Zoomlion Crawler Crane ZCC88H Maintenance & Service Manual - PDF DOWNLOAD

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Maintenance and Service Manual

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:410131 Service-hotline:400-800-1680 Fax:0086-0731-85585850 E-mail:sc@zoomlion.com Website:www.zoomlion.com

ZCC800H 800H CRAWLER CRANE

MAINTENANCE AND SERVICE MANUAL

The 1st edition (April, 2013)

Crawler Crane

For you 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 safety’s 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 crane’s 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.

I

Crawler Crane

Special information 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.

Ⅱ

ZCC800HWG Crawler Crane

Contents

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 III

ZCC800HWG Crawler Crane

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

IV

Maintenance and Service Manual for Crawler Crane Chapter 1 About this manual

ZCC800HWG Crawler Crane

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 01 - 1

Chapter 1

1.1 General

ZCC800HWG Crawler Crane

Chapter 1

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 “ instructions involved in the book are only the conventional contents.

”, the safety

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.

01 - 2

Maintenance and Service Manual for Crawler Crane Chapter 2 Safety instructions

ZCC800HWG Crawler Crane

2.1 Safety guidelines

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.

02 - 1

Chapter 2

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.

ZCC800HWG Crawler Crane

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 people’s 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.

Chapter 2

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 person’s 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.

02 - 2

Maintenance and Service Manual for Crawler Crane Chapter 3 Description of the crane

ZCC800HWG Crawler Crane

3.1 Description of main components

Tip boom Main boom anchoring rods Auxiliary load hook Wire rope for hoisting winch 1 Main load hook

Chapter 3

Wire rope for hoisting winch 2 Derricking pulley block

Main boom

A-frame

Main boom tilting-back support

Rear anchoring rods of A-frame

Travel gear

Fig. × 3-001 Overview of crawler crane

03 - 1

ZCC800HWG Crawler Crane

Left crawler carrier Slewing mechanism

Operator’s cab

Fuel tank

Chapter 3

Main valve Hoisting winch 1 Oil cooling fan Hoisting winch 2

Hydraulic oil tank

Engine system

Right crawler carrier Main boom derricking winch

Oil pump

Counterweight

Fig. × 3-002 Overview of crane undercarriage

03 - 2

ZCC800HWG Crawler Crane

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

Hoisting motor

winch

Reducer Reducer

1

Traveling motor (R)

Engine

Triple valve

Hoisting motor

winch

Reducer 1

Chapter 3

Main pump

Dual valve

Traveling motor (L)

Reducer

Slewing pump

Triple gear pump

Derricking motor

Reducer

Slewing motor

Reducer

Cooling motor

Control valve block

Fig. × 3-003 Hydraulic system diagram

03 - 3

ZCC800HWG Crawler Crane

3.2.2 Arrangement of hydraulic elements in slewing table

Derricking brake valve

Ratchet control valve

Winch brake valve

Outer brake valve

Slewing valve

Slewing brake solenoid valve

Chapter 3

Slewing cushion valve

Hydraulic oil tank

Oil radiator

Control valve

Triple main valve

Dual main valve

Travel control valve

Control valve block

Energy accumulator

Central revolving joint

Solenoid valve

Pump unit

Pilot control valve

Clutch control solenoid valve

Fig. × 3-004 Arrangement of hydraulic elements

03 - 4

Pilot oil filter

ZCC800HWG Crawler Crane

3.3 Electrical system

Chapter 3

3.3.1 Electrical system diagram

Fig. ×3-005 Electrical system diagram

03 - 5

ZCC800HWG Crawler Crane

3.3.2 Arrangement of electrical elements in slewing table

Fig. ×3-006 Arrangement of electric elements

Chapter 3

Junction box 2

Junction box 1

Video camera

Working floodlight

Main boom angle limit switch

03 - 6

To connector on boom

ZCC800HWG Crawler Crane

Horn

Traveling alarm

Slewing limit switch Battery

Electrical control box

Battery master switch

Oil level sensor

Lowering limiter for hoisting winch 1

Lowering limiter for hoisting winch 2

Junction box 3

Shutoff valve limit switch Slewing alarm

Slewing alarm

03 - 7

Chapter 3

Fig. ×3-007 Arrangement of electric elements

Inclinometer

ZCC800HWG Crawler Crane

Working floodlight

Chapter 3

Fig. × 3-008 Arrangement of electric elements

Tricolor light

Junction box 3

03 - 8

Maintenance and Service Manual for Crawler Crane Chapter 4 Maintenance and service

ZCC800HWG Crawler Crane

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

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.

04 - 1

Chapter 4

General precautions during the maintenance work are described as follows:

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.

Chapter 4

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.

04 - 2

ZCC800HWG Crawler Crane

(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

Chapter 4

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

04 - 3

ZCC800HWG Crawler Cranes

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.

Chapter 4

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.

04 - 4

ZCC800HWG Crawler Crane

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

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 1 st 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 operator’s cab.

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

04 - 5

Chapter 4

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

ZCC800HWG Crawler Cranes

Table × 4 - 001 Maintenance cycle Maintenance type

Operating time (hours)

Maintenance cycle

10

Before being started up every day

Daily inspection (D) 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 Maintenance No.

Working task

Maintenance of the power system Daily inspection of 4.5.1 the engine Inspection of the 4.5.2 engine operation status Maintenance of 4.5.3 the engine Cleaning of the air 4.5.4 suction filter Replacement of 4.5.5 the air suction filter elements Inspection of the cooling fluid (antifreeze fluid) 4.5.6 level and supplementation of the cooling fluid Change of the 4.5.7 cooling fluid Inspection of the 4.5.8 fuel pipeline Drainage and discharge of the 4.5.9 oil-water separator Cleaning of the 4.5.10 fuel tank Maintenance of 4.6 the reducer Inspection of the 4.6.1 oil level Change of the 4.6.2 gear oil

Inspection

Annual Monthly Quarterly Semiannual Daily Weekly maintenance maintenance maintenance maintenance inspection inspection M M1 M3 M6 D W 12

Chapter 4

4.5

04 - 6

● ● (as required in the maintenance manual of the engine) ● ●

●

2 years ● ● ●

● ●

ZCC800HWG Crawler Crane

Maintenance No.

Working task

Lubrication of bearings of the reducer Inspection of 4.6.4 brakes of the winch reducer Inspection of 4.6.5 securing bolts Inspection of brake straps of 4.6.6 the hoisting winch 1 with free-fall function Maintenance of 4.7 the slewing ring Routine 4.7.1 inspection Lubrication of the 4.7.2 gear surface Lubrication of the 4.7.3 raceway 4.6.3

Inspection

Annual Monthly Quarterly Semiannual Daily Weekly maintenance maintenance maintenance maintenance inspection inspection M M1 M3 M6 D W 12 ●

Inspection of the ● slewing ring bolt Maintenance of 4.8 the crawler travel Regular 4.8.1 ● inspection Cleaning of the 4.8.2 crawler Lubrication of the 4.8.3 crawler pin Tension of track 4.8.4 ● pad Maintenance of 4.9 hydraulic system Routine 4.9.1 inspection of Multiple items hydraulic system Inspection of the 4.9.2 oil level of the hydraulic tank Replacement of 4.9.3 the return filter Replacement of 4.9.4 the air cleaner Cleaning of the 4.9.5 filter element Change of the 4.9.6 hydraulic oil Cylinder 4.9.7 inspection Installation of the 4.9.8 pipeline Maintenance of 4.10 the electrical system

● ●

●

● ● ●

Chapter 4

4.7.4

● ●

● ● 2 years In time ● ● ●

04 - 7

ZCC800HWG Crawler Cranes

Maintenance No.

Working task

Inspection

Annual Monthly Quarterly Semiannual Daily Weekly maintenance maintenance maintenance maintenance inspection inspection M M1 M3 M6 D W 12

Inspection of the lighting system Inspection of windshield wipers 4.10.2 in the operator's cab as well as cleaning solution Inspection of the 4.10.3 video monitoring system 4.10.1

4.10.4 Battery inspection Inspection of the limit switch Inspection of 4.10.6 cable terminals and dust guards Prevention of electrical parts or 4.10.7 cables from catching fires Maintenance of 4.11 hooks and pulleys Daily 4.11.1 maintenance of hooks

●

●

● ●

Chapter 4

4.10.5

● Upon the basic machine disassembly or site transition every time

Upon the basic machine disassembly or site transition every time

●

4.11.2 Pulley inspection

●

Inspection of 4.11.3 rolling bearings on the pulleys Replacement of 4.11.4 rolling bearings 4.11.5 Pulley lubrication Inspection of the safety catch Inspection of each 4.11.7 hook body Maintenance of 4.12 the wire rope Cleaning of wire 4.12.1 ropes Lubrication of wire 4.12.2 ropes Inspection of wire 4.12.3 ropes

● ● ●

4.11.6

4.13

●

In time In time ●

Air conditioner

Daily 4.13.1 maintenance of air conditioners Maintenance of air 4.13.2 conditioners in low seasons Regular 4.13.3 inspection of air Multiple items conditioners

04 - 8

●

● ●

ZCC800HWG Crawler Crane

Maintenance No.

