ZOOMLION CRAWLER CRANE ZCC800HWG Maintenance Manual

Vision creates futureProfession Heavy-industry Science & technology

Zoomlion Heavy Industry Science and Technology Co., Ltd.

Add: Quantang Industrial Park, 2nd Yuanda Road, Changsha Economic and Technological Development Zone, Hunan Province, China PC:410131Service-hotline:400-800-1680Fax:0086-0731-85585850E-mail:[email protected]:www.zoomlion.com

Maintenance and Service Manual

MAINTENANCE AND SERVICE


ZCC800H CRAWLER CRANE


800H CRAWLER CRANE

MAINTENANCE AND SERVICE MANUAL

The 1

800H CRAWLER CRANE


The 1st edition (April, 2013)

800H CRAWLER CRANE


edition (April, 2013)

800H CRAWLER CRANE



800H CRAWLER CRANE





I

Crawler Crane

Our respectable users, thank you very much for choosing ZOOMLION crawler crane. Before operating the crane, read these operating instructions carefully.

Regular inspection, maintenance and service of crane are very important to make full use of crane performance, ensure crane safe operation and extend the service life of crane. Therefore, we offer you this Maintenance & service manual to facilitate your inspection, maintenance and service work.

This manual details the inspection, maintenance and service work to ZOOMLION crawler crane, and lists some common problem occurred and their solutions.

For safetys sake, do not maintain the crane before you fully understand the contents in this manual, operating manual and other technical documents. If there is anything in this manual you do not understand, please contact local service engineer of Zoomlion, and they will provide you efficient technical support in time. Any risks associated with unspecified and improper use are the sole responsibility of the cranes owner, operator or user.

Unauthorized person is not allowed to dismantle or adjust the hydraulic elements during maintenance. When the hydraulic system of crane fails or the components are damaged, please contact local service engineer of Zoomlion.

Our products and technical documents are subject to technical improvements and changes without notice. Therefore, please acquaint yourself with our updated technology information. If there are differences between illustration and product, refer to the product. If there is any question, please contact the local service engineer of Zoomlion.

For you

Crawler Crane

The following symbols appear in this manual:

Indicate an imminent threat or danger, which could lead to

life-threatening or fatal injury of one or more persons.

Indicate a danger, which could lead to serious injury of one or more

persons.

Indicate a potential danger, which could lead to slight or minor injury of

one or more persons.

Indicate a danger which could lead to severe damage to the machine

or other assets.

Indicate a tip or hint in the machine operating instructions.

Emphasize the importance of the information in operating instructions.

Is located wherever an action that could create a dangerous situation is prohibited.

Special information

III

ZCC800HWG Crawler Crane

For you ......................................................................................................................................... I

Special information .................................................................................................................... II

Chapter 1 About this manual ............................................................................................. 01-1

1.1 General ......................................................................................................................... 01-1

1.2 Product identification .................................................................................................... 01-1

1.3 Illustration and symbols ................................................................................................ 01-2

1.4 Hazard indicator ........................................................................................................... 01-2

Chapter 2 Safety instructions ............................................................................................. 02-1

2.1 Safety guidelines .......................................................................................................... 02-1

2.2 Environmental protection disposal ................................................................................ 02-2

Chapter 3 Description of the crane .................................................................................... 03-1

3.1 Description of main components .................................................................................. 03-1

3.2 Hydraulic system .......................................................................................................... 03-3

3.3 Electrical system ........................................................................................................... 03-5

Chapter 4 Maintenance and service ................................................................................... 04-1

4.1 General ......................................................................................................................... 04-1

4.2 Precautions ................................................................................................................... 04-1

4.3 Cycle description .......................................................................................................... 04-5

4.4 Maintenance plan ......................................................................................................... 04-6

4.5 Maintenance of the power system ................................................................................ 04-9

4.6 Maintenance of the reducer ........................................................................................ 04-15

4.7 Maintenance of the slewing ring ................................................................................. 04-19

4.8 Maintenance of the crawler travel .............................................................................. 04-20

4.9 Maintenance of hydraulic system ............................................................................... 04-22

Contents

IV


4.10 Maintenance of the electrical system ....................................................................... 04-29

4.11 Maintenance of hooks and pulleys ........................................................................... 04-33

4.12 Maintenance of wire ropes ....................................................................................... 04-36

4.13 Maintenance of air conditioning equipment .............................................................. 04-40

4.14 Maintenance of the lubricating system ..................................................................... 04-41

4.15 Appearance inspection for structure components .................................................... 04-45

Chapter 5 Troubleshooting ................................................................................................. 05-1

5.1 Troubleshooting of mechanical drive ............................................................................ 05-1

5.2 Troubleshooting of power system ................................................................................. 05-1

5.3 Troubleshooting of hydraulic system ............................................................................ 05-4

5.4 Troubleshooting of electrical system ............................................................................ 05-7

5.5 Troubleshooting of air conditioning system ................................................................. 05-11

Chapter 6 Application of oil ................................................................................................. 06-1

6.1 Antifreeze coolant ......................................................................................................... 06-1

6.2 Lubricating oil ............................................................................................................... 06-1

6.3 Diesel oil ....................................................................................................................... 06-2

6.4 Gear oil of reducer ........................................................................................................ 06-3

6.5 Hydraulic oil .................................................................................................................. 06-3

6.6 Lubricating grease ........................................................................................................ 06-5

Chapter 7 Appendix ............................................................................................................. 07-1

7.1 Tightening torque of threaded parts .............................................................................. 07-1

7.2 Tightening torque of thread parts at pipe orifices ......................................................... 07-2

7.3 Attached tools for maintenance .................................................................................... 07-3

7.4 Checklist for periodic inspection ................................................................................... 07-4

Chapter 1 About this manual

Maintenance and Service Manual for Crawler Crane

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1.1 General

This manual is compiled for crane maintenance personnel to carry out daily maintenance and periodic service. Read and understand the content in this manual before crane maintenance and service work.

Perform the crane maintenance and service work in accordance with the requirements

stipulated in this manual, especially the information about ,

and .

This manual does not include all requirements for maintenance and service. They are only for reference to help maintenance personnel to do the work. It is no substitute for official training.

This manual is compiled according to the working status of crane. However, it may be different from the actual status of crane due to technical improvements. Therefore, you can contact us if you want to know about more accurate information about the crane.

1.2 Product identification

The crane name plate is located in a prominent position at the outside of cab. The following figure shows the detail position of name plate.

The user can distinguish this crane from the other via the name plate. The information on it is helpful for crane maintenance and service. Please keep it in a good condition within the service life of crane.

The serial number on the name plate is for crane identification. The users can confirm the crane components and relevant technical data by this serial number. The serial number of this crane shown in the following figure is ZCC80-0001.

Fig. 1-001 Position of name plate

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1.3 Illustration and symbols

This manual has a mass of illustrations, which are schematic. The meanings of illustrations are as follows:

Position of working mechanism to be operated

Sequence of operation

Correct operating way

Unpermitted or dangerous operating way

The illustrations in this manual may be different from the actual condition of crane. However, this does not hinder the user from understanding the meanings of illustrations.

1.4 Hazard indicator

The content with respect to the safety is marked with , the safety instructions involved in the book are only the conventional contents.

The following terms that are used in this manual CAUTION, WARNING, and DANGER are intended to point out certain important rules of conduct to all persons who maintain and service the crane.

Indicate a potential danger, which could lead to slight or minor injury of one

or more persons.

Indicate a danger, which could lead to serious injury of one or more persons.

Indicate an imminent threat or danger, which could lead to life-threatening

or fatal injury of one or more persons.

