XCMG QAY220 User manual

QAY220 All Terrain Crane Operation Manual
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QAY220 All Terrain Crane Operation Manual
QAY220 All Terrain Crane Operation Manual
VIN
Date
The operation manual is part of the crane. Always keep on hand!.
Please read it carefully before operating the crane.
This equipment is designed and manufactured by complying with the standards of
GB 6067.1-2010 Safety rules for lifting appliances,
GB 7258-2012 Safe specifications for power-driven vehicles operating on roads,
GB/T 6068-2008 Test code for truck crane and mobile crane,
JB/T 9738-2000 Truck crane and wheel crane-Technical requirements,
GB/T 27996-2011 All terrain crane,
Q/320301JAF22, Q/320301JAF158 and Q/320301JAF253.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD., CHINA
Address: No.165 Tongshan Road, Xuzhou, Jiangsu Province, China
Tel: [phone]
Fax: [phone]
Post code: 221004
Service Tel: [phone]
Service Fax: [phone]
Spare Parts Tel: [phone]
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QAY220 All Terrain Crane Operation Manual
I
Contents
Contents
Preface ......................................................................................................................................................ⅤII
Chapter 1 General safe operating practices ............................................................................................... 1-1
1-1 Highway traffic regulations ......................................................................................................... 1-1
1-2 Axle load...................................................................................................................................... 1-1
1-3 Transport of hook block............................................................................................................... 1-2
1-4 Crew............................................................................................................................................. 1-2
1-5 Safety technical notes .................................................................................................................. 1-2
1- Environment influence to cranes................................................................................................. 1-2
1-5-2 Job site requirements.............................................................................................................. 1-3
1-5-3 Set up crane ........................................................................................................................... 1-3
1-5-4 Planning the job ..................................................................................................................... 1-4
1-6 “Ten don’t lifting”................................................................................................................ 1-4
1-7 Operation precautions.................................................................................................................. 1-5
1-8 Operations under special working conditions.............................................................................. 1-6
1-8-1 Slopes and trenches................................................................................................................ 1-6
1-8-2 Working near transmitters ...................................................................................................... 1-6
1-8-3 Influence of wind ................................................................................................................... 1-7
1-9 Safety information ....................................................................................................................... 1-8
1-9-1 Minimum distance between any part of the crane and electrical overhead wires.................. 1-8
1-9-2 Permissible ground-bearing load ........................................................................................... 1-9
1-9-3 Wind speed description ........................................................................................................ 1-10
1-9-4 Wind pressure-height conversion factor Kh......................................................................... 1-11
1-10 Emergency methods................................................................................................................. 1-12
1-10-1 Emergency methods when natural disaster occurs............................................................ 1-12
1-10-2 Emergency methods when accident occurs........................................................................ 1-13
1-11 Safety protective equipments .................................................................................................. 1-14
1-12 Noise ........................................................................................................................................ 1-14
1-13 Cleaning of the crane............................................................................................................... 1-14
1-14 Indication plates...................................................................................................................... 1-15
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QAY220 All Terrain Crane Operation Manual
II
1-14-1 Nameplate ......................................................................................................................... 1-15
1-14-2 Indicating plates ................................................................................................................ 1-16
1-14-3 Warning plates.................................................................................................................... 1-20
1-15 Use the manual correctly ......................................................................................................... 1-23
Chapter 2 Applications and features .......................................................................................................... 2-1
2-1 Composition and meaning of crane model .................................................................................. 2-1
2-2 Main application and working scope........................................................................................... 2-1
2-3 Operating conditions.................................................................................................................... 2-1
2-4 Main features of QAY220 All terrain crane................................................................................. 2-2
2-5 Terminology................................................................................................................................. 2-3
2-6 Main parts .................................................................................................................................... 2-5
Chapter 3 Main technical specifications .................................................................................................... 3-1
3-1 QAY220 technical specifications and performance..................................................................... 3-1
3-2 Structure and specifications of main parts.................................................................................. 3-8
Chapter 4 Crane operation ......................................................................................................................... 4-1
4-1 Operation of engine ..................................................................................................................... 4-1
4-1-1 Starting engine ....................................................................................................................... 4-2
4-1-2 Preheating engine................................................................................................................... 4-3
4-1-3 Stopping engine...................................................................................................................... 4-3
4-1-4 Notes on operation ................................................................................................................. 4-4
4-2 Operation of PTO ........................................................................................................................ 4-5
4-2-1 Engaging PTO........................................................................................................................ 4-5
4-2-2 Disengaging PTO................................................................................................................... 4-5
4-3 Acceleration ................................................................................................................................. 4-6
4-3-1 Operating method.................................................................................................................. 4-6
4-3-2 Notes on operation ................................................................................................................. 4-6