Working task

4.15 4.15.1 4.15.2

Inspection

Annual Monthly Quarterly Semiannual Daily Weekly maintenance maintenance maintenance maintenance inspection inspection M M1 M3 M6 D W 12

Structure component Rotary table inspection 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 engine’s components to ensure that all parts are intact and function normally.

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.

04 - 9

Chapter 4

Items to be inspected:

ZCC800HWG Crawler Cranes

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 70°C, 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.

Chapter 4

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.

04 - 10

ZCC800HWG Crawler Crane

The schematic diagram for the cleaning process is as follows:

b) Blow the compressed air over the filter element surface.

Chapter 4

a) Shack off the dusts on the filter element.

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.

04 - 11

ZCC800HWG Crawler Cranes

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.

Chapter 4

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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ZCC800HWG Crawler Crane

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 Chapter 4

Items to be inspected: 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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ZCC800HWG Crawler Cranes

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.

Chapter 4

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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ZCC800HWG Crawler Crane

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.

Oil change cycle and oil change amount of each mechanism

Mechanism name

Gear oil grade

Hoisting winch reducer Derricking winch reducer

L-CKD220 industrial enclosed gear oil L-CKD220 industrial enclosed gear oil L-CKD220 industrial enclosed gear oil L-CKD220 industrial enclosed gear oil L-CKD220 industrial enclosed gear oil

Slewing reducer Travelling reducer Gear transfer box

Inspection interval (hours)

Oil change interval (hours)

Oil change amount (L/each)

250

1,000

3

250

1,000

3

250

1,000

5.5

250

1,000

10

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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Chapter 4

Table × 4 - 003

ZCC800HWG Crawler Cranes

4)

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

Inject oil after the plug screw is unscrewed.

When oil is injected, this plug screw at the sight hole shall 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.

Fig. × 4 - 010

Chapter 4

b)

Schematic diagram for change of the gear oil

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.

Unscrew the oil drain rubber tube plug screw Inspect the oil level

Fig. × 4 - 011

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Schematic diagram for change of the gear oil

ZCC800HWG Crawler Crane

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.

The oil cup for lubricating grease injection

Fig. × 4 - 012

Chapter 4

Direction A (enlarged)

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.

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ZCC800HWG Crawler Cranes

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.

Chapter 4

The adjusting nut and con-rod of the brake strap

Rivet

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.

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ZCC800HWG Crawler Crane

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 oil’s 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.

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 1 st 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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Chapter 4

4.7.3 Lubrication of the raceway

ZCC800HWG Crawler Cranes

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.

Chapter 4

Items to be inspected: 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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ZCC800HWG Crawler Crane

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.

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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Chapter 4

Adjustment steps:

ZCC800HWG Crawler Cranes

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 S/N 1 2 3 4 5 6

Chapter 4

7 8 9 10 11 12

Inspection and maintenance items Oil level inspection of hydraulic oil Sediment inspection of hydraulic oil tank Replace the return oil filter element Replace the pilot filter element Replacement of the air cleaner Replacement of the hydraulic oil Oil leak and damage inspection of pipelines and joints Air cleaner block inspection Oil leak of oil cooler and damage inspection hydraulic motor, oil leak of pump and unusual sound inspection Oil leak of hydraulic valve inspection Oil leak of accumulator and damage inspection

Inspection period of the hydraulic system 8

100

Inspection interval (hours) 250 500 1000 1500

2000

Remarks

★ ★ ☆

▲

☆

▲ ▲ ☆

▲

800 L

★ ▲

★ ★ ★ ★ ★

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

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ZCC800HWG Crawler Crane

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.

Dust and metal powder from outside Mixing of foreign objects Water

Degradation

Spares Test tube (transparent) and fresh hydraulic oil

Decision of hydraulic oil status

Determination

Determination method

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.

Test tube or transparent containers, fresh oil

Appearance comparison and heating estimation

Test tube or transparent containers, fresh oil

Appearance estimation and sensation 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.

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 items

Inspection after starting the engine

Inspection method

Determination

Hydraulic oil temperature

Visual inspection hydraulic oil tank thermometer

Normal temperature from + 30 °C to + 80 °C

Oil leakage

Visual inspection

No leakage allowed

Purpose Find the abnormality of the hydraulic system at early stage, and extend the service life of hydraulic components.

Find the leakage at early stage.

04 - 23

Chapter 4

Table × 4 - 005

ZCC800HWG Crawler Cranes

Inspection items Pump temperature

Inspection method

Determination

Purpose

Infra-red thermometer

Temperature is 5 °C higher than the oil tank

Pump noises

Sensation (volume/acoustic)

Abnormal sound/change of noises

Find the abnormality of pump at early stage.

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

Remarks

Find the abnormality of the motor at early stage.

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.

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.

Chapter 4

a)

Return filter

Air cleaner

Liquid thermometer

Oil tank

Butterfly valve

Fig. ×4-015 Diagram of hydraulic oil tank

04 - 24

ZCC800HWG Crawler Crane

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

Fig. × 4 - 016 Diagram of return filter

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

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.

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

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

Fig. × 4 - 017 Diagram of air cleaner

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Chapter 4

4.9.4 Replacement of the air cleaner

ZCC800HWG Crawler Cranes

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

Chapter 4

S/N

Inspection items and replacement cycle for hydraulic oil

Inspection of the oil level Oil tank cleaning Change of the hydraulic oil

1 2 3

Inspection and replacement cycle (hour) 5 500 2,000

Inspection items

Remarks

○ Main oil tank

○ ○

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.

04 - 26

ZCC800HWG Crawler Crane

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.

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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Chapter 4

Precautions for replacement:

ZCC800HWG Crawler Cranes

b)

Ensure sufficient radius of bending.

Incorrect

Incorrect

Correct Correct

Fig. × 4 - 019 c)

Use elbow and other connectors when necessary.

Chapter 4

Incorrect

Correct

Fig. × 4 - 020 d)

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

Correct

Incorrect

Fig. × 4 - 021 e)

04 - 28

Ensure fixed position of a hose with a clamp.

ZCC800HWG Crawler Crane

Incorrect

Correct

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) Chapter 4

Fig. ×4-023 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.

Fig. × 4 - 024

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 operator’s cab before using vehicles.

Fig. × 4 - 025

04 - 29

ZCC800HWG Crawler Cranes

4.10.4 Battery inspection

Chapter 4

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 5°C to 40°C. 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 1.28±0.01g/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.

04 - 30

ZCC800HWG Crawler Crane

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.

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.

2—Hoisting 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.

3—Hoisting 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.

4—Hoisting 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.

04 - 31

Chapter 4

1—Hoisting winch 1 over-winding alarm

ZCC800HWG Crawler Cranes

5—Main 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.

Chapter 4

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.

04 - 32

ZCC800HWG Crawler Crane

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.

Pulley

Pulley spindle

Side plate

Bearing

Safety catch

Hook body

Hook Chapter 4

Fig. × 4 - 026 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.

04 - 33

ZCC800HWG Crawler Cranes

4.11.2 Pulley inspection

Fig. × 4 - 027

Pulley

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

Chapter 4

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.

04 - 34

ZCC800HWG Crawler Crane

4.11.5 Pulley lubrication

Oil filling nozzle

Fig. × 4 - 028

Oil passage

Rolling bearing

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

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.

Deformation inspection

Wear/crack inspection

Fig. × 4 - 029

Schematic diagram for hook body inspection

04 - 35

Chapter 4

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

ZCC800HWG Crawler Cranes

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

Chapter 4

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:

04 - 36

ZCC800HWG Crawler Crane

By cotton yarn

By brush

Fig. × 4 - 030

By cotton yarn

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.

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.

04 - 37

Chapter 4

Parts to be inspected:

ZCC800HWG Crawler Cranes

Chapter 4

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).

04 - 38

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)

Fracture of rope strands: In case an entire rope strand fractures, it is caused by the damage of rope core resulting in reduced rope diameter;

g)

Reduction of elasticity: Rope diameter reduces, the lay length of a wire rope extends, parts press tightly against each other and space between wires and between ropes is inadequate. These phenomena indicate the reduction of elasticity. At this moment, although no fractured wire exists, the wire rope is obviously difficult to be bended, which may abruptly break and should be discarded immediately;

h)

Corrosion: When severe corrosion occurs at inside and outside of a wire rope;

i)

Distortion: Distortion of wire ropes are disposed of by the following means:

ZCC800HWG Crawler Crane

Wave

In case of d1≥4d/3, with the length of a wire rope not more than 25d, the wire rope should be discarded as useless, where d is the nominal diameter of the wire rope; and d1 is the envelope diameter after the wire rope distorts.