Chapter 2 Safety instructions


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2.1 Safety guidelines

Since various dangerous factors exist during maintenance and service of crane, the following are the safety guidelines for service technician to maintain and service crane superstructure and undercarriage. Read and understand these safety guidelines before maintenance and service work.

a) The maintenance work must be done by qualified personnel who have received training in crane technology, especially in electrical and hydraulic systems of crane.

b) The service technician must read and understand the operating manual, acquainting himself with crane and its operation.

c) Do not perform any maintenance work if the service technician is in low spirits, or he has drunk, or he has taken medicine which may affect the work.

d) No unauthorized personnel are accessible to crane during maintenance and service.

e) Make sure that the platforms, handrails, ladders and slewing table are free from dust, snow and ice.

f) The service technician must wear tight-fitting protective clothing when servicing the crane, together with the correct personal protective gear such as safety goggles, breathing mask for the particular activity.

g) Correctly use auxiliary equipment and set up working platform before performing high-level operation.

h) Do not reach into moving drives or parts of the crane. The service technician must remove the ignition key and hang the Prohibit sign on the control device before operating these drives or parts.

i) Do not touch hot components, hot pipelines, hot liquid and engine when the engine just stops. Only when the engine is cooled down for more than one hour, can the relevant maintenance work be carried out.

j) Depressurize all pipelines or containers before demounting the fittings or disconnecting the pipeline. Take preventive measures to protect personnel against injuries due to escaping hydraulic oil or air under high pressure.

k) The customer must use original spare parts which meet with technical requirements, and must use standard components which comply with the technical standards in Spare Parts Catalogue so that the designed service life of crane can be fulfilled and the crane safety can be guaranteed.

l) Cut off the grounding terminal of battery and turn off mast power switch before dismantling battery and welding operation on the crane.

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2.2 Environmental protection disposal

Some harmful substances such as engine oil, lubricating grease, fuel, antifreeze coolant, hydraulic oil and refrigerant will be produced during maintenance. These substances and relevant things will damage the environment and peoples health, therefore, they must not get into the ground, into water or into the sewer system, and they must be recycled and disposed of according environmental protection regulations.

Dispose harmful substances according to the following regulations:

a) The maintenance personnel must wear suitable protective gear such as protective clothing, protective gloves, safety goggles, breathing mask for the particular activity, since the polluted substance is corrosive and poisonous.

b) When supply the crane with oil or lubricating grease which can pollute the environment, proper filling equipment such as refueling pump, oil filling device, hose, container and funnel must be used to prevent these substances from coming contact with the natural environment.

c) Some lubricating oil may flow out when dismantling and changing the components. Some oil may get into ground or into sewer system when changing oil. This will severely pollute the environment. Therefore, a proper container must be used to collect the waste oil and other waste materials. The refrigerant can not be released into the air.

d) The pollutant must be gathered together and preserved according to different categories for follow-up disposal, thus reducing the costs. During this time, take measures to prevent loss of pollutant.

e) Use special container to move the pollutant from one position to another. Ask specialized company to recycle the pollutant. Dispose of the waste materials according to relevant environmental protection regulations.

f) If the pollutant comes into contact with the natural environment or persons skin due to unexpected conditions, some emergency measures must be taken. If the pollutant falls down on the ground, collect it into a container to avoid it permeating into soil or sewer system. If the pollutant is sprayed on the skin, it must be rinsed away as quickly as possible with a lot of clean water. In the event of eye injuries, use an eye-bath to rinse the eyes, and seek medical attention.

Chapter 3 Description of the crane


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3.1 Description of main components

Fig. 3-001 Overview of crawler crane

Main boom anchoring rods

Wire rope for hoisting winch 2

Wire rope for hoisting winch 1

Main boom

Tip boom

Main load hook

Auxiliary load hook

Travel gear

Rear anchoring rods of A-frame

Derricking pulley block

Main boom tilting-back support

A-frame

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Fig. 3-002 Overview of crane undercarriage

Operators cab

Left crawler carrier

Main valve

Oil cooling fan

Hydraulic oil tank

Counterweight

Main boom derricking winch

Oil pump

Engine system

Hoisting winch 2

Hoisting winch 1

Fuel tank

Right crawler carrier

Slewing mechanism

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3.2 Hydraulic system

The hydraulic system consists of main pump, triple gear pump, main valve, motor and so on. The pump-control hydraulic system is applied in the crane.

3.2.1 Hydraulic system diagram

Fig. 3-003 Hydraulic system diagram

Engine

Main pump Triple gear pump

Dual valve Triple valve

Slewing pump

Cooling motor

Control valve block

Slewing motor Reducer

Hoisting winch 1 motor

Derricking motor Reducer

Reducer

Hoisting winch 1 motor

Reducer

Traveling motor (L) Reducer

Traveling motor (R) Reducer

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3.2.2 Arrangement of hydraulic elements in slewing table

Fig. 3-004 Arrangement of hydraulic elements

Hydraulic oil tank Oil radiator Control valve Triple main valve Dual main valve

Travel control valve

Control valve block

Central revolving joint

Pilot oil filter Clutch control solenoid valve Pilot control valve Pump unit Solenoid valve

Energy accumulator

Derricking brake valve Ratchet control valve Winch brake valve Outer brake valve

Slewing valve

Slewing brake solenoid valve

Slewing cushion valve

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3.3 Electrical system

3.3.1 Electrical system diagram

Fig. 3-005 Electrical system diagram

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3.3.2 Arrangement of electrical elements in slewing table

Fig.

3-

006

Arr

ange

men

t of e

lect

ric e

lem

ents

Junction box 2

Junction box 1

Video camera

Working floodlight

Main boom angle limit switch To connector on boom

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Fig.

3-

007

Arr

ange

men

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lect

ric e

lem

ents

Shutoff valve limit switch

Inclinometer

Electrical control box

Horn Traveling alarm

Slewing limit switch Battery

Battery master switch

Oil level sensor

Lowering limiter for hoisting winch 1

Lowering limiter for hoisting winch 2

Junction box 3

Slewing alarm Slewing alarm

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Tricolor light

Working floodlight

Junction box 3

Fig.

3

-008

Arr

ange

men

t of e

lect

ric e

lem

ents

Chapter 4 Maintenance and service


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4.1 General

A crane should be maintained regularly to ensure that it is always in a good state for safe use.

In addition to oil inspection and change, the maintenance work also involves frequent inspections to ensure that components are in good state.

Appropriate workshop equipment shall be available for the lubrication and maintenance work.

The regulations and instructions in the Operating Manual for Crawler Crane shall be followed.

When being removed during the maintenance, safety devices should be reinstalled and inspected upon completion of the maintenance work.

Fuels, lubricants and replaced parts must be safely treated in compliance with the regulations for environmental protection.

4.2 Precautions

General precautions during the maintenance work are described as follows:

a) Wear work clothes when conducting the maintenance.

b) Put a crane on a firm and flat site and set a warning board marked with Crane in inspection.

c) Working at a position higher than 2m is considered as work at heights. Use ladders and safety belts in such a situation.

d) Act in accordance with the commander's signal when moving a crane for maintenance.

e) Prevent dusts and dirty articles from entering the hydraulic system which is in inspection or maintenance.

f) If any items have to be maintained and adjusted immediately, maintain and adjust them immediately.

g) If repair is necessary, contact the local office of Zoomlion Mobile Crane Branch Company.

h) In order to ensure the performances of a crane, use the accessories and lubricating grease designated by Zoomlion.

i) Replace consumables, such as filter elements, in time as specified to avoid faults.

j) When any problems are difficulty to be determined in inspection or maintenance, contact the local office of Zoomlion Mobile Crane Branch Company.

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ZCC800HWG Crawler Cranes

To ensure safety, pay attention to the following points during the maintenance:

l When a crane is in inspection and maintenance, drop the boom to the ground, stop the engine, lock the engine and remove the switch key to prevent other operators from starting up the engine during the inspection and maintenance work.

Failing to follow this instruction may cause personnel injury or death.

l Set up a warning board for the inspection and maintenance process.

In inspection and maintenance, a warning board marked with In Inspection and Maintenance, Please Do not Start it Up should be set at the key switch.

l Use the clean lubricating grease.

Keep the rooms for storing the lubricating grease clean. Do not make dusts, water, or other things enter the vessels. Ensure that the lubricating grease is free of water.

Fig. 4 - 001

l Keep the body clean.

Clean the body with water to inspect for oil leakage, cracks, looseness of connectors, and other abnormalities. Especially, keep grease nipples, vent holes and dipsticks clean to prevent dusts from entering them.

Fig. 4 - 002

(1) After cleaning the body, lubricate the transmission shafts and slewing connectors of the crane.