4-4 Operation of winches................................................................................................................... 4-7
4-4-1 Operation of main winch (right lever) ................................................................................... 4-7
4-4-2 Operation of auxiliary winch (left lever) ............................................................................... 4-8
4-4-3 Notes on operation ................................................................................................................. 4-9
4-5 Boom telescoping operation (left lever) .................................................................................... 4-10
4-Operating method ....................................................................................................................... 4-10
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QAY220 All Terrain Crane Operation Manual
III
4-5-2 Boom extending and retracting procedure ........................................................................... 4-13
4-5-3 Notes on operation ............................................................................................................... 4-16
4-6 Boom elevating operation.......................................................................................................... 4-17
4-6-1 Operating method (right lever) ............................................................................................ 4-17
4-6-2 Relationship among boom angle, total rated load and working radius................................ 4-18
4-6-3 Notes on operation ............................................................................................................... 4-18
4-7 Slewing operation ...................................................................................................................... 4-19
4-7-1 Operating method (left lever)............................................................................................... 4-19
4-7-2 Notes on operation ............................................................................................................... 4-20
4-8 Operation of tilting operator’s cab .......................................................................................... 4-21
4-8-1 Operating method................................................................................................................. 4-21
4-8-2 Notes on operation ............................................................................................................... 4-21
4-9 Operation of turntable locking device ...................................................................................... 4-22
4-9-1 Operating method................................................................................................................. 4-22
4-9-2 Notes on operation ............................................................................................................... 4-22
Chapter 5 Accessories ................................................................................................................................ 5-1
5-1 Counterweight ............................................................................................................................. 5-1
5-1-1 Notes on operation.................................................................................................................. 5-1
5-1-2 Counterweight combination................................................................................................... 5-1
5-1-3 Counterweight erection .......................................................................................................... 5-3
5-1-4 Counterweight dismantling .................................................................................................... 5-6
5-1-5 Transportation of counterweight ............................................................................................ 5-8
5-2 Jib................................................................................................................................................. 5-9
5-2-1 Erecting and stowing jib ........................................................................................................ 5-9
5-2-2 Notes on operation ............................................................................................................... 5-15
5-3 Single top .................................................................................................................................. 5-16
5-4 Auxiliary winch ......................................................................................................................... 5-17
5-4-1 Installation of auxiliary winch ............................................................................................. 5-17
5-4-2 Pipeline connection .............................................................................................................. 5-18
5-5 Hook block ............................................................................................................................... 5-19
5- Basic type and structure ............................................................................................................ 5-19
5-5-2 Inspections ........................................................................................................................... 5-19
Contents
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QAY220 All Terrain Crane Operation Manual
IV
5-6 Re-reeving winch rope.............................................................................................................. 5-21
5-6-1 Working conditions .............................................................................................................. 5-21
5-6-2 Reeving method ................................................................................................................... 5-23
5-6-3 Installation of the weight...................................................................................................... 5-27
Chapter 6 Crane electric system ................................................................................................................ 6-1
6-1 Safety control............................................................................................................................... 6-1
6-2 Operation control......................................................................................................................... 6-1
6-3 Electric system of operator’s cab ............................................................................................. 6-2
6-3-1 Devices in operator’s cab .................................................................................................... 6-2
6-3-2 Instrument panel .................................................................................................................... 6-3
6-3-3 Notes on operation ................................................................................................................. 6-6
6-4 Superstructure battery.................................................................................................................. 6-7
Chapter 7 Hydraulic system....................................................................................................................... 7-1
7-1 Check the level of oil in hydraulic tank....................................................................................... 7-1
7-2 Hydraulic system description ...................................................................................................... 7-2
7-3 Main winch circuit....................................................................................................................... 7-3
7-4 Auxiliary winch circuit ................................................................................................................ 7-4
7-5 Slewing circuit............................................................................................................................. 7-5
7-6 Elevating circuit........................................................................................................................... 7-6
7-7 Telescoping circuit....................................................................................................................... 7-6
7-8 Auxiliary circuit........................................................................................................................... 7-7
7-9 Main valve .................................................................................................................................. 7-7
7-10 Balance valve............................................................................................................................ 7-7
7-11 Hydraulic oil tank ..................................................................................................................... 7-8
