring rod
Dismantling
Assembly and
Single-anchoring
6 00663025400201020
rod
Single-anchoring
7 00663025400201010
rod

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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.
Dismantling
Assembly and
13m 16m 19m 22m 25m
Figure 5-16 Combination of main boom anchoring rods for different main boom length

Dismantling
Assembly and
28m 31m 34m 37m 40m 43m

Operator’s
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Dismantling
Assembly and
46m 49m 52m 55m 58m

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 G31

G75
1, 2
3, 4, 5, 6
Dismantling
Assembly and
Figure 5-19 Assembly of fixed jib

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Table 5-6 Connecting parts of fixed jib
Names of the
parts
1 Pin spindle 00663000200001022
Retaining
2 spring 006340000029
(D30,32,35)
GB/T5783-2000
3 Bolt 1040000108
(ISO4017-1999)
4 Washer 1040300054 GB/T93-1987
Retaining
5 006340000019 PD0406
plate 60
6 Pin spindle 00663050200001010
Table 5-7 Description of fixed jib components

Dismantling
Assembly and
Names of the
Code ID code Length Weight
components
G31 Fixed jib pivot section 00663020200200000 3m 0.18t
G32 Fixed jib head 00663050200400000 3m 0.21t

6m fixed jib intermediate
G34 00663020200600000 6m 0.17t
section
G37 FA-frame 00663027800000000 3m 0.26t
Front tilting-back support of
G74 00663003100600001 1.6m-2.8m 0.05t
fixed jib
Rear tilting-back support of
G75 00663050101200000 1.5m-2.33m 0.04t
fixed jib

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 G31+G34×2+G32
12m G31+G34+G32
The assembly of fixed jib of different length is shown in the figure 5-20.
G32
G34
G32
G74
G34 G34
G37 G32
G31 G31
G31
G75

Dismantling
Assembly and

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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
4
5, 6
3 Dismantling
Assembly and
10
11
Figure 5-21 Combination of fixed jib rear anchoring rods

Table 5-9 Components of fixed jib rear anchoring rods
Names of the
components
1 Pin spindle 00663025400401010
2 Retaining pin 00663065400201010
Double-anchoring
3 00663025400410000
rod
Reducing
4 00663025400420000
anchoring rod
5 Pin 1040500173 GB/T91-2000/6.3×80

Dismantling
Assembly and
6 Pin spindle 00663015410401050
7 Reducing piece 00663025400401050

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Table 5-9 Components of fixed jib rear anchoring rods
Names of the
components
Double-anchoring
8 00663025400430000
rod
9 Coupling link 00663025400440000
Single-anchoring
10 00663025400401030
rod
Single-anchoring
11 00663025400401040
rod
Dismantling
Assembly and

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
5
Dismantling
Assembly and
To FA-frame
Figure 5-22 Combination of fixed jib front anchoring rods

Operator’s
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Table 5-10 Components of fixed jib front anchoring rods
Names of the
components
1 Pin spindle 00663025400401010
2 Retaining pin 00663065400201010
Double-anchoring
3 00663025400410000
rod
4 Plate 00663025400601010
Single-anchoring
5 00663025400601030
rod Dismantling
Assembly and

The combination of fixed jib front anchoring rods of different length is shown in the figure 5-23.
6m 12m 18m
Figure 5-23 Combination of fixed jib front anchoring rods

Dismantling
Assembly and

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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
Dismantling
Assembly and
components as boom sections and anchoring rods according to working requirements.
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.

9m main boom
intermediate section
6m main boom
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
Main boom
Dismantling
Assembly and
Main boom
head
Figure 5-25 Connecting main boom intermediate section to main boom head

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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.
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.
Table 5-11 Parts used for assembly of main boom

Dismantling
Assembly and
Names of the
parts
1 Pin spindle 00663000100001031
Retaining spring
2 006340000001
(D40,45)

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
Dismantling
Assembly and
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.

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Figure 5-28 Rope reeving
c) 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.
d) 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.
Dismantling
Assembly and
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.

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 To fixed jib

limit for junction box
H1
Dismantling
Assembly and
Hoisting limit for H2
A view
Figure 5-32 Wire layout of main boom junction box

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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
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
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.
d) All limit switches have been correctly fitted and are fully operational.
Dismantling
Assembly and
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.

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.
Dismantling
Assembly and
Figure 5-33 Raising main boom

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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.
CAUTION
Dismantling
Assembly and
(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

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.
Dismantling
Assembly and

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5.8 Assembly and dismantling of main boom with fixed jib

5.8.1 Preparation for assembly
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
Dismantling
Assembly and
G74
G31
Figure 5-34 Fixed jib pivot section assy.

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.
3
Dismantling
Assembly and
- 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:

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G32
G34
1 2
G31
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.
Joint one end of front tilting-back support of fixed jib (G74) to fixed jib pivot section with pin
Dismantling
Assembly and
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.