Cage distortion

Discard as useless immediately

Strand extrusion

Discard as useless immediately

Single wire strand extrusion

Discard as useless in case distortion is severe

Multiple wire strands extrusion

Discard as useless in case distortion is severe

The diameter of rope increases at some positions

In case the diameter of rope increases greatly at some positions, the rope should be discarded as useless without delay

The diameter of rope reduces at some positions

In case the diameter of rope reduces greatly at some positions, the rope should be discarded as useless without delay

Part positions are flattened

Discard as useless in case the flattening is severe

Twist

Discard as useless in case the flattening is severe

Bending

Discard as useless immediately

04 - 39

Chapter 4

Table × 4 - 008 Disposal of distortion of wire ropes

ZCC800HWG Crawler Cranes

Damages caused by the action of heating or electric arc

Discard as useless in case of any color change

4.13 Maintenance of air conditioning equipment

Chapter 4

4.13.1 Daily maintenance a)

Regularly inspect the refrigeration equipment of the air conditioning system, especially check whether pipe joints are loose, whether oil stains exist at the oil seal of a compressor, and whether coupling screws are loose. If any, repair should be performed in time;

b)

Regularly inspect wire joints to prevent looseness and exfoliation and avoid accidents;

c)

Regularly remove dirty, sundries, etc. from the cooling fin of the condenser to maintain a good heat dissipation effect;

d)

Keep the air interchange outlet unimpeded and do not put any substance at the air outlet to prevent air circulation from being impacted which will lower the evaporability of the evaporator and the refrigeration effect.

e)

Observe whether refrigerant is charged properly via the liquid window of the reservoir (when the environment temperature is 30-35 °C, and the engine speed is 1,600-1,800 RPM).

Appropriate

Excessive

Insufficient

Fig. × 4 – 032

04 - 40

Schematic diagram for whether refrigerant injection is appropriate

ZCC800HWG Crawler Crane

4.13.2 Off season maintenance After the off season of air conditioner (winter) comes, air conditioners should be started every week and operate for ten minutes to make refrigerant circulate so as to prevent refrigerant leakage caused by dry shaft seal of compressor to keep the compressor in a good condition and prevent such components as expansion valve, etc. from rusting.

When summer comes each year, the assembly of refrigerating system should be comprehensively inspected, cleaned, checked for leakage and refrigerant should be applied to ensure normal operation of the refrigerating system.

4.13.3 Contents of regular inspection and adjustment for air conditioners Table × 4 - 009 Contents of regular inspection and adjustment for air conditioners

Evaporator cooling fin

Content Inspect the looseness and damage conditions of pipelines and pipe joints, and whether oil dirt exists on pipe joints. Oil dirt indicates microscale leakage, and repair should be conducted.

Inspect whether dust and muddiness exist on the cooling fin, and high pressure water should be utilized for washing if necessary Inspect whether cleaning dirt exists and utilize compressed air to blow off it

Compressor

Inspect the oil level of compressor and replace refrigerant oil

Once two quarters

Check the pressure of high & low pressure ends

Once a quarter

Inspect, and adjust if necessary

Once a quarter

Inspect the operation condition of blower, charge lubricating oil and no abnormal sound should exist on components during operation Inspect whether bolts of assembly parts are loose, and if any, fasten them.

Once three quarters

Piping joint Condenser

Pressure of high & low pressure ends Electrical components Blower Assembly parts

Time Weekly Weekly Once a quarter

Once a quarter

4.14 Maintenance of the lubricating system The basic machine lubricating system is a manual lubricating system, and lubrication needs to be completed manually by an oil gun.

Precautions for oil filling: a)

Mineral high quality grease which is pressed into oil gun or utilized mainly to lubricate equipment should not be liquefied when temperature raises and should not condense under freezing point;

b)

Lubricating grease with the same grade is required to be utilized, and it is forbidden to utilize grease of different grades.

Before grease (lithium-based grease) is charged, the grease nipple should be wiped to be clean.

04 - 41

Chapter 4

Inspection items

ZCC800HWG Crawler Cranes

4.14.1 Grades of lubricating grease Table × 4 - 010 ZL-2 and ZG-3 lubricating grease recommended by our company

Type

Appearance

ZL-2 lubricating grease ZG-3 lubricating grease

Smooth ointment with color from light yellow to brown Uniform ointment with color from light to dark brown

Parameters Dropping point (°C)

Working penetration (1/10mm)

Moisture, (%) Max.

175

265~295

——

90

220~250

2.5

4.14.2 Injection method

Chapter 4

Daubing or injection by oil gun.

Fig. × 4 - 031 Schematic diagram of lubricating grease injection 4.14.3 Injection position and cycle Lubrication and maintenance for lubricating positions should be performed regularly to ensure good operation of equipment.

4.14.3.1 Basic machine The basic machine includes superstructure and lower structure. Lubricating points and cycle are shown in the following table and figure: Table × 4 - 011

Super and lower structures lubricating grease injection table

S/N

Oil filling position

1

Ratchet latching mechanism

2

Slewing ring

3

Winch bearing

4 5 6

Track carrier roller Track roller Driven sprocket

04 - 42

10/day

Oil filling interval (hour) 50/week 200/month 500/quarter

● ● ● ● ● ●

Remarks Lubricating grease, daub Lubricating grease, daub Lubricating grease, oil gun injection GL-5 85W/90 GL-5 85W/90 GL-5 85W/90

ZCC800HWG Crawler Crane

Every week or 25 hours

Every week or 25 hours

Every day or 5 hours

Chapter 4

Every quarter or 500 hours

Fig. × 4 - 032 Super and lower structures lubricating grease injection 4.14.3.2 Boom Table × 4 - 012 S/N 1 2 3 4 5 6 7 8 9

Boom system lubricating grease injection

Oil filling position Main boom pivot section pin spindle A-frame movable pulley pin spindle Main boom tilting-back support pin spindle Hinge joint position of derricking anchoring rod and A-frame shaft Main winch, auxiliary winch and derricking wire rope Derricking pulley and pin spindle Auxiliary hook shaft and bearing Main hook shaft and bearing Boom pulley and pin spindle

Oil filling interval (hour) 10/day 50/week 200/month

Remarks

● ● ● ● Based on service conditions ● ● ● ●

04 - 43

ZCC800HWG Crawler Cranes

Chapter 4

Each month or 200 hours According to service conditions Each week or 50 hours

Every day or 10 hours

Fig. × 4 - 033 Boom system lubricating grease injection

(1) Before oil filling, wipe the oil cup and the surface where oil is to be applied to make them clean.

(2) Lubricating grease should be also applied regularly for the sliding surface which is not listed in the table.

(3) Lubricating grease with different grades should not be mixed to each other.

(4) For bush, axle and bearing, lubricating grease should be injected till the original grease is extruded.

(1) Shut down the engine before lubricating.

(2) When one climbs a crane, it should be ensured that the ladder, platform and railing are clean and dry, and he should wear safety belt to avoid high-altitude falling resulted from wet and slippery conditions.

(3) Running counter to this stipulation may cause severe casualty.

04 - 44

ZCC800HWG Crawler Crane

4.15 Appearance inspection for structure components Structure members are the bearing components of basic machine, hence structure work inspection is necessary to be performed.

Recommended inspection cycle: a)

Normally, inspection should be conducted once half a month or a month.

b)

When load of lifting operation ≥ 90% of the rated load, inspection should be performed once respectively before and after the operation.

c)

Experts must be invited each year to inspect the anchoring rod once

Inspection items: a)

Crack

b)

Distortion

The straightness tolerance of the main chord member of boom section shall be in line with the attached table, and the straightness tolerance per meter of the web member of boom section shall not be greater than 1.5mm.

Table × 4 - 013

Rated value of boom section main chord member straightness

Length of boom section Local straightness tolerance Overall length straightness tolerance

≤3,000

3,000 – 6,000

Chapter 4

tolerance >6,000

2 per meter 3

4

6

Attached: Method to test boom section chord member straightness u

Local straightness of chord member As shown in the figure, put a 1-meter ruler close to the boom section chord member from two directions with an angle of 90°, and the difference between the maximum space and the minimum space between the ruler and the pipe wall should not be more than 2mm.

Maximum

Ruler

Minimum

Chord member

Ruler

Fig. × 4 - 034 Chord member local straightness test schematic diagram

04 - 45

ZCC800HWG Crawler Cranes

u

Overall length straightness of chord member As shown in the figure, arrange a φ0.49 - 0.52 mm wire rope along the direction of length outside the chord member and 30mm away from the pipe end, with the tension as 147 N. Measure the horizontal distance from the wire to the chord pipe. The difference between the maximum and the minimum should be in line with the requirements of Table × 4 - 013.

Minimum

Maximum

Turn the boom by 90°, and repeat the above test for the same chord member.

Chord Wire rope member

Chapter 4

Fig. × 4 - 035 Chord member overall length straightness test schematic diagram 4.15.1 Turntable inspection Key inspection position: a)

Lug connecting to the boom, A-frame rear anchoring rod and front A-frame;

b)

Counterweight hanging point;

c)

Base plate connecting to the slewing ring;

d)

Joints of left & right wallboards and upper & lower cover plates;

e)

Reinforce the joints of U-bar and left & right wallboards (upper & lower cover plates).