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(2) Clean the steering wheels, central consoles, control panels, base plates, and the decorations in the stained cab only with the warm water that contains cleaning agents.

(3) Do not use corrosive cleaning agents.

l Treatment of oil stains

When fuel, hydraulic oil, lubricating grease are injected or changed, or filter elements are replaced, the oil might splash out. Therefore, wipe off the oil having splashed out in time to avoid fires. When cleaning the machine, do not spray water on the electric elements and connectors.

Fig. 4 - 003

l Pay attention to fire prevention

Put oil stained or other combustible stained garbage in safe places, and be familiar with the places of storing and methods of using the fire extinguishers.

Fig. 4 - 004

l Pay attention to the rotating parts

When inspecting fan belts or pump, stop the engine in advance to avoid dangers of being caught.

Fig. 4 - 005

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l Pay attention to the water and oil temperature.

It is dangerous to drain water, drain oil or replace filter elements when the engine is just stopped. For this reason, drain water, drain oil, or replace filter elements only after the temperatures have dropped. When the oil temperature is too low, the oil shall be heated properly (to the temperature ranging from 20 - 50 C) before being drained.

Fig. 4 - 006

l Inspect the drained waste oil and the old filter elements.

When changing the oil or filter elements, pay attention to inspecting whether there are metal chips or foreign articles.

l Prevent the intrusion of dusts.

Protect the dismantled hydraulic oil pipes and hydraulic elements with plugs or seal covers against the intrusion of dusts.

Fig. 4 - 007

l Clean joint surfaces.

After removing O-rings or other gaskets, clean the sealing surfaces, and replace the seal parts with new ones. When reassembling them, coat the sealing with a thin layer of oil.

l Pay attention to the internal pressure

When dismantling the pipelines, connectors or other relevant components with internal pressure, such as the hydraulic system, compressed air system, and fuel system, release the pressure in advance.

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Fig. 4 - 008

l Precautions for the welding process

Turn off the power, disconnect power lines of the batteries, do not apply a voltage of more than 200V successively, set the grounding within 1m from the welding points, and set no sealing or bearings between the welding points and the grounding points. Dismantle the load torque limiter or controller for welding around it to avoid damage.

l Treatment of the waste oil

Put the waste oil into the vessels and treat it as industrial emissions.

l Unprofessional personnel are forbidden to servicing the cranes or replacing parts for them.

l Record inspection

In order to learn about the correct working status of a crane and its components, perform regular inspections and recordings (Upon the use for the 1st time, use for the 1st time after a long-term out-of- service or maintenance, perform inspection according to the following requirements.).

For the record list recommended for inspection, see section 7.3.

4.3 Cycle description

All maintenance work is conducted intermittently and the interval is the maintenance cycle which is determined according to the operation status of the crane.

The maintenance cycle shall be subject to the following aspects:

a) The specific operating time (hours) of functional parts of the crane

b) The calendar time (date, month and year) when the crane is in operation and storage

In the maintenance of the crane, the maintenance cycle usually determined according to the first method and the special items are determined according to the second method.

Operation hours of the maintenance cycle refer to the operation hours of the engine, which can be read on the main display of the operators cab.

The maintenance cycle can be classified as follows according to duration of the interval.

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Table 4 - 001 Maintenance cycle

Maintenance type Operating time (hours) Maintenance cycle

Daily inspection (D) 10 Before being started up every day Weekly maintenance (W) About 50 Weekly

Monthly maintenance (M1) About 200 Monthly

Quarterly maintenance (M3) About 500 Every 3 months

Semiannual maintenance (M3) About 1,000 Every 6 months

Annual maintenance (M12) About 2,000 Yearly

4.4 Maintenance plan

Table 4 - 002 Maintenance plan

No. Working task

Maintenance Inspection

Monthly maintenance

M1

Quarterly maintenance

M3

Semiannual maintenance

M6

Annual maintenance

M 12

Daily inspection

D

Weekly inspection

W

4.5 Maintenance of

the power system

4.5.1 Daily inspection of the engine

4.5.2 Inspection of the engine operation

status

4.5.3 Maintenance of the engine (as required in the maintenance manual of the engine)

4.5.4 Cleaning of the air suction filter

4.5.5 Replacement of the air suction filter elements

4.5.6

Inspection of the cooling fluid

(antifreeze fluid) level and

supplementation of the cooling fluid

4.5.7 Change of the cooling fluid 2 years

4.5.8 Inspection of the fuel pipeline

4.5.9

Drainage and discharge of the

oil-water separator

4.5.10 Cleaning of the fuel tank

4.6 Maintenance of the reducer

4.6.1 Inspection of the oil level

4.6.2 Change of the gear oil

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No. Working task


Monthly maintenance

M1


M3


M6

Annual maintenance

M 12

Daily inspection

D

Weekly inspection

W

4.6.3 Lubrication of

bearings of the reducer

4.6.4 Inspection of brakes of the winch reducer

4.6.5 Inspection of securing bolts

4.6.6

Inspection of brake straps of

the hoisting winch 1 with free-fall

function

4.7 Maintenance of the slewing ring

4.7.1 Routine inspection

4.7.2 Lubrication of the gear surface

4.7.3 Lubrication of the

raceway

4.7.4 Inspection of the slewing ring bolt

4.8 Maintenance of the crawler travel

4.8.1 Regular inspection

4.8.2 Cleaning of the crawler

4.8.3 Lubrication of the crawler pin

4.8.4 Tension of track pad

4.9 Maintenance of hydraulic system

4.9.1 Routine

inspection of hydraulic system

Multiple items

4.9.2 Inspection of the

oil level of the hydraulic tank

4.9.3 Replacement of the return filter

4.9.4 Replacement of the air cleaner 2 years

4.9.5 Cleaning of the filter element In time

4.9.6 Change of the hydraulic oil

4.9.7 Cylinder inspection

4.9.8 Installation of the pipeline

4.10 Maintenance of

the electrical system

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No. Working task


Monthly maintenance

M1


M3


M6

Annual maintenance

M 12

Daily inspection

D

Weekly inspection

W

4.10.1 Inspection of the lighting system

4.10.2

Inspection of windshield wipers in the operator's cab as well as

cleaning solution

4.10.3 Inspection of the video monitoring

system

4.10.4 Battery inspection

4.10.5 Inspection of the limit switch

4.10.6 Inspection of

cable terminals and dust guards

Upon the basic machine disassembly or site transition every time

4.10.7

Prevention of electrical parts or

cables from catching fires

Upon the basic machine disassembly or site transition every time

4.11 Maintenance of

hooks and pulleys

4.11.1 Daily

maintenance of hooks

4.11.2 Pulley inspection

4.11.3 Inspection of

rolling bearings on the pulleys

4.11.4 Replacement of rolling bearings

4.11.5 Pulley lubrication

4.11.6 Inspection of the safety catch

4.11.7 Inspection of each hook body

4.12 Maintenance of the wire rope

4.12.1 Cleaning of wire ropes In time

4.12.2 Lubrication of wire ropes In time

4.12.3 Inspection of wire ropes

4.13 Air conditioner

4.13.1 Daily

maintenance of air conditioners

4.13.2 Maintenance of air conditioners in low

seasons

4.13.3 Regular

inspection of air conditioners

Multiple items

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No. Working task


Monthly maintenance

M1


M3


M6

Annual maintenance

M 12

Daily inspection

D

Weekly inspection

W

4.15 Structure component

4.15.1 Rotary table inspection

4.15.2 Inspection of substructures

4.15.3 Boom inspection

4.15.4 Inspection of the anchoring rod

4.5 Maintenance of the power system

4.5.1 Daily inspection of the engine

Inspect appearances of the engines components to ensure that all parts are intact and function normally.

Items to be inspected:

a) Inspect whether each part of the air suction pipeline is securely connected and free of breakage and leakage.

b) Inspect whether the circulating cooling water way, the fuel pipeline and the engine oil are all free of leakage.

c) Inspect whether the fan blades are free of damage and whether fan blades and other parts are not scraped.

d) Inspect whether the belts are not worn or torn and whether their tensions are within in the normal range.

e) Inspect whether there is water or materials of the sludge state in the transparent glass cup of the oil-water separator.

f) Inspect whether installation bolts (screws) of the engines and its subsidiary systems are reliably tightened and free of looseness.