7, 8
- 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.
Dismantling
Assembly and
9, 10

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Table 5-11 Connecting parts of fixed jib
Names of
the parts
1 Pin spindle 00663000200001022
Retaining
2 spring 006340000029
(D30,32,35)
GB/T5783-2000
3 Bolt 1040000108
(ISO4017-1999)
4 Washer 1040300054 GB/T93-1987
Retaining
5 006340000019 PD0406
plate 60
6 Pin spindle 00663050200001010
7 Pin spindle 00663308000001020

Dismantling
Assembly and
8 Pin - 5×50 1040500057 GB/T91-2000
9 Pin spindle 00663003100401010
10 Retaining pin 00663604100001050

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.
Dismantling
Assembly and
Figure 5-39 Installation of load hook

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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.
Dismantling
Assembly and

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.
b) Check warning light on boom head
Dismantling
Assembly and
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
triggered, and then check whether the icon “upper limit switch on H2” on the screen will
flash and the buzzer will sound.

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
5.8.4 Raising main boom with fixed jib
5.8.4.1 Prerequisites
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.
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
Dismantling
Assembly and
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.

Figure 5-42 Raising main boom with fixed jib

Dismantling
Assembly and
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.

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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,
dismantling fixed jib rear anchoring rods and then fixed jib front anchoring rods.
Dismantling
Assembly and
- Dismember fixed jib sections one by one, leaving fixed jib pivot section assembled.
- Detach fixed jib pivot section assy. from main boom head.
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
(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.

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
3
Figure 5-44 Mounting parts of tip boom
Table 5-12 Mounting parts of tip boom
Names of
the parts
1 Retaining pin 00663300100001230

Dismantling
Assembly and
2 Pin spindle 00663000100001162
3 Pin spindle 00663020100001010

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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.
Dismantling
Assembly and

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 Transport dimensions and weights of main components
Names of the
Dimensions (mm) Weight Qty. Remarks
components
Width:
Basic machine 41.5t 1
3400mm
Counterweight Height:
2.7t 1
base plate 705mm
3.825t 2
plate 620mm
Dismantling
Assembly and
3.825t 2
plate 620mm
4.5t 2
plate 620mm

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
Crawler Crane
Names of the
components
Width:
80t load hook 1.25t 1
650mm
Width:
582mm
Width:
504mm
Width:
504mm Dismantling
Assembly and
Width:
350mm
Main boom Width:

1.2t 1
head 1700mm

Names of the
components
3m main
boom Width:
0.3t 1
intermediate 1700mm
section
6m main
boom Width:
0.44t 1
intermediate 1700mm
section
9m main
boom Width:
0.63t 4
intermediate 1700mm
section
Fixed jib pivot
section +
FA-frame +
Width:
front and rear 0.7t 1
740mm
tilting-back
supports of
fixed jib
6m fixed jib
Width:
intermediate 0.17t 2
560mm
section
Dismantling
Assembly and
Width:
Fixed jib head 0.21t 1
560mm

Operator’s
Operator’s Manual
Manual for
for Crawler Crane
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
are in good condition.
Dismantling
Assembly and
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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ZCC800H Crawler Crane

Edition 1 04, 2017

This manual applies to ZCC800H crawler crane.

Refers to a dangerous situation which, if you do not prevent, will cause

Refers to a possible dangerous situation which, if you do not prevent,

Refers to a possible dangerous situation which, if you do not prevent, may

Refers to a situation which, if you do not prevent, may cause property or

Safety Instructions ............................................................................................................................ II

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

Chapter 2 Description of Crane

2.1 Product model .................................................................................................................. 2-1

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

Chapter 3 Safety Guidelines

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

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

Chapter 4 Crane Operation

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

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

Chapter 5 Assembly and Dismantling

5.1 Safety-technical notes ...................................................................................................... 5-1

ZCC800HWG.1 CRAWLER CRANE 1-1

The content with respect to safety is marked with “ DANGER ”,

“ WARNING ”, “ CAUTION ” and so on. And the safety instructions involved

1-2 ZCC800HWG.1 CRAWLER CRANE

1.3 Alarms and warnings

1.4 Component safety features

1.5 Features for operator safety

ZCC800HWG.1 CRAWLER CRANE 1-3

1.6 Environmental safety

with maintenance procedures to ensure that engine emission is close to a

1.6.2 Consumable materials

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

1.7 Personal protective equipment (PPE)

1-4 ZCC800HWG.1 CRAWLER CRANE

1.8 Measured noise level

1.9 Vibration levels

1.10 Organizational safety measures

ZCC800HWG.1 CRAWLER CRANE 1-5

1.11 Personnel qualification, requirements and responsibilities

1.12 Safety advice regarding specific operational phases

1.12.3 Unguarded areas

1.13 Special Hazards

1.13.1.1 External considerations and hazards

1-6 ZCC800HWG.1 CRAWLER CRANE

b) If your machine comes into contact with a live wire:

1.13.1.2 Machine – Electrical

1.13.2 Gas, dust, steam, smoke and noise

1.13.3 Welding or naked flames

ZCC800HWG.1 CRAWLER CRANE 1-7

1.13.4 Hydraulic equipment

experience of hydraulic system.

1-8 ZCC800HWG.1 CRAWLER CRANE

Chapter 2 Description of Crane

ZCC800HWG.1 CRAWLER CRANE 2-1

Figure 2-2 Position of product name plate

2-2 ZCC800HWG.1 CRAWLER CRANE

2.1.2 Engine type and its manufacturer

2.1.3 Intended use of the crane

2.1.4 Crane design calculation

ZCC800HWG.1 CRAWLER CRANE 2-3

2.1.4.2 Classification of the crane

2.1.4.3 Service life

2-4 ZCC800HWG.1 CRAWLER CRANE