04 - 46

ZCC800HWG Crawler Crane

Fig. × 4- 036 Turntable inspection schematic diagram

Chapter 4

4.15.2 Inspection of lower structure parts

Fig. × 4 - 037 Crawler frame inspection schematic diagram

04 - 47

ZCC800HWG Crawler Cranes

Fig. × 4 - 038 Crawler frame lug inspection schematic diagram

Fig. × 4 - 039 Slewing ring bottom inspection schematic diagram

4.15.3 Boom inspection

Chapter 4

Routine inspection: a)

whether the rope support of boom head rotates smoothly;

b)

whether the boom pin spindle, anchoring rod and spring bolt are damaged or come off;

c)

whether the phenomena of peeling and coming off exists on boom paint;

d)

whether the structure member distorts;

e)

whether the structure member possesses any crack;

f)

Other abnormities.

Corrosion prevention and lubrication: a)

Paint surface: painting make-up should be performed based on needs;

b)

Mating surface: apply lithium-based grease.

(1) Before injecting lithium-based grease, wipe the grease nipple to make it clean; (2) Before painting make-up, clean the surface.

04 - 48

ZCC800HWG Crawler Crane

Chapter 4

Fig. × 4 - 040 Main boom welding line inspection schematic diagram

Fig. × 4 - 041 Fixed jib welding line inspection schematic diagram

04 - 49

ZCC800HWG Crawler Cranes

4.15.4 Anchoring rod inspection

Chapter 4

Overall length inspection must be performed for the anchoring rod when installation and connection are conducted including the hidden surface and inner bores. The positions of anchoring rod needing inspection are shown in the following figure.

Fig. × 4 - 042 Anchoring rod inspection schematic diagram Contents to be inspected include: a)

Inspect whether any crack exist on the anchoring rod 1)

Regularly inspect whether any crack exist on the anchoring rod;

2)

The surface crack test should be conducted for at least yearly, such as magnetic particle testing;

3)

In case any crack is found, the anchoring rod must be replaced in time;

4)

In case any bow A-frame possesses cracking welding line, it should be replaced in time.

Do not perform repair work.

04 - 50

ZCC800HWG Crawler Crane

b)

Inspect the length of the anchoring rod The length of anchoring rod must be measured to inspect the extension of the anchoring rod. The maximum allowable extension of the anchoring rod is 0.2% of the original length. For example, for the anchoring rod with the length as 5700mm, the maximum extension is 11.4mm.

For the original length of each anchoring rod, please refer to Maintenance and Service Manual for ZCC800H Crawler Crane. c)

Inspect the abrasion of anchoring rod Inspect whether any abrasion trace exists on the anchoring rod pin hole and connecting pin spindle, including the spring bolt which is utilized to fasten the pin spindle.

d)

Inspect the paintcoat of anchoring rod Regularly inspect whether corrosion and coming off exist on the paintcoat of anchoring rod, and in case of any corrosion pit, paint in time.

Inspect the plastic deformation of anchoring rod Inspect whether the anchoring rod possesses twist, and in case of any twist, the anchoring rod should not be utilized any more and should be replaced without delay.

Inspection cycle: Inspection should be conducted based on the conditions of operation area and the actual operation situation. If utilization is frequent, the inspection cycle should be shortened accordingly, and experts must be invited annually to conduct inspection for anchoring rods.

In case the damages described above exist, replacement must be performed immediately. An anchoring rod with any defect will cause a severe accident.

04 - 51

Chapter 4

e)

Maintenance and Service Manual for Crawler Crane Chapter 5 Troubleshooting

ZCC800HWG Crawler Crane

Some irregular phenomenon may occur during crane operation, therefore, checks must be done in time to find true causes, and maintain the crane if necessary.

5.1 Troubleshooting of mechanical drive The following table shows the troubles of mechanical drive and their solutions.

Table × 5-001 Troubles

Causes

Solutions

1

When crane is traveling in straight line, it deviates to one side.

1. The crawler tensions on both sides are different from each other.

1. Adjust the crawler tension.

2. The crawler is slack.

2. Adjust the crawler tension.

1. The crawler is tight.

1. Adjust the crawler tension.

2. The ground is soft.

2. Fill up the ground to make it solid and flat.

1. The crawler is slack.

1. Adjust the crawler tension.

2. The track pad is worn.

2. Change the track pad.

The track roller is mounted unevenly, thus leading to the deformation of sealing ring of track roller.

Unscrew the bolt, pad a 1mm-thick iron plate under the track roller, and then tighten the bolt.

1. The crawler is slack.

1. Tighten the crawler.

2. The drive sprocket is meshed with track pad improperly.

2. Grind and correct the top edge of drive sprocket.

2

The traveling resistance is large.

3

The crawler slips.

4

The track roller leaks oil or it does not rotate.

5

The drive sprocket is meshed with track pad irregularly

5.2 Troubleshooting of power system Chapter 5

X X X X X X

No.

The following table shows the troubles of power system and their solutions.

Table × 5-002 No.

1

Troubles

Causes

The starting motor does not rotate or it rotates weakly.

1. The battery is charged insufficiently.

2. The wire connected to starting motor has come loose.

3. The solenoid switch of starting motor fails.

1. The fuel tank is empty.

2

The engine can not start up, or the engine stops suddenly after it starts.

2. The fuel filter is clogged.

3. The fuel pipe, coarse filter or filtering screen is clogged.

4. The fuel supply system or fuel filter leaks oil.

Solutions 1. Charge the battery.

2. Tighten the wire of terminal on the motor. Weld a new terminal if necessary.

3. Make a check by special personnel.

1. Add oil.

2. Change the filter cartridge of fuel coarse filter.

3. Clean the fuel pipe, coarse filter or filtering screen.

4.

Check the sealing elements of fuel supply system or fuel filter.

05 - 1

ZCC800HWG Crawler Crane

No.

Troubles

Causes 5. The fuel has cold-resisting property.

Solutions not

The fuel loop leaks oil or the pressure of fuel loop is too low.

The fuel loop leaks oil, or the pressure of fuel loop is lower, or the oil pump drive is invalid.

3

The engine difficultly.

starts

4

The engine suddenly.

stops

5

The engine outputs weakly.

The fuel supply system is clogged or leaks oil.

6

The fuel consumption is severe.

The fuel temperature is too high.

7

oil is

The charge indicator light lights up when the engine is running.

Chapter 5

8

The engine consumption severe.

9

The temperature of engine is too high.

1. There is leakage at the outside of engine.

2. The engine oil is unqualified or it is dirty.

3. The oil seal of turbocharger leaks.

1. The conveying belt is slack.

Check the fuel loop for leaks.

Make pressure test by qualified repair plant.

Check the fuel supply system for oil leaks, and consult the qualified repair plant.

Change the fuel temperature sensor, and consult the qualified repair plant.

1. Check and repair the leaking points.

2. Change engine oil and oil filter.

3. Check the sealing elements of turbocharger, and repair oil seal by a special person.

1. Check the tension of conveying belt. And change the driven sprocket if necessary.

2. The conveying belt is worn.

2. Change the conveying belt.

3. The generator or voltage stabilizer fails.

3. Check the generator or voltage stabilizer, and consult the qualified repair plant.

1. The antifreeze coolant temperature sensor fails.

2. The antifreeze coolant is insufficient or the cooling system does not discharge air completely.

3. The conveying belt is damaged.

4. The outside and inside of radiator are dirty or the radiator is blocked by lime deposit.

5. The thermostat fails.

05 - 2

5. Check the sealing elements. Clean the fuel coarse filter. Change the fuel filter. Use the fuel suitable for cold climate.

Check the fuel loop for leaks.

Make pressure test by qualified repair plant.

1. Change the sensor.

2. Add antifreeze coolant, and discharge air completely.

3. Change the conveying belt.

4. Clean the radiator or remove the lime deposit.

5. Check the thermostat, and change it if necessary.

Consult the qualified repair plant.

X X X X X X

ZCC800HWG Crawler Crane

Troubles

Causes 1. The injector fails.

10

The engine emits the black smoke.

11

The engine emits the blue smoke.

12

The engine emits the white smoke.

13

Knocking of engine

2. The exhaust turbocharger or air intake pipe fails, or the air filter is not clean.

The oil level in the engine is too high, and thus the engine oil flows into combustion chamber.

There is leakage at the cylinder head or the cylinder-head gasket, thus making antifreeze coolant enter into combustion chamber.

Burning failure 1. There is leakage in air intake pipe and exhaust pipe.

14

X X X X X X

15

16

Abnormal sound is made.

The consumption of antifreeze coolant is severe.

The temperature of antifreeze coolant is lower than the normal temperature.

Solutions 1. Consult the qualified repair plant.

2. Make a visual check, and consult the qualified repair plant about the problem.

Set proper oil level, and check oil level by qualified repair plant.

Use compressed pressure to test the cylinder, and consult the qualified repair plant about the problem.

Consult the qualified repair plant.

1. Repair the leaking points.

And change the sealing elements if necessary.

2. The turbine or air compressor is scraped with the cover, or the object enters into turbine or air compressor, or the bearing gets stuck into the rotary components.