4.5.2 Inspection of the engine operation status

Inspect the engine oil manometer, water temperature gauge, revolution counter and fault alarm indicator to make sure that the engine operates normally.

Inspection steps:

a) Start up the engine with the key switch and idle for 3 - 5 minutes.

b) Accelerate the engine slowly to increase the rotational speed of the engine to about 1500RPM.

c) Observe whether readings on the revolution counter change correspondingly during the acceleration.

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d) Read the values displayed on the engine oil manometer from the display screen, and the values are not less than 0.5bar in the idling process and not more than 6.5bar at the rated rotational speed. Inspection is required and repair is also required if necessary when the values are out of the ranges mentioned above.

e) When the engine has operated normally for about 10 minutes, the water temperature readings on the instrument panel shall increase; if the engine has operated for 30 minutes and the water temperature still remains below 70C, corresponding service is required.

f) When the engine operates normally, it is normal if the alarm indicator of the engine does not flash.

(Note: For detailed operation methods, refer to the Operating Manual for Cranes.)

4.5.3 Maintenance of the engine

The engine shall be maintained according to requirements of the Operating Manual and Maintenance and Service Manual prepared by the engine manufacturer and provided together with the engine.

4.5.4 Cleaning of the air suction filter

When the engine is at the rated rotational speed, if the pointer of the air filter s blocking indicator points at the read zone, it indicates that filter elements of the air filter are seriously blocked and need to be cleaned.

Inspection steps:

a) Loosen the bolts at tails of the air filters and dismantle the tail covers to pick out the external filter elements.

b) Pat on the filter elements to shake off the dusts and dirt on the external filter elements. Connect the compressed air with hoses and blow the compressed air out to the filter elements until all dusts are blown away.

c) Install the external filter elements back into the air filter and install the tail covers as before.

d) Nip the dust nozzle of the air filter open and knock on the shell of the air filter lightly to shake off the accumulated dusts.

e) Reset the air suction filter.

f) Start up the engine and stabilize the rotational speed to the rated rotational speed to confirm that the pointer of the blocking indicator points at the green zone.

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The schematic diagram for the cleaning process is as follows:

a) Shack off the dusts on the filter element. b) Blow the compressed air over the filter element surface.

c) Blow the compressed air over the filter surface.

d) Clean the sealed supporting surface.

Fig. 4 - 009 Schematic diagram for the cleaning process

Do not damage the filter elements when cleaning the external filter elements. Do not clean the internal filter elements (safety filter elements). Do not clean external filter elements for more than 5 times.

Do not start up the engine during the cleaning work.

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4.5.5 Replacement of the air suction filter elements

The external filter element must be replaced when it is cleaned for many times to avoid degradation of its filtering performance.

When changing the external filter element, replace the internal filter element (safety filter element) at the same time.

The replacement cycle for filter elements is 2,000 hours which will be shortened in the severe dust environment.

When changing the filter element, dismantle and install it in the method described in section 4.5.4.

Purchase the internal and external filter elements (safety filter elements and main filter elements) according to part numbers.

To ensure the quality of filter elements, purchase the filter element accessories from the basic machine manufacture.

4.5.6 Inspection of the cooling fluid level and supplementation of the cooling fluid

The cooling fluid (antifreeze fluid) of the engine might reduce continuously due to causes such as leakage and evaporation. Severe lose of the cooling fluid will result in poor capability for heat dissipation of the engine, causing damages to the engine.

Inspection of the cooling fluid level: unscrew the water tank cap to check the fluid level in the upper water chamber of the water tank, which shall be higher than 1/3 of the upper water chamber.

Supplementation of the cooling fluid: unscrew the water tank cap and add appropriate cooling fluid into the water tank to make the fluid level between 1/3 and 1/2 of the upper water chamber.

For requirements for performances of the cooling fluid, refer to section 6.1.

(1) Before adding the cooling fluid, stop the operation of the engine and make the engine cool naturally for a certain time.

(2) When unscrewing the expansion water tank cap, avoid getting burnt.

(3) Ensure that the added cooling fluid is the same as the original one.

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4.5.7 Replacement of the cooling fluid

When the cooling fluid has been used for 2 years, it must be changed. Even though the engine has not operated for a long time, the cooling fluid also needs to be changed.

Change steps:

a) Put a proper vessel under the cooling water tank to collect the cooling fluid.

b) Unscrew the water drain plug screw at the lower end of the cooling water tank to let the water flow into the collection vessel.

c) Install the plug screw at the water drain hole and inject about 43L of cooling fluid in total from the water inlet of the water tank.

d) Start up the engine and let it operate for several minutes to make the cooling fluid free of air bubbles before the fluid level is inspected again.

For the change cycles of the cooling fluid, refer to section 4.4.

Do not drain the cooling fluid to the natural environment.

4.5.8 Inspection of the fuel pipeline


a) Each welding line on the diesel tank shall be free of oil leakage marks.

b) Fuel hoses shall be free of leakage due to damages.

c) Connectors of the pipeline shall be free of oil leakage.

d) The diesel pump, injection nozzle, etc. of the engine shall be free of oil leakage.

e) The accumulated water in the transparent shell of the oil-water separator shall be checked. In the case of much water accumulated in it, drainage is necessary.

Once leakage is found, corresponding maintenance treatment is necessary.

For requirements for the fuel quality, see section 6.3.

Use the approved fuel to extend the service life of the engine.

4.5.9 Drainage and discharge of the oil-water separator

The water contained in the fuel is separated in the oil-water separator and the impurities with a large particle size (more than 30 micrometers) are filtered and settled down in the water collection cup at the bottom of the oil-water separator to form the sludge. When the water is accumulated a lot, it shall be discharged outside to prevent it from entering the engine cylinder together with the fuel. When a lot of sludge is formed, it will increase the resistance to the fuel system, thus reducing the output power of the engine and even making it unable to start up the engine when it get serious.

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The drainage process is as follows:

a) Put a proper vessel under the oil-water separator to collect the residual water.

b) Rotate the water drain valve at the lower end of the oil-water separator in the counter-clockwise direction to make the accumulated water flow out slowly.

c) When the diesel begins to flow out, rotate (close) the water drain valve in the clockwise direction until no diesel flows out.

The discharge process is as follows:

a) Disconnect the fuel tube between the oil-water separator and the fuel tank.

b) Put a proper vessel under the oil-water separator to collect the fuel.

c) Rotate the water drain valve at the lower end of the oil-water separator in the counter-clockwise direction to drain the fuel in it.

d) Unscrew off the oil-water separator shell in the counter-clockwise direction with a special-purpose belt wrench with the sludge accumulated in the shell cleaned.

e) When the water drain valve is closed, install the oil-water separator shell in the opposite direction and tighten it with the belt wrench.

f) Connect the fuel tube between the oil-water separator and the fuel tank.

g) Open the outlet of the oil-water separator (unscrew the plug screw).

h) Pump oil with the manual fuel pump and close the outlet when there is oil flowing out at the outlet.

i) Continue pumping oil with the manual fuel pump and stop it until it feels heavy on the hands.

4.5.10 Cleaning of the fuel tank

When the fuel tank has been used for half a year, oil sludge and water will be accumulated in the fuel tank. In order to keep the fuel tank clean, the fuel tank needs to be cleaned.

The cleaning method is as follows:

a) Put a proper vessel under the fuel tank.

b) Unscrew the oil drain bolts at the bottom of the fuel tank to make the residual oil flow out.

c) Dismantle the air filter over the oil tank and clean the filter screen.

d) Clean the internal surface of the oil tank with brushes and then flush it clean with diesel.

e) Reinstall the plug screw of the oil drain hole at the bottom of the fuel tank as well as the air filter.

f) Inspect whether there is any leakage at the plug screw of the oil drain hole after the

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diesel is injected and whether the oil level is normally indicated on the main display.

g) Install the cleaning cover for the fuel tank.

Treat the collected waste diesel according to relevant environmental regulations, and do not discharge it to the environment.

Take preventive measures to avoid fires when cleaning the oil tank.