7-12 Specifications............................................................................................................................ 7-8
7-13 Hydraulic oil description .......................................................................................................... 7-9
Chapter 8 Safety devices............................................................................................................................ 8-1
8-1 Load moment indicator................................................................................................................ 8-1
8-1-1 Working principle................................................................................................................... 8-1
8-1-2 Safety function ....................................................................................................................... 8-1
8-1-3 Logic control function............................................................................................................ 8-1
8-1-4 Hoist height limit function ..................................................................................................... 8-1
Contents
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QAY220 All Terrain Crane Operation Manual
V
8-1-5 Notes ...................................................................................................................................... 8-2
8-2 Lowering limiter (counter) .......................................................................................................... 8-3
8-3 Safety switch of electric proportional system.............................................................................. 8-4
8-4 Electronic level gauge.................................................................................................................. 8-5
8-5 Hydraulic safety valve ................................................................................................................ 8-6
8-6 Hydraulic oil filter clogged warning lamp.................................................................................. 8-6
8-7 Low oil pressure warning lamp .................................................................................................. 8-7
8-8 High water temperature warning lamp ....................................................................................... 8-7
Chapter 9 General cautions in operation.................................................................................................... 9-1
Chapter 10 Periodic inspections............................................................................................................... 10-1
10-1 General..................................................................................................................................... 10-1
10-2 Daily check .............................................................................................................................. 10-1
10-3 Weekly inspections .................................................................................................................. 10-2
10-4 Irregular inspections ................................................................................................................ 10-2
10-5 Test requirements..................................................................................................................... 10-2
10-6 Checklist .................................................................................................................................. 10-3
Chapter 11 Transporting and loading crane ............................................................................................. 11-1
11-1 Notes on railroad transportation ............................................................................................. 11-1
11-2 Notes on road transportation.................................................................................................... 11-1
11-3 Notes on sea transportation...................................................................................................... 11-2
Chapter 12 Hand signs............................................................................................................................. 12-1
12-1 General signs ........................................................................................................................... 12-1
12-2 Dedicated signs........................................................................................................................ 12-3
Total pages.................................................................................................................................................159
Contents
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QAY220 All Terrain Crane Operation Manual
VIPreface
Preface
This manual is suitable for QAY220 All terrain crane.
Methods about operation, inspection and adjustment of QAY220 All terrain crane as well as erecting
and transporting accessories are supplied in the manual. Lifting operation is a work that may be involved
with risk, in order to ensure safety while give full rein to the crane high performance, please read,
understand and use the operating instructions in this manual. And pay more attention to the contents of
“Danger”, “Warning”, “Caution”and “Check”in this manual.
All cranes have been checked strictly in our factory and are supplied to Customers with all control
components correctly set. Please don’t regulate them randomly.
Only the trained and qualified personnel can work on this crane.
Pay attention to periodic inspections of crane safety devices and don’t use reluctantly the devices
with any defects and abnormalities. What you should always keep in mind is “Safety Is a Top Priority”.
Please keep the supplied technical documents and operation manual carefully, and operate the
machine according to instructions in them. We don’t take any liability in case of unfavorable result due
to nonobservance of the operation manual. For special application, please contact our company, we would
like to supply technical support in time and effectively.
All products made by our company have gained “3C”certification. In order to keep
the conformity of products, during maintenance and service, replace parts with those, which have same
models and are made by original manufacturers, otherwise our company will not bear the responsibility
for loss resulted.
Due to the product modification and improvement, what described in this manual may vary from the
real one. We reserve the right to modify the design without notice.
First edition, August 2011
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QAY220 All Terrain Crane Operation Manual
VII
Symbols and their meanings are as follows:
——It means there is an imminent danger, serious injury or death will be caused if
it could not be avoided.
——It means there is a potential danger, injury or death may be caused if it could
not be avoided.
——It means there is a potential danger, light or medium injury may be caused if it
could not be avoided.
—— related inspections are required by requirements.
Preface
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QAY220 All Terrain Crane Operation Manual
1-1
Chapter 1 General safe operating practices
1-1 Highway traffic regulations
Before travelling on the municipal highway, main stem and square, make sure that the total weight,
axle load and outline dimension do not exceed the limited value prescribed in municipal and local
traffic regulations.
1. Travel configuration
When the deadweight of XZJ5721JQAY220 All Terrain Crane in travel configuration is 72 t, it does not
include the weight of counterweight, hook block, auxiliary hoist mechanism, auxiliary winch rope & slings,
and jib extension;
When the deadweight of XZJ5723JQZ220 All Terrain Crane in travel configuration is 72 t, it does not
include the weight of counterweight, hook block, auxiliary hoist mechanism, auxiliary winch rope & slings,
and jib extension.
2. Short distance job site transfer
During short distance job site transfer, the deadweight of QAY220 All Terrain Crane does not
include the weight of all optional parts and parts transported along with the machine. In special case, a
counterweight slab of 22 t, jib, auxiliary winch or various hook blocks may be taken on board. Refer to
related items in the manual for details.
1-2 Axle load
Axle load has maximum design value and maximum permissible value prescribed in traffic
regulations, the crane is not allowed to exceed the limited value when travelling on highways.
The following dangers will happen if overloading occurs while the crane is travelling on
highways:
●The increase of vehicle braking distance may result in dangers;
●The damage of parts in steering system may cause steering system out of control;
●Brake drum may quicken up abrasion, decrease braking performance and increase
traveling dangers;
●Parking brake (hand brake) cannot be ensured acting