2. Change the exhaust turbocharger by a qualified repair plant.

1. Some components may leak antifreeze coolant.

1. Check the engine, oil pipeline and radiator for leaks. Repair the leaking points by special person.

2. The temperature of engine is too high, and the temperature of antifreeze coolant is higher than the normal temperature.

2. Eliminate the failure by special person.

1. The temperature sensor fails.

1. Detect the signal output from the temperature sensor, and change the sensor if necessary.

2. The thermostat fails.

2. Repair it by special person.

05 - 3

Chapter 5

No.

ZCC800HWG Crawler Crane

5.3 Troubleshooting of hydraulic system The following table shows the troubles of hydraulic system and their solutions.

Table × 5-003 No. 1

2

Troubles The engine runs normally, however, no pilot pressure is generated.

The engine runs normally, however, the pilot pressure is too low.

Causes The shutoff valve of oil suction pipe is not opened.

1. There is leakage of pilot system.

2. The pressure release valve fails.

4. The valve or oil pipeline is blocked.

5. The circuit is out of order.

5. Change the circuit.

6. The control lever fails.

6. Change control lever.

7. An amount of air enters into the pipeline after maintenance.

8. The shutoff valve on hydraulic oil tank is not opened.

1. The shutoff valve of oil suction pipe is not opened.

7. Run the engine without load for 5 minutes to discharge the air.

2. The pressure release valve fails.

Chapter 5

3

3. The main overflow valve of main valve malfunctions.

2. The slewing valve malfunctions.

3. The slewing pump fails.

4

05 - 4

No slewing movements are performed.

Open the shutoff valve.

1. Determine the leaking point.

2. Check and adjust the overflow pressure.

1. Check and repair the main pump, and change it if necessary. ※ 2. Check pressure release valve. ※ 3. Check and adjust the overflow pressure of main overflow valve.

4. Clean the oil pipeline or valve.

1. The hydraulic pump fails.

The engine runs normally, however, no crane movements are performed after moving the control lever.

Solutions

4. The slewing brake is not actuated.

8. Check the shutoff valve and open it.

1. Open the shutoff valve.

2. Check and adjust the overflow pressure of slewing valve.

3. Check and repair the slewing pump, or change it if necessary. ※ 4. Check if the pressure is output from slewing brake solenoid valve. ※

5. The fuse of controller fails.

5. Change the fuse.

6. The circuit is out of order.

6. Check if the brake is electrified. And change the circuit if necessary.

7. The slewing control lever fails.

7. Change the control lever.

X X X X X X

ZCC800HWG Crawler Crane

5

6

Troubles

The slewing movements are performed weakly.

No traveling movements are performed or the traveling movements are carried out weakly.

Causes 1. There is leakage at the inside of slewing motor.

1. Check and repair the motor, or change it if necessary.

2. The crane is overloaded.

2. Reduce the load. ※

3. The valves and oil pipeline of slewing hydraulic system are blocked.

1. The traveling resistance is large.

2. The central revolving joint or oil pipeline of travel gear hydraulic system is blocked.

3. The traveling motor leaks oil.

4. The hydraulic pump fails.

5. The fitting of travel gear hydraulic system is not screwed tightly.

7 The travel gear pedal fails.

7

X X X X X X

The speed of actuating assembly is low.

1. The pump or motor leaks oil.

8

9

The hydraulic system makes the noise.

3. Clean the oil pipeline and valves.

1. Reduce the traveling speed.

2. Clean the central revolving joint or oil pipeline of travel gear hydraulic system.

3. Check and repair the motor, or change it if necessary. ※ 4. Check and repair the main pump, or change it if necessary. ※ 5. Tighten the fitting with special wrench. ※ 7. Change the travel gear pedal.

1. Check and repair the pump or motor, or change them if necessary.

2. The oil pipeline is blocked.

2. Clean the oil pipeline.

3. The pilot pressure is not enough.

3. Detect the pilot pressure. ※ 1. Check and repair the main pump, or change it if necessary.

1. The hydraulic pump fails.

No movements are performed by hoisting winch 1 (or 2), or the movements of hoisting winch 1 (or 2) are carried out weakly.

Solutions

2. The oil pipeline is blocked.

2. Clean the oil pipeline.

3. The crane is overloaded.

3. Adjust the load.

5. The hoisting winch 1 (or 2) control lever fails.

6. The brake cylinder is not actuated.

7. The quick-release coupling is not screwed tightly.

8. The pressure of overflow valve on main valve is too low.

5. Change the control lever. ※ 6. Detect the starting pressure of brake cylinder.

7. Screw the quick-release coupling tightly.

8. Detect the pressure of overflow valve. Reset the pressure if necessary.

1. The oil viscosity is too low.

1. Change hydraulic oil.

2. The oil temperature is too low.

3. The back pressure of oil return pipe is too high.

2. Preheat the hydraulic system.

3. Modify the hydraulic pipeline.

05 - 5

Chapter 5

No.

ZCC800HWG Crawler Crane

No.

Troubles

The oil temperature is too high.

10

The hydraulic pipeline vibrates fiercely.

11

The pipe fitting leaks oil.

12

13

The hose bursts.

Causes 1. The radiator or oil pipeline is blocked.

1. Clean the radiator or oil pipeline.

2. The radiator is damaged.

2. Change the radiator.

3. The brand of hydraulic oil is wrong.

4. The hydraulic oil deteriorates.

5. The oil in the hydraulic oil tank is insufficient.

6. The solenoid valve of cooler fails.

1. There is an amount of air in hydraulic system.

Chapter 5

14

3. Change the hydraulic oil.

4. Change the hydraulic oil. ※ 5. Add oil to specific value.

6. Change the solenoid valve.

1. Discharge the air.

2. The pipe clamp is loose.

2. Adjust the pipe clamp and fix the pipeline.

3. The overflow valve or safety valve is blocked.

3. Clean the valve. ※

4. The pump, motor or valve fail.

4. Check and repair the pump, motor or valve, or change them if necessary.

1. The pipe fitting is not screwed tightly.

2. The sealing element is damaged.

1. The hose does not match the applied pressure.

2. The hose is aging and scratched.

3. The fitting of hose is blocked.

1. The reducer leaks gear oil.

The connectors of hydraulic pump and hydraulic motor leak oil.

Solutions

2. The hydraulic pump and hydraulic motor leak oil.

1. Tighten the fitting.

2. Change the sealing element.

1. Change the hose.

2. Change the hose.

3. Clean the hose and fitting.

1. Change the oil seal of reducer.

2. Detect the pressure of oil drain hole of pump and motor. If it exceeds 3bar, modify the oil drainage pipeline, and change the oil seal of pump and motor. ※

If the component marked with ※ fails, never dismember or adjust it. You must contact the crane manufacturer.

05 - 6

X X X X X X

ZCC800HWG Crawler Crane

5.4 Troubleshooting of electrical system 5.4.1 Troubleshooting of cab electrics Table × 5-004 Troubles

Causes

Solutions

1. The wiper switch is damaged.

1

The wiper does not work.

1. Change the wiper switch.

2. Check and repair the wiper motor. Or change it if necessary.

3. Check and repair the drive device of wiper.

1. Check and repair the fan motor. Or change it if necessary.

1. Check and repair the circuit.

2. The wiper motor fails.

3. The drive device of wiper gets stuck or damaged.

2

The electric fan does not work.

1. The fan motor fails.

1. The circuit is out of order.

1. The safety fuse is broken.

3

The cigarette lighter does not work.

2. The resistance wire blows out.

3. The circuit connection is incorrect.

4. Poor contact of switch.

4

X X X X X X

5

CD player does not work.

The interior light of cab fails.

1. The circuit is out of order.

Nothing is shown in the LCD of monitor.

7

The rocker switch is not in functional work.

8

9

The switch on dashboard is not in functional work.

The control lever is not in functional work.

2. Change the wire.

3. Check and repair the circuit.

4. Check or change the switch.

1. Check and repair the circuit.

2. The CD player is damaged.

2. Change the CD player.

1. The circuit is out of order.

1. Check and repair the circuit.

2. The interior damaged.

light

is

1. The circuit is out of order.

6

1. Change the fuse.

2. The relevant video camera is damaged.

3. The LCD is damaged.

switch

1. Check and repair the circuit.

2. Change the relevant video camera.

3. Change the LCD. 1. Check and repair the circuit.

1. The circuit is out of order.

2. The rocker damaged.

2. Change the interior light.

is

2. Change the rocker switch.

1. The circuit is out of order.

1. Check and repair the circuit.

2. The switch is damaged.

2. Change the switch.

1. The circuit is out of order.

1. Check and repair the circuit.

2. The control damaged.

lever

is

2. Change the control lever.

05 - 7

Chapter 5

No.

ZCC800HWG Crawler Crane

No.

Troubles

Causes 1. The circuit is out of order.

10

The horn switch on control lever can not work normally.

11

The buzzer can not sound.