4.6 Maintenance of the reducer

4.6.1 Inspection of the oil level

Inspect the oil level frequently. In the case of the oil level lower than the oil level mark, the gear oil shall be injected in time. In addition, the recommended gear oil shall be used according to different environmental temperatures.

Table 4 - 003 Oil change cycle and oil change amount of each mechanism

Mechanism name Gear oil grade Inspection

interval (hours)

Oil change interval (hours)

Oil change amount (L/each)

Hoisting winch reducer

L-CKD220 industrial enclosed gear oil 250 1,000 3

Derricking winch reducer

L-CKD220 industrial enclosed gear oil 250 1,000 3

Slewing reducer L-CKD220 industrial enclosed gear oil 250 1,000 5.5

Travelling reducer L-CKD220 industrial enclosed gear oil 250 1,000 10

Gear transfer box L-CKD220 industrial enclosed gear oil 250 1,000 3.5

4.6.2 Change of the gear oil

When the gear oil is changed, it shall be changed again after the machine has operated for a long time. It shall be drained off when the oil is hot and special-purpose tools are required when the oil is injected.

a) Change of the gear oil for the lifting and derricking winch reducers

1) Unscrew plug screws of the oil drain holes at the lower ends of the winch reducers and those of the oil fillers at the upper ends of the winch reducers to drain the original gear oil.

2) Open the oil filling plug screw and clean the gear with the cleaning oil (warm and clean oil) to remove the abrasive matters and foreign matters.

3) Tighten the oil drain plug screw, insert the head of a hopper into the oil filler, inject the specified gear oil to the plug screw of the sight hole, and then stop injecting the oil when the oil level reaches the middle position of the plug screw of the sight hole.

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4) Inspect the cleaning status and tighten the plug screw of the oil filler at the upper end.

Fig. 4 - 010 Schematic diagram for change of the gear oil

b) Change of the gear oil for the slewing reducer

1) Unscrew the oil drain rubber tube plug screw at the lower end of the slewing reducer and the screw plug of the oil filler at the upper end of the slewing reducer to drain the original gear oil.

2) Open the oil filling plug screw and clean the gear with the cleaning oil (warm and clean oil) to remove the abrasive matters and foreign matters.

3) Re-screw the oil drain rubber tube screw plug at the lower end, insert the head of a hopper into the oil filler, inject the specified gear oil to the plug screw of the sight hole, and then stop injecting oil when the oil level reaches the middle position of the plug screw of the sight hole.

4) Inspect the cleaning status and tighten the plug screw of the oil filler at the upper end.

Fig. 4 - 011 Schematic diagram for change of the gear oil

When oil is injected, this plug screw at the sight holeshall be screwed to inspect whether the oil level reaches the cock hole edge

Drain oil after the plug screw of the oil drain hole is screwed.

Inject oil after the plug screw is unscrewed.

Inspect the oil level

Unscrew the oil drain rubber tube plug screw

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4.6.3 Lubrication of bearings of the reducer

When the winch reducer operates every month or has worked for 200 hours, its bearings shall be lubricated with the lubricating grease injected with an oil gun.

Fig. 4 - 012 Schematic diagram for lubrication of the winch reducer

4.6.4 Inspection of brakes of the winch reducer

Inspect brakes of the hoisting winch reducer according to the following order:

a) Start up the engine and make it operate at a slightly high idle speed.

b) Apply a maximum load that the wire rope can bear to the corresponding hoisting winch.

c) Operate the control lever to make the hoisting winch 1 (2) lift the heavy objects up.

d) When the heavy object is suspended in the air, push the control lever of the hoisting winch 1 (2) to the middle position and then make a mark at a certain place on the winch drum.

e) Retain the heavy object suspended in the air freely for several minutes and then observe whether the position of the mark moves. In the case of no movement, it indicates that brakes of the winch reducer are good.

Inspect brakes of the derricking winch reducer according to the following order:

a) Start up the engine.

b) Pull out the oil tube at the brake cylinder of the derricking winch reducer.

c) Operate the derricking erection action.

The oil cup for lubricating grease injection

Direction A (enlarged)

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d) If the holding pressure reaches the overflow pressure of the main pump and the derricking winch does not operate, it indicates that the derricking winch is effectively braked.

Assign only well-trained professionals to inspect the brake of a winch reducer. Incomplete brake may cause accidents.

There are dangers of being dragged. When carrying out the maintenance, inspection and installation work, and exercise caution to avoid dangers of being drawn or dragged between the winch and the winch wire rope.

4.6.5 Inspection of securing bolts

Inspect whether securing bolts of the winch are loose. If they are loose, tighten them.

4.6.6 Inspection of brake straps of the hoisting winch 1 with free-fall function

When selecting the hoisting winch 1 with free-fall function, inspect the brake straps.

Fig. 4 - 013 Schematic diagram for inspection of brake straps of the hoisting

winch 1 with free-fall function

a) When the hoisting winch 1 with free-fall function cannot be braked, its brake strap shall be adjusted through its own adjusting nut and con-rod. Prior to inspection of the brake strap, rivets within the areas shown in the picture above shall be inspected. If rivets have been worn or are to be worn, the brake strap shall be replaced immediately.

b) Brake straps of the hoisting winch 1 with free-fall function shall be inspected every week or after having worked for 50h. If rivets have been worn or are to be worn, the brake straps shall be replaced immediately.

The adjusting nut and con-rod of the brake strap

Rivet

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4.7 Maintenance of the slewing ring

4.7.1 Routine inspection

a) Inspect the flexibility of the slewing ring. If noises, impacts and powers are found to increase suddenly, it shall be shut down for inspection, troubleshooting and overhauling when necessary.

b) Regularly inspect whether there are defects such as cracks or damages on the slewing gear ring, seizing, bite and peeling of on the gear surface.

c) Frequently inspect the perfection of the sealing. If the seal belt is found to be damaged, replace it in time. If it is found to peel off, reset it in time.

4.7.2 Lubrication of the gear surface

Gear rings of slewing rings have been coated with the rust preventive oil before being delivered from the factory. This rust-proof oils period of validity is usually 3 to 6 months. Upon expiration of the period of validity, they shall be coated with the rust preventive oil in time. At the same time, it is forbidden to flush the slewing rings with water directly to prevent the water from flowing into the raceway.

4.7.3 Lubrication of the raceway

Raceways must be injected with lubricating grease regularly according to the work environment. After having worked for 50h, raceways shall be injected with the lubricating grease. In special work environment, such as tropical belts, large humidity, many dusts and large temperature variation and having worked continuously, the lubrication cycle shall be shortened and the slewing ring must be injected with grease before and after a long-term placement.

The grease should be injected when the slewing ring operates. When the lubricating grease flows over from the seal, it indicates that the injection is completed and the over flown grease will form a thin film to seal it.

4.7.4 Inspection of the slewing ring bolt

Requirements for inspection:

a) When the slewing ring has been used for 100 working hours for the 1st time, inspect the pre-tightening torque of the bolts for once. If more than 10% of bolts get loose, tighten them and then inspect them again at the 200th working hour.

b) Then inspect them every 500 working hours and the inspection interval shall be shortened under poor working conditions.

c) When the equipment has worked for 2,000 hours accumulatively, if a bolt has been loosened to less than 80% of the specified torque, replace this bolt and its two adjacent bolts. If 20% of bolts are found to get loosened to less than 80% of the specified torque, replace all the bolts.

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d) Usually, it is necessary to replace all bolts every 7 years or after having worked for 4,000 hours.

e) When bolts are replaced, wipe them clean and then tighten them after coating them with the lubricating oil. The tightening torque shall be 1800N.m.

4.8 Maintenance of the crawler travel

4.8.1 Regular inspection

Insufficient lubrication of the connecting pin of crawler, improper tension degree of track pad, or smudginess on the crawler will cause noises and premature wear. Therefore, inspect the crawler at intervals of less than one month before each work or after the crane has traveled for a long journey.


a) The wear of crawler traveling devices, lubrication of crawler pin, and tensity of track pad.

b) The wear of the track roller or track carrier roller of the crawler, and lubrication of roller.

c) The wear of driving device, lubrication of reducer and smudginess of the crawler.