2. The horn damaged.

Solutions

switch

1. Check and repair the circuit. is

1. The circuit is out of order.

1. Check and repair the circuit.

2. The buzzer is damaged.

2. Change the buzzer.

3. No signal is output from the control program.

3. Consult the after-sale service man.

1. Check and repair the circuit.

1. The circuit is out of order.

12

The main screen fails.

2. Change the horn switch.

2. The screen is damaged.

2. Change the screen.

3. The communication to PLC fails.

3. Check and repair the circuit or consult the after-sale service man.

5.4.2 Troubleshooting of slewing table electrics

Chapter 5

Table × 5-005 No.

Troubles

Causes

Solutions

1

The battery master switch fails.

The battery master switch is damaged.

2

The rotational speed sensor fails.

3

The pressure sensor fails.

4

The inclination sensor fails.

5

The traveling alarm does not sound the alarm.

6

The electric horn can not sound.

Change the battery master switch.

1. Check and repair the circuit.

2. Change the rotational speed sensor.

1. Check and repair the circuit.

2. Change the pressure sensor.

1. Check and repair the circuit.

2. Change the inclination sensor.

1. Check and repair the circuit.

2. Change the traveling alarm.

3. Consult the after-sale service man.

1. Check and repair the circuit.

1. The circuit is out of order.

2. The rotational speed sensor is damaged.

1. The circuit is out of order.

2. The pressure sensor is damaged.

1. The circuit is out of order.

2. The inclination sensor is damaged.

1. The circuit is out of order.

7

05 - 8

LED acoustic control light fails.

2. The traveling alarm is damaged.

3. The controller can not output the signal.

1. The circuit is out of order.

2. The electric damaged.

horn

is

2. Change the electric horn.

1. The circuit is out of order.

1. Check and repair the circuit.

2. LED acoustic control light is damaged.

2. Change control light.

LED

acoustic

X X X X X X

ZCC800HWG Crawler Crane

Troubles

Causes

Solutions

1. The circuit is out of order.

8

The slewing alarm does not sound the alarm.

9

The lowering switch fails.

10

No fuel shown.

11

The shutoff valve limit switch fails.

12

13

14

X X X X X X

15

16

limit

level

2. The slewing alarm is damaged.

3. The controller can not output the signal.

1. The circuit is out of order.

2. The lowering limit switch is damaged.

is

The main boom angle (80°) limit switch fails.

The slewing limit switch fails.

1. The circuit is out of order.

2. The fuel level sensor is damaged.

1. The circuit is out of order.

2. The limit damaged.

switch

is

switch

is

switch

2. Change the limit switch.

1. Check and repair the circuit.

1. The circuit is out of order.

2. The limit damaged.

2. Change the limit switch.

1. Check and repair the circuit.

1. The circuit is out of order.

2. The limit damaged.

1. Check and repair the circuit.

2. Change the slewing sensor.

3. Consult the after-sale service man.

1. Check and repair the circuit.

2. Change the lowering limit switch.

1. Check and repair the circuit.

2. Change the fuel level sensor.

1. Check and repair the circuit.

is

2. Change the limit switch.

1. The circuit is out of order.

1. Check and repair the circuit.

2. The engine oil pressure sensor is damaged.

2. Change the sensor.

The water temperature sensor fails.

1. The circuit is out of order.

1. Check and repair the circuit.

2. The water temperature sensor is damaged.

2. Change the sensor.

The working floodlights do not light up.

1. The circuit is out of order.

The engine oil pressure sensor fails.

2. The working floodlights are damaged.

1. Check and repair the circuit.

2. Change the working floodlights.

05 - 9

Chapter 5

No.

ZCC800HWG Crawler Crane

5.4.3 Troubleshooting of boom electrics Table × 5-006 No.

Troubles

Causes

1

The solar lamp can not light up.

The solar lamp is damaged.

Change the solar lamp.

1. The circuit is out of order.

2

The wind speed is not shown.

1. Check and repair the circuit.

3

The warning icon “Hoisting limit for H1/H2” flash irregularly.

2. The anemometer is damaged.

1. The circuit of boom is out of order.

2. The hoisting limit switch is damaged.

Solutions

2. Change the anemometer.

1. Check and repair the circuit.

2. Change the hoisting limit switch.

5.4.4 Troubleshooting of load moment limiter Table × 5-007 No.

1

The screen of load moment limiter becomes black.

The data shown in the screen is not correct.

Chapter 5

2

Troubles

3

05 - 10

No data is shown in the screen.

Causes

Solutions

2. The circuit is not connected well.

1. Check and repair the safety fuse.

2. Check and repair the circuit.

3. The screen is damaged.

3. Change the screen.

1. The safety fuse is broken.

1. The parameter is set wrong.

2. The selected operating mode is wrong.

3. The circuit is not properly connected to the interface of sensor.

1. Readjust the parameter.

2. Readjust the operating mode.

3. Check and repair the circuit and interface of sensor.

4. The sensor is damaged.

4. Change the sensor.

1. No data is downloaded.

1. Download the data again.

2. The main board of load moment limiter is damaged.

3.

The communication between central unit of load moment limiter and screen fails.

2. Change the load moment limiter.

3. Check the connecting cable from central unit to screen.

X X X X X X

ZCC800HWG Crawler Crane

5.5 Troubleshooting of air conditioning system The following table shows the troubles of air conditioning system and their solutions.

1

2

Troubles

The system can not generate the hot air.

The system can not generate the cold air.

Causes 1. The temperature control switch is damaged, or the cooling/heating rocker switch is not pushed to “heating” position.

2. The hot-water valve of air conditioning system is not opened.

3. The water temperature of engine is too low.

1. Change the temperature control switch, or push the cooling/heating rocker switch to “heating” position.

2. Open the hot-water valve.

3. Increase the rotational speed of engine.

4. Wire connection is wrong.

4. Connect the earth wire.

1. The air compressor is damaged.

2. The air compressor belt slips.

3.

The condenser high-pressure pipe leaks gas.

1.

Change compressor.

4. The switch is cut off.

5.

The damaged.

X X X X X X

Solutions

condenser

is

6. The temperature controller is damaged.

7.

The refrigerant is insufficient.

the

air

2. Change or adjust the belt.

3. Change the high-pressure pipe.

4. Connect the switch or adjust the pressure of system.

5. Check and repair the condenser fan. Change it if necessary.

6. Change the temperature controller.

7. Add refrigerant Chapter 5

No.

05 - 11

Maintenance and Service Manual for Crawler Crane Chapter 6 Application of oil

ZCC800HWG Crawler Crane

6.1 Antifreeze coolant Antifreeze coolant, a mixed fluid of water and anti-freezing and anti-corrosion agent, plays the following important roles in cooling system: -

Corrosion protection;

-

Anti-freeze protection;

-

Lower the freezing point and raise the boiling point.

It is recommended that the pure water is used to make the antifreeze coolant. The water and anti-freezing and anti-corrosion agent may mingle with each other in the proportion 1: 1. The proportion of anti-freezing and anti-corrosion agent can vary from 45% to 55%.

This kind of antifreeze coolant enable the crane to work in -37℃ temperature.

The anti-freezing and anti-corrosion agent must be added into the antifreeze coolant no matter where the crane works, to protect the cooling system.

The high-quality water is most important to cooling system, since the ordinary water has too much calcium and magnesium which will cause water scale formation, and too much fluoride and nitrate that will corrode the cooling system.

Do not add sealing agent and soluble oil to cooling system. Otherwise, the cooling system will be damaged.

It is advised to use the brand of anti-freezing and anti-corrosion agent approved by Weichai Power. If you want to use other brand, please consult the service centre of Weichai. Please buy the antifreeze coolant from Zoomlin.

The volume of antifreeze coolant is 43L. Change it every two years. If other kind of antifreeze coolant is used, shorten the change interval.

6.2 Lubricating oil The recommended lubricating oil brand is shown in the following table: Table × 6-001 Ambient temperature Brand of lubricating oil

- 45℃

- 35℃

- 25℃

- 15℃

0℃

15℃

25℃

35℃

45℃

5W-40 10W-30 15W-40

06 - 1

Chapter 6

X X X X X X

ZCC800HWG Crawler Crane

1. As to the high-quality lubricating oil, its quality grade is above CH-4.

2. The high-viscosity lubricating oil will reduce oil consumption and help the engine to run well in cold climate.

The lubricating oil (15W-40) is widely used and it can keep its property when crane is working in high temperature.

The low-viscosity lubricating oil (5W-40) can facilitate engine startup and ensure oil fluidity when ambient temperature is below -5℃. However, long-time use of this oil will shorten engine service life due to wear and tear.

3. Lubricating oil volume is 23 L. 6.3 Diesel oil The common diesel oil is shown in the following table.

Table × 6-002 Ambient temperature Brand of oil

-45℃

-30℃

-15℃

-5℃

0℃

5℃

10℃

20℃

30℃

40℃

50℃

5# 0# -10 # -20 # -35 # -50 # The engine only uses vehicle diesel oil, which must comply with National Standard GB19147-2009.

Chapter 6

The sulfur content of vehicle diesel oil must not exceed 350 ppm. If this sulfur content is exceeded, the diesel oil is not allowed to use. If you have to use this kind of diesel oil, you must shorten the oil change interval.

Do not add any special fuel additive into vehicle diesel oil. If a fuel additive is added, your warranty will be limited.

The fuel tank capacity is 300L. Top the crane up with diesel oil using the diesel pump attached to the crane or special-purpose diesel pump. If the crane is fueled via oil drum or oil tank, the oil in fuel system will not be pure, thus leading to failure of fuel system. Therefore, filter the oil before fueling the crane.

06 - 2

X X X X X X

ZCC800HWG Crawler Crane

1. Top the crane with clean fuel. Otherwise, it will cause severe damage to engine!

2. Do not use the diesel oil with gasoline, alcohol and other inflammable liquid.

Otherwise, it will result in explosion.

6.4 Gear oil of reducer The gear oil of reducer is classified under two types: mineral oil and synthetic oil. These two kinds of oil can not be mixed together to use.

The gear oil can not have any impurities such as water.

Select proper oil according to ambient temperature so as to meet the lubricating requirements of reducer.

Check oil level regularly. If too much oil is in reducer, the oil pressure will increase, thus leading to oil leakage, damage to the oil seal of half-shaft and braking failure. If the oil is insufficient, the gear bearing will not be lubricated well, thus enhancing wear of bearing.

Check the performance index and pollution of gear oil. If it exceeds the standard value, change the oil. During oil change, clean the gear box, and then add new oil. (For detailed oil quantity, see section 4.6.1.)

Table × 6-003 Prevailing gear oil Brand of gear oil

Ambient temperature (℃)

L-CKD220 industrial closed gear oil

-25 - 40

6.5 Hydraulic oil Take a sample of hydraulic oil for periodic inspection. For crane working under normal condition, its hydraulic oil must be checked every 3 months. For crane working in adverse environment, its hydraulic oil must be checked every month. The inspected items and hydraulic oil physical & chemical character variation limitation values are shown in the following table. If the hydraulic oil does not meet the requirements, change it at once.

Inspected item Kinematic viscosity (40℃) (mm2/s) Acid value addition (mgKOH/g) Moisture (%) Flash point (°C) Solid grain pollution grade

Hydraulic Oil Physical & Chemical Character Variation Limitation Value L-HS L-HV L-HM ±10%

±10%

±10% - 15%

0.3

0.3

0.3

0.1

0.1

0.1

-76

-76

-76

20/16

20/16

20/16

06 - 3

Chapter 6

Table × 6-004 X X X X X X

ZCC800HWG Crawler Crane

Recommended brand of hydraulic oil used in different ambient temperature Table × 6-005 Ambient temperature Below -30℃

Above -30℃

The lowest temperature for cold start (without load)

The lowest temperature for cold start (with load)

The lowest working temperature with load

The highest temperature of hydraulic oil

-40℃

-35℃

-15℃

50℃

-35℃

-22℃

-5℃

60℃

-28℃

-15℃

0℃

70℃

Between -20℃ and

-20℃

-10℃

5℃

-5℃

-3℃

20℃

SH 0358-95 10# aviation hydraulic oil GB11118.1-94 low condensed hydraulic oil L-HV32

* 80-85℃

GB11118.1-94 low condensed hydraulic oil L-HM46

** 100℃

GB11118.1-94 low condensed hydraulic oil L-HM68

40℃

Above 40℃

Hydraulic oil brand

1. If the crane starts in cold area, it should first run without load for a while. After the lowest working temperature is reached, the load can be added gradually and the system can work.

2. The oil property should be identical with that of the original brand when changing oil. The original oil should be washed away thoroughly. The hydraulic oil of different types can not be mixed together!

3. The domestic brands of hydraulic oil mainly include Kunlun, the Great Wall, Tongyi, Haibrand, Daqing, Hengyun, Guta, Jiali, Jiarun, Haili, etc. and foreign brands such as ESSO, Mobil, etc. are also available in china.

Chapter 6

4. If you find any special working conditions which are not listed in the above table, please consult the related departments of our company.

1. Check and measure oil temperature of system at any time!

2. The suitable temperature range for hydraulic system in working condition is 20℃ to 80℃. The 85℃ may occur for a short time or in some position.

3. When oil temperature is too high (nearly 100°), pay attention to the cooling of system. The working load should not be too heavy and the working frequency should not be too high.

06 - 4

X X X X X X

ZCC800HWG Crawler Crane

6.6 Lubricating grease In order to keep crane in good working condition, all machinery parts should be supplied with specified grease periodically.

Type ZL-2 lubricating grease ZG-3 lubricating grease

Table × 6-006 Recommended lubricating greases Drop Work wimble point degree Appearance (℃) (1/10mm) Smooth inunctum with the color from pale 175 265 - 295 yellow to brown Equal inunctum with the color from pale yellow to 90 220 - 250 brown

Moisture (%) no more than —— 2.5

Chapter 6

X X X X X X

06 - 5

Maintenance and Service Manual for Crawler Crane Chapter 7 Appendix

ZCC800HWG Crawler Crane

7.1 Tightening torque of threaded parts

4.6

4.8

5.8

6.8

8.8

10.9

12.9

Stress (MPa)

230

310

380

440

600

830

970

M6

4-5

5-6

7-8

8-9

10 - 12

14 - 17

17 - 20

M8

10 - 11

13 - 15

16 - 18

18 - 22

25 - 30

34 - 41

41 - 48

M8×1

10 - 12

14 - 17

17 - 20

20 - 23

27 - 32

37 - 43

43 - 52

M10

19 - 23

26 - 31

31 - 36

36 - 43

49 - 59

68 - 81

81 - 96

M10×1

21 - 25

28 - 34

35 - 41

41 - 48

55 - 66

76 - 90

90 - 106

M12

33 - 39

45 - 53

55 - 64

64 - 76

86 - 103

119 - 141

141 - 167

M12×1.5

35 - 41

47 - 56

57 - 67

67 - 79

90 - 108

124 - 147

147 - 174

M14

53 - 63

71 - 85

87 - 103

103 - 120

137 - 164

189 - 224

224 - 265

M14×1.5

57 - 68

77 - 92

94 - 110

110 - 131

149 - 179

206 - 243

243 - 289

M16

82 - 98

111 - 132

136 - 160

160 - 188

214 - 256

295 - 350

350 - 414

M16×1.5

87 - 104

113 - 141

144 - 170

170 - 200

228 - 273

314 - 372

372 - 441

M18

113 - 135

152 - 182

186 - 219

219 - 259

294 - 353

406 - 481

481 - 570

M18×1.5

127 - 152

171 - 205

210 - 247

247 - 291

331 - 397

457 - 541

541 - 641

M20

160 - 192

216 - 258

264 - 312

312 - 366

417 - 500

576 - 683

683 - 808

M20×1.5

178 - 213

239 - 287

294 - 345

345 - 407

463 - 555

640 - 758

758 - 897

M22

218 - 261

293 - 351

360 - 431

416 - 499

568 - 680

786 - 941

918 - 1099

M20×1.5

239 - 286

322 - 386

395 - 473

458 - 548

624 - 747

863 - 1034

1009 - 1208

M24

277 - 337

373 - 446

457 - 547

529 - 634

722 - 864

998 - 1195

1167 - 1397

M24×2

301 - 360

406 - 486

497 - 595

576 - 689

785 - 940

1086 - 1300

1269 - 1520

M27

405 - 485

546 - 653

669 - 801

774 - 801

1056 - 1264

1461 - 1749

1707 - 2044

M27×2

437 - 524

589 - 706

723 - 865

837 - 1002

1141 - 1366

1578 - 1890

1845 - 2208

M30

550 - 658

741 - 887

908 - 1087

1052 - 1259

1434 - 1717

1984 - 2375

2318 - 2775

M30×2

608 - 728

820 - 982

1005 - 1203

1164 - 1393

1587 - 1900

2196 - 2629

2566 - 3072

M36

961 - 1150

1295 - 1550

1587 - 1900

1838 - 2200

2506 - 3000

3466 - 4150

4051 - 4850

M36×3

1017 - 1218

1371 - 1641

1680 - 2011

1946 - 2329

2653 - 3176

3670 - 4394

4289 - 5135

M42

1536 - 1839

2071 - 2479

2538 - 3039

2939 - 3519

4008 - 4798

5544 - 6637

6479 - 7757

M42×3

1653 - 1979

2228 - 2667

2731 - 3269

3162 - 3786

4312 - 5162

5965 - 7141

6921 - 8345

M48

2308 - 2763

3110 - 3723

3813 - 4564

4415 - 5285

6020 - 7207

8327 - 9969

9732 - 11651

M48×3

2513 - 3008

3387 - 4055

4152 - 4970

4807 - 5755

6556 - 7848

9069 - 10857

10598 - 12688

Specification of bolt

Performance grade

07 - 1

Chapter 7

Table ×7-001 Tightening torque (N.m) of threaded parts (8.8-12.9 grade)