4.8.2 Cleaning of the crawler

Clean the crawler when it is dirty. The cleaning involves wiping off the dirt on track pad, sundries on the crawler carrier, and soil being mingled in between the drive sprocket or track roller and the track pad, etc.

4.8.3 Lubrication of the crawler pin

Put the crawler pin in a position that can be lubricated, and spray the crawler pin at joint with lubricant. Move the crane forward until the lower crawler pin is located on track carrier roller, and spray the crawler pin at this part with lubricant. You can also lubricate the crawler pin by daubing the waste oil.

4.8.4 Tension of track pad

Before checking the tensity of track pad driving, the track pad must be cleaned. The tensity of track pad driving is estimated by its relaxation around 15 5 millimeter, and the crawler components must be tightened or loosened subject to their tightness.

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Fig. 4 - 014 Schematic diagram of relaxation estimation of the crawler driving

The tensity of crawler must be adjusted when the machine is on level ground. Slightly move the crane body forward before adjusting to concentrate the loose parts of the crawler on the top of drive sprocket, so that it can be easily adjusted.

Adjustment steps:

a) Unload the bolts and shields from both right and left sides.

b) Align the hydraulic jacks with the push rods respectively under nature state.

c) Press the handle of the hydraulic jack slowly to move its driving axis and tension wheel forward, causing spacing between crawler frames and gaskets.

d) After adjusting the crawler to appropriate tension, stop the movement of hydraulic jacks and fill in the spacing between crawler frames and gaskets with gaskets, and then mount the shield. After adjusting the crawler to appropriate tension, stop moving forward the tension cylinder.

e) If the wear of pin hole on of the track pad is relatively larger, remove one track pad and tension it again when the track pad still fails to be tensioned after the tense wheel block reaches the end.

f) Mount the shield.

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4.9 Maintenance of hydraulic system

To ensure that the hydraulic system is in a good status for long-term operation, maintain the hydraulic system on time.

4.9.1 Routine inspection of hydraulic system

For the inspection period of hydraulic system, see the following table.

Table 4 - 004 Inspection period of the hydraulic system

S/N Inspection and maintenance items Inspection interval (hours) Remarks 8 100 250 500 1000 1500 2000

1 Oil level inspection of hydraulic oil

2 Sediment inspection of hydraulic oil tank

3 Replace the return oil filter element

4 Replace the pilot filter element

5 Replacement of the air cleaner

6 Replacement of the hydraulic oil 800 L

7 Oil leak and damage

inspection of pipelines and joints

8 Air cleaner block inspection

9 Oil leak of oil cooler and damage inspection

10 hydraulic motor, oil leak

of pump and unusual sound inspection

11 Oil leak of hydraulic valve inspection

12 Oil leak of accumulator and damage inspection

Note: The sign indicates initial replacement. The sign indicates that the inspection is required. The sign indicates periodic replacement.

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4.9.2 Inspection of the oil level of the hydraulic tank

The level of hydraulic oil must be checked every 8 hours, and the status of hydraulic oil is inspected as described the following table.

Table 4 - 005 Decision of hydraulic oil status

Mixing of

foreign objects

Spares Determination Determination method Dust and

metal powder

from outside

Test tube (transparent)

and fresh hydraulic oil

Appearance comparison

In the state of starting up the engine, take the sample from hydraulic oil tank or pipeline, and compare it with fresh oil for its turbid condition.

Water

Test tube or transparent containers,

fresh oil

Appearance comparison and heating estimation

Oil within the hydraulic oil tank becomes opaque. Heat up the opaque oil sample to see the settled

water at the bottom. Take out the opaque oil sample and insert the red-hot bar iron. Then

sizzle is generated. Dropping the opaque hydraulic oil on a heated iron plate will also

sizzle. Before starting the engine, unscrew the oil drain valve of the hydraulic oil tank. Take out the

oil sample, and then observe the subsidence situation of water.

Degradation

Test tube or transparent containers,

fresh oil

Appearance estimation

and sensation estimation

Take the oil sample from the hydraulic oil tank or the pipeline, inject it into the container, and

compare its color and odor (smell) with the fresh oil. Oxidation and deterioration oil will turn to black brown, and badly degenerative oil will

stink.

a) Before starting the engine, check the oil level in the hydraulic oil tank. The level displayed on the liquid level meter below the visual position indicates insufficient hydraulic oil of the hydraulic system. Fill the hydraulic oil till it reaches the visual position, and then start the engine.

b) If the oil in the oil tank reduces fast, check the hydraulic pipelines and elements, find the leak position, and stop the leakage before starting the engine.

c) Over temperature (above 80 C) of hydraulic oil will accelerate the degradation of hydraulic oil and shorten the service life of hydraulic elements. Low temperature (below 20 C) indicates that the flow of hydraulic oil is poor, and an overhasty operation may damage hydraulic elements. Therefore, after starting the engine at low temperature, preheat it to make the temperature of hydraulic oil reach around 20 C.

d) Refer to the following table for the inspection after starting the engine.

Table 4 - 006 Inspection after starting the engine

Inspection items Inspection method Determination Purpose

Hydraulic oil temperature

Visual inspection hydraulic oil tank thermometer

Normal temperature from + 30 C to + 80 C

Find the abnormality of the hydraulic system at early

stage, and extend the service life of hydraulic

components.

Oil leakage Visual inspection No leakage allowed Find the leakage at early stage.

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Inspection items Inspection method Determination Purpose

Pump temperature Infra-red thermometer

Temperature is 5 C higher than the oil tank

Find the abnormality of pump at early stage.

Pump noises Sensation (volume/acoustic) Abnormal sound/change of

noises

Find the abnormal change of the hydraulic oil,

entrained air, wear of pump and filter blocking.

Motor temperature and noises

Hand touch/sensation (volume/acoustic)

Abnormal sound/change of noises

Find the abnormality of the motor at early stage.

Remarks Hydraulic oil cannot be used permanently. Therefore, it must be inspected and replaced in

accordance with whether impurities have been mixed into the hydraulic oil or the degradation degree.

4.9.3 Replacement of the return filter

A signal on the pressure switch of a filter element of the return filter indicates that the filter element is blocked. In such a situation, replace the filter element.

a) Unscrew the filter cover (cleaning cover) of the return filter, and replace the filter element or refuel the oil tank. Set two M18*1.5 oil ports at the filter head, and install the pinger at any part.

b) Replace the filter element of the return filter every 500 hours, with the initial replacement subject to 50 hours.

Fig. 4-015 Diagram of hydraulic oil tank

Air cleaner

Oil tank Liquid

thermometer

Butterfly valve

Return filter

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Fig. 4 - 016 Diagram of return filter

When replacing the filter element, do not install it reversely to avoid serious consequences.

4.9.4 Replacement of the air cleaner

In hydraulic system, the air cleaner of oil tank needs to be checked on time subject to every hydraulic oil adding for the hydraulic system. Inspect the hydraulic system, clean the dirt on it in time, and replace the damaged one if any.

Fig. 4 - 017 Diagram of air cleaner

1. Open the cover of the air cleaner while injecting the hydraulic oil.

Cleaning cover of return filter, unscrew and replace the filter element.

2. Check the air cleaner after injecting the hydraulic oil.

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4.9.5 Cleaning of the filter element

Inspect the filter, find the dirt on it, and then clean the filter in time.

Steps for cleaning:

a) Take out the filter with a special-purpose wrench.

b) Clean the filter element with dedicated cleaning solution or clean diesel.

4.9.6 Change of the hydraulic oil

Before delivery, the hydraulic oil tank of this product is filled with 800-liter hydraulic oil whose oil grade is GB11118.1-94 L-HV32, L-HM46, L-HM68, or HS 0358-95 aviation hydraulic fluid 10# subject to the regional work.

Inspection and replacement cycle of hydraulic oil:

The normal replacement cycle for hydraulic oil is 2,000 working hours. If it is obviously dirty, replace it immediately regardless of the running time. Inspection items and replacement cycle for hydraulic oil are as follows:

Table 4 - 007 Inspection items and replacement cycle for hydraulic oil

S/N Inspection items Inspection and replacement cycle (hour) Remarks 5 500 2,000

1 Inspection of the oil level Main oil tank

2 Oil tank cleaning

3 Change of the hydraulic oil 800 Liters

Oil level inspection of hydraulic oil:

Check the oil level when the crane is traveling. The liquid thermometer is provided with scales through which you can check the temperature of hydraulic oil and the oil level. The lowest oil level line is the 0 C scale mark. Thus, an oil level of lower than 0 C scale mark indicates that the hydraulic oil should be supplemented.

Oil change steps:

a) Drain the hydraulic oil in oil tank.

b) Dismantle the general return oil pipe, clean the oil tank and filter carefully. Specifically, clean the oil tank and filter with the chemical cleaning agent whose solid contamination degree does not exceed 18/15. After cleaning and airing them, clean them with fresh hydraulic oil whose solid contamination degree does not exceed 18/15.

c) Drain the flushing oil and fill in fresh hydraulic oil again.

d) Start the engine, run the engine in low velocity to energize the oil pump.

e) Manipulate each mechanism respectively and drain the used oil of each loop of the system one by one on the basis of fresh hydraulic oil. The used oil drained cannot flow into the hydraulic oil tank.

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f) Stop the oil pump when there is fresh oil flowing out from the general return oil pipe.

g) Connect the general return oil pipe with oil tank and set each element to initial working state at last.

h) Supplement hydraulic oil for the oil tank until it reaches the visible window of the liquid level meter of hydraulic oil tank.

Precautions for replacement:

a) Do not use the hydraulic oil for more than 24 months.

b) Filter or replace hydraulic oil in time upon heavily contaminated hydraulic oil.

c) Select appropriate hydraulic oil in accordance with the ambient temperature.

d) Do not mix the hydraulic oil of different grades.

e) When changing the oil, flush all of the original oil, and do not allow sundries like sand and dirt entering the oil tank.

f) When changing oil at each loop, constantly add fresh oil into the hydraulic oil to avoid empty oil pump.

g) When starting the engine at cold areas, ensure that the minimum temperature for starting is reached, and start the engine in no-load state. After the temperature of the no-load system reaches the minimum temperature required for running, slowly apply load to the system, and keep the system running at the temperature on the minimum load.

4.9.7 Cylinder inspection

Check for the oil leakage at the installation oil port and nearby pipelines of each hydraulic oil cylinder, and the scratches on the extension of piston rod.

4.9.8 Installation of the pipeline

When installing a hydraulic pipeline, pay attention to the following items:

a) Avoid distortion of a hose.

Fig. 4 - 018

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b) Ensure sufficient radius of bending.

Fig. 4 - 019

c) Use elbow and other connectors when necessary.

Fig. 4 - 020

d) Allow certain looseness to offset the shrinkage of the hose under pressure.

Fig. 4 - 021

e) Ensure fixed position of a hose with a clamp.

Incorrect

Correct

Correct Incorrect

Correct

Incorrect

Incorrect

Correct

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Fig. 4 - 022

4.10 Maintenance of the electrical system

4.10.1 Inspection of the lighting system

Check for normal operation of the illumination system.

As shown in the figure on the right (e.g.: aviation lighting devices)

4.10.2 Inspection of windshield wipers in the operator's

cab as well as cleaning solution

Check for normal operation of the windshield wiper weekly.

Location of sprayer is at the left rear side of the cab seat.

Add water into the sprayer constantly, and add a little cleaning agent when necessary.

4.10.3 Inspection of the video monitoring system

The monitor system is optional. If the monitor system is equipped, check for normal operation of the monitor system camera and the definition of LED image in the operators cab before using vehicles.

Fig. 4-023

Fig. 4 - 025

Incorrect

Correct

Fig. 4 - 024

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4.10.4 Battery inspection

Batteries must be well maintained and kept for use, because they function as the power supply of starting the engine, electrical control system, illumination and electrical auxiliary devices of the machine.

a) Store the battery (a filled and charged lead-acid battery) at the temperature ranging from 5 C to 25 C and in a dry, clean and ventilated environment. Do not expose the battery to direct sunshine to avoid degradation of the performance caused by high ambient temperature.

b) Do not inverse and place the battery horizontally. Do not shock and press the battery mechanically.

c) Recharge the battery in time to avoid performance degradation caused by the sulfating of the battery.

d) Do not overcharge the battery. Avoid premature failure of the battery caused by too much water loss, growth of grid and drop of diachylon.

e) Remove the batteries from the car and store them in a well-ventilated and dry place if they are used for long time (usually more than 15 days). Charge the batteries every 3-6 months (see if the indicator is black or not).

This series of lead-acid batteries for cars is the dry charged batteries produced in accordance with JIS Japan and DIN Germany. Dry charged batteries can start the car in 30 minutes after injecting the electrolyte. If possible, charging for 3 - 5 hours before use will result in a better starting performance.

Preparation before use:

a) Make sure the level of electrolyte is 10 mm higher than the minimum waterline.

b) Make sure the blow cock is crewed in case of acid leakage.

c) Check the air hole of the blow cock to ensure a smooth venting.

d) Pay attention to the positive and negative poles when connecting wires to avoid reverse connections.

Storage and maintenance:

a) The storage battery should be stored in a clean, dry, and ventilated storeroom at ambient temperature ranging from 5C to 40C. Be sure not to unpack the sealing bar or blow cock of the dry charged battery before use.

b) Under exceptional circumstances, the storage battery should be stored in company with electrolyte and be charged monthly through common charging method. The liquid level and density of electrolyte should also be regulated as required, and the density of electrolyte is 1.280.01g/cm3.

c) Do not prepare the electrolyte with river water, well water or water containing impurities. When using a battery, keep the external and wiring of the battery dry and clean.

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d) After discharging battery, charge it in time to avoid long-term idleness.

e) Open the blow cock while it is charging and screw up the blow cock before use.

f) Do not smoke and light fires at the charging site.

Exterior charging is required under the following circumstances:

a) The density of electrolyte falls to 1.170 and below.

b) Brownout.

c) Under-voltage, the voltage of the battery is under 0.8 V.

4.10.5 Inspection of the limit switch

Provide references for crane operators by real-time monitoring the working condition of the crawler crane, and displaying the condition on the moment limiter. In abnormal working condition, the crawler crane generates an alarm by an icon flashing on the system display interface, and interrupts the operations that could increase the danger.

1Hoisting winch 1 over-winding alarm

Over-winding of the hoisting winch 1 is also known as the main hook reaching the upper limit. By this time, the corresponding alarm indication blinks in the display, along with audible alarm. Meanwhile, the reel in movement of hoisting winch 1 and reel out movement of derricking winch will be cut automatically, and the bypass key switch operation is effective.

2Hoisting winch 1 over-release alarm

Over-release of the hoisting winch 1 is also known as only three circles of wire ropes left on the hoisting winch 1. By this time, the corresponding alarm indication blinks in the display, along with audible alarm. Meanwhile, the reel out movement of hoisting winch 1 will be cut automatically, and the bypass key switch operation is effective.

3Hoisting winch 2 over-winding alarm

Over-winding of the hoisting winch 2 is also known as the auxiliary hook reaching the upper limit. By this time, the corresponding alarm indication blinks in the display, along with audible alarm. Meanwhile, the reel in movement of hoisting winch 2 and reel out movement of derricking winch will be cut automatically, and the bypass key switch operation is effective.

4Hoisting winch 2 over-release alarm

Over-release of the hoisting winch 2 is also known as only three circles of wire ropes left on the hoisting winch 2. By this time, the corresponding alarm indication blinks in the display, along with audible alarm. Meanwhile, the reel out movement of hoisting winch 2 will be cut automatically, and the bypass key switch operation is effective.

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5Main boom 80 alarm

When the elevation angle of the main boom reaches 80, and limit switch at the root of main boom is closed, the corresponding alarm indication blinks in the display, along with audible alarm. Meanwhile, the reel in movement of derricking winch will be cut automatically, and the bypass key switch operation is ineffective.

4.10.6 Inspection of cable terminals and dust guards

Every dismantling of the basic machine and site transport requires the inspection for whether the cable terminal is aligned and plugged tightly and whether the dust guard is well covered.

4.10.7 Prevention of electrical parts or cables from catching fires

Fire of the electrical parts or cables can be prevented, and effective measures can be taken to avoid such danger.

Precautions:

a) Inspect or exam the electrical devices of the crane regularly. Find out the cause for faults like loose connection and cable heat, etc., and troubleshoot these devices immediately.

b) Check all cables, connectors and terminals for looseness or damages (see if there is any oxides formed on both poles of the terminal or battery), and rectify all confirmed faults immediately.

c) Use the original spare parts and original fuse in compliance with the specified rigidity only.

d) Close the crane immediately in case the power fails.

e) No unauthorized replacements, supplements or modifications toward the electrical system are allowed unless approved by the manufacturer.

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4.11 Maintenance of hooks and pulleys

Since the service condition of the main hook varies from day to day, inspection is required every day (starting with duty shifting). Pay attention to observe any defect that could affect the security before and in the process of the operation.

4.11.1 Daily maintenance of hooks

Daily inspection and maintenance involve the following items:

Wipe the main hook clean.

a) Lubricate the pulleys, rotating parts and other parts with the grease nipples.

b) Inspect all bolts and screws, and make sure all cotter pins are complete and the openings are opened.

c) Check for the uniformity of pulley race and rim wear, the matching of wire rope and pulley race and looseness or shaking of the pulley.

d) Make sure that the rotating part of the hook moves freely and the spacing is not large. Any feeling of difficulty or jamming requires the inspection for bearing and shaft sleeve damage or insufficient lubrication.

e) Inspect the overload damage of the main hook.

f) Inspect the elongation of side plate, extension of bore diameter, and bending, elongation or cracking of bolt.

g) Inspect the safety catch.

Fig. 4 - 026 Hook

Pulley

Pulley spindle

Safety catch

Hook body

Side plate

Bearing

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4.11.2 Pulley inspection

Fig. 4 - 027 Pulley

Check all pulleys for damages like fractures, diagonal plane or similar damages.

Scrap or replace the pulleys immediately upon the following damages:

a) Cracks, rim damages or relatively serious wear.

b) The wear extent of the pulley groove wall reaches 80 % of the original wall thickness.

c) The wear extent of the pulley groove bottom exceeds 25 % of the diameter of the wire rope.

d) Other defects that damages the wire rope.

Pulley groove must be larger than the diameter of the wire rope. Too thick a wire rope will fracture the rim of pulley and increase the wear of the wire rope and the pulley.

4.11.3 Inspection of rolling bearings on the pulleys

The following inspections are conducted annually for all pulleys:

a) Surplus of grease.

b) Sealing socket for bearing.

c) Running noise and rolling resistance.

The corresponding rolling bearing must be replaced in case defects are detected.

4.11.4 Replacement of rolling bearings

We suggest a maximum running of 1,000 hours or replacing all the rolling bearings of pulley in every 5 years.

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4.11.5 Pulley lubrication

Fig. 4 - 028 Schematic diagram for pulley lubrication

Each pulley has only one oil filling nozzle. Before the pulley lubrication, wipe the nozzle, clean and inject the grease with grease gun until the fresh grease overflows from the end face of bearing.

4.11.6 Inspection of the safety catch

The safety catch must be complete and undamaged so that it can limit the loose lifting slings and other lifting devices on the hook.

Safety catch cannot bear the load. Therefore, lifting slings and other lifting devices cannot be hung on the safety catch.

4.11.7 Inspection of each hook body

The hook body must be inspected at least yearly using liquid penetrate test, magnetic particle testing, ultrasonic flaw detection or X - ray inspection, etc.

Fig. 4 - 029 Schematic diagram for hook body inspection

Wear/crack inspection

Deformation inspection

Oil passage

Rolling bearing

Oil filling nozzle

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Check the hook for deformation, local cold deformation and extrusion, crack, wear and rust of clamping jaw. Lock the joint of hook nut.

Deformation: The hook must be replaced if the falcula has increased more than 10 % in comparison with the original size y. The original size y is recorded on the hook. Conduct measurement one by one.

Corrosion: Check the thread and shaft being operated for corrosion and wear. Therefore, unscrew the hook nut on shaft.

If reprocessing is required to remove the corrosion, such process should not make the diameter of the threaded core exceeds 5 %, otherwise the hook must be replaced.

(1). Do not use the hook with defects.

(2). Do not repair the hook by welding.

4.12 Maintenance of wire ropes

4.12.1 Cleaning of wire ropes

For dirty wire ropes, their external surface should be cleaned frequently. Especially, for the wire ropes that are used in a corrosive environment or near chemical substances, dirt on the surface should be removed in time.

4.12.2 Lubrication of wire ropes

The manufacturer has sufficiently lubricated wire ropes during manufacture to prevent corrosion and reduce friction between wire rope strands, wire ropes and pulleys, and wire ropes and drums.

When black spots or rust exist on the surfaces of wire ropes, the wire ropes need secondary lubrication. Timely secondary lubrication plays a positive role in extending the operating life of wire ropes. The lubricating oil for secondary lubrication can hardly penetrate and flow into wire ropes, so it should not be applied excessively. Excessive lubricating oil will stay on the surface of a wire rope, making the check for wire rope fracture relatively difficult. It would be best to adopt acid-free grease as the lubricating oil and the grease should be heated and diluted before utilization.

Lubricating oil should be applied by the following means:

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Fig. 4 - 030 Schematic diagram for wire rope lubricating oil application method

4.12.3 Inspection of wire ropes

The working life of a wire rope is different based on the operating condition of the machine. Wire ropes for both lifting and derricking must be strictly inspected regularly to find abrasion and damage in time.

Parts to be inspected:

a) Overall length of a wire rope;

b) The part which bends most frequently on a pulley or drum;

c) The parts which bend on pulleys or drums at the moment when load is lifted;

d) In the multi-layer winding system, the part where a wire rope contacts a drum flange, and the transboundary zone where the upper wire rope crosses the lower wire rope.

Inspection interval

It is recommended to inspect whether damage exists on wire ropes and ending joints.

For the beginning weeks after new wire ropes are installed and the fracture occurs for the first time, the inspection interval is shorter than that in other time periods. When overload occurs or suspicious damage which can not be seen is detected, the inspection interval should be shortened accordingly.

In addition, when operation ceasing duration is extended and the wire rope transmission gear is re-installed, or when winch equipment is disassembled and re-installed at a new location, or when an accident happens or damage exists during the operation of wire ropes, the inspection must be performed.

4.12.4 Replacement standards of wire ropes

Wire ropes are always damaged as a result of the combination and accumulation of kinds of factors. The executive staff should judge the cause and decide whether the wire rope should be discarded or be used continuously.

For the damage of a wire rope, inspection personnel should firstly investigate whether it is caused by the defect of equipment, and if so, such defect should be eliminated before the wire rope is replaced.

By brush By cotton yarn By cotton yarn

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Whether the wire rope should be replaced may be decided based on the following factors. Refer to relevant Chinese National Standards (GB/T 5972) and ISO standards (ISO 4309).

a) Fractured wire: In case more than 10% of the single wires (excluding filling wires) of a wire rope within one lay length fracture, for the wire rope with multilayer strands (typical multi strand structure), fractured wires mainly exist inside, making such fracture invisible. In case lubrication at any local position becomes dry or deteriorated, special attention should be paid;

b) Fractured line: In case fractured wires exist at or near the end of the rope, even in a small number, it indicates that the stress at such position is great. If the length of the rope permits, the position of fractured wires should be cut out and re-installation should be performed properly;

c) Local aggregation of fractured wires: In case fractured lines cling together and aggregate in the range of the rope length less than 6d (d: diameter of wire rope) or exist almost in one strand, even though the number of fractured wires is small;

d) Increase of fractured wires: Fractured wires would appear after a wire rope has been used for a period of time, the number of fractured wires will increase gradually, and the interval will be shorter and shorter.

e) Abrasion: Abrasion reduces the sectional area of a wire rope resulting in lower strength; when the external wires are abraded to 4% of its diameter, or when the diameter of the wire rope is reduced by 7% compared with the nominal diameter;

f) Fr

Date post:	04-Sep-2015
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ZOOMLION CRAWLER CRANE ZCC800HWG Maintenance Manual

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