ZCC800HWG Crawler Crane

7.2 Tightening torque of thread parts at pipe orifices Table × 7-002 Tightening torque of thread parts at pipe orifices (applicable to light pipe fittings) Pipe thread Specification Metric of pipe orifice taper thread Specification of oil pipe (mm) Pipe thread (light) Tightening torque Metric (N.m) taper thread (light)

1/8″

1/4″

1/4″

3/8″

1/2″

1/2″

3/4″

1″

11/4″

11/2″

M10×

M12×

M14×

M16×

M18×

M22×

M26×

M33×

M42×

M48×

1

1.5

1.5

1.5

1.5

1.5

1.5

2

2

2

φ6

φ8

φ10

φ12

φ15

φ18

φ22

φ28

φ35

φ42

18

35

35

70

90

90

180

310

450

540

18

25

45

55

70

125

180

310

450

540

Table × 7-003 Tightening torque of thread parts at pipe orifices (applicable to heavy pipe fittings)

Chapter 7

Pipe thread Specification Metric of pipe orifice taper thread Specification of oil pipe (mm) Pipe thread (heavy) Tightening torque Metric (N.m) taper thread (heavy)

07 - 2

1/4″

1/4″

3/8″

3/8″

1/2″

1/2″

3/4″

1″

11/4″

11/2″

M12×

M14×

M16×

M18×

M20×

M22×

M27×

M33×

M42×

M48×

1.5

1.5

1.5

1.5

1.5

1.5

2

2

2

2

φ6

φ8

φ10

φ12

φ14

φ16

φ20

φ25

φ30

φ38

55

55

80

80

115

115

180

310

450

540

35

55

70

90

125

135

180

310

450

540

ZCC800HWG Crawler Crane

7.3 Attached tools for maintenance Table ×7-004 Attached tools for maintenance ID code

1

1019900187

2

1019900189

3

1140102826

4

1140207054

5

1140102828

6

00663009100001010

7

1991100032

8

1090100043

9

1140102830

10

1102900001

Names of the tools Pressure gauge

Specification

QTY.

SPG063-00060-01-S-M04

1

Pressure gauge Pressure testing joint Testing hose Pressure testing joint Square timber

SPG063-00400-01-S-M04

1

SMK20-M14X1.5-PC

1

P20-PM14-3-1500

1

SMK20-G1/4-PC

1

Tool box assy.

Flexible belt with two ends fastening Pressure testing joint Screw jack

GJX70-91-0

1

ST009 2T-8000

2

SMK20-10L-PK

2

QL5

2

12

Chapter 7

No.

07 - 3

ZCC800HWG Crawler Crane

7.4 Checklist for periodic inspection In order to keep the crane in safe condition during operation, the inspector must carry out inspection to crane systems and components at regular intervals. For the sake of convenience, we make the following checklist for periodic inspection. You can conduct the inspections according to the inspection category.

This checklist is only for reference. The user can make your own checklist according to actual conditions.

Table ×7-005 Checklist for periodic inspection Crane type: ZCC800H

Crane manufacturer:

Serial Number:

Company:

Inspected by:

Recorded by:

1. Inspection category: Power system Components Inspection inspected intervals Engine Engine mounting fastening bolts and engine housing Fan blade and belt Antifreeze coolant level Engine oil level Radiator core

Result

Serial Number of user: Date:

Remarks Check rotational speed, water temperature, oil pressure and relevant warning icons etc.

Check the bolts for tight fit and the housing for oil leakage

Check it for deformation and water leaks

Wind drag of air filter Air intake pipe

Chapter 7

Intercooler core Fuel pipeline Fuel pre-filter Fuel tank

07 - 4

Check it for deformation and wind leaks Check it for oil leaks and damage Check if there is water in the filter.

Check if there is sediment and water in the tank.

Check the tank for corrosion.

ZCC800HWG Crawler Crane

Crane type: ZCC800H Crane manufacturer:

Serial Number:

Serial Number of user:

Company:

Recorded by:

Date:

Inspected by:

2. Inspection category: winch reducer Inspection Components inspected intervals

Result

Remarks Check if the load falls down uncontrollable after engine stops.

Status of load Wire rope wound onto the drum Sound made by the reducer when it is running Brake Gear oil level

Demount the seal plate and check the lubricating condition of bearing.

Bearing of reducer Lowering limiter

Check them for oil leaks

Reducer and motor Mounting screw (or bolts) 3. Inspection category: slewing mechanism Components inspected

Inspection intervals

Result

Remarks

Sound made by slewing reducer and slewing ring when they are running Gear oil level

Slewing reducer

Check it for oil leaks

Slewing motor

Check it for oil leaks

Torque of mounting bolt of slewing ring Lubrication on the surface of large and pinion gear Wear on the surface of large and pinion gear

07 - 5

Chapter 7

Brake

ZCC800HWG Crawler Crane

Crane type: ZCC800H Crane manufacturer:

Serial Number:

Serial Number of user:

Company:

Recorded by:

Date:

Inspected by:

4. Inspection category: travel gear Components inspected

Inspection intervals

Result

Remarks

Track pad

Check the convex teeth of track pad for wear

Pin spindles of track pad

Check them for cracks Check the slot of drive sprocket for wear Check it for oil leaks and cracks

Drive sprocket Track roller Tension of crawler Traveling reducer

Check it for oil leaks

5. Inspection category: hydraulic system Components inspected

Inspection intervals

Result

Remarks

Oil level in the hydraulic oil tank Hydraulic oil tank Oil return filter Pipelines and pipe fittings Air filter Oil cooler

Check if there is sediment in the tank.

Change the filter cartridge Check them for oil leaks and damage Check if the filter is clogged.

Check it for oil leaks and damage.

Hydraulic motor and pump

Chapter 7

Valves in the hydraulic system Energy accumulator

07 - 6

Check them for oil leaks Check it for oil leaks and damage

ZCC800HWG Crawler Crane

Crane type: ZCC800H Crane manufacturer:

Serial Number:

Company:

Recorded by:

Inspected by:

Serial Number of user: Date:

6. Inspection category: electrical system Inspection intervals

Result

Remarks

Load moment limiter

Check if the value shown is correct and the warning icon flashes when irregular condition occurs.

Hoisting limit switch

Check it for functional work

Lowering limit switch

Check it for functional work

Tilting-back limit switch

Check it for functional work

Shutoff valve limit switch

Check it for functional work

Angle limit switch

Check it for functional work Check if the wind speed is shown or the sensor is damaged.

Check if the inclination shown is correct or the sensor is damaged.

Check if the pressure shown is correct or the sensor is damaged.

Check the clearness of image, and the video for damage Check if the plug and socket are connected tightly, or they are damaged.

Check if the oil level is shown or the sensor is damaged.

Wind speed sensor Inclination sensor Pressure sensor Monitoring system Connector on the boom and slewing table Oil level sensor 7. Inspection category: load hook and pulley Components inspected Pulley Pulley spindle Hook shaft Load hook

Inspection intervals

Result

Remarks Check the lubricating condition of pulley Check the sealing seat of spindle and its roll resistance Check the sealing seat of shaft and its roll resistance Check it for cracks and wear 07 - 7

Chapter 7

Components inspected

ZCC800HWG Crawler Crane

Crane type: ZCC800H Crane manufacturer:

Serial Number:

Company:

Recorded by:

Inspected by:

Serial Number of user: Date:

8. Inspection category: wire rope Components inspected

Inspection intervals

Result

Remarks Check rope end point, number of wire breaks and strand breaks Check rope end point, number of wire breaks and strand breaks Check rope end point, number of wire breaks and strand breaks Check them for cracks and deformation

Wire rope for hoisting winch 1 Wire rope for hoisting winch 2 Derricking rope Rope thimble and rope lock 9. Inspection category: safety equipment Components inspected

Inspection intervals

Result

Remarks Check the spring for functional work and the tilting-back support for deformation and corrosion.

Check the spring for functional work and the tilting-back support for deformation and corrosion.

Check the spring for functional work and the tilting-back support for deformation and corrosion.

Main boom tilting-back support Front tilting-back support of fixed jib Rear tilting-back support of fixed jib Mounting spindle of tilting-back support

Check it for tight fit

10. Inspection category: Boom, jib and other load-bearing parts

Chapter 7

Components inspected

Main boom

Fixed jib

FA-frame

07 - 8

Inspection intervals

Result

Remarks Check the attachment points on the boom, and check the boom for deformation, corrosion and cracks.

Check the attachment points on the jib, and check the boom for deformation, corrosion and cracks.

Check the attachment points on FA-frame, and check the boom for deformation, corrosion and cracks.

ZCC800HWG Crawler Crane

A-frame

Rope pulley on A-frame Main boom anchoring rods Fixed jib front anchoring rods Fixed jib rear anchoring rods

Inspection intervals

Result

Remarks Check the attachment points on A-frame, and check the boom for deformation, corrosion and cracks.

Check the lubricating condition of rope pulley Check it for deformation, corrosion and cracks.

Check it for deformation, corrosion and cracks.

Check it for deformation, corrosion and cracks.

Chapter 7

Components inspected

07 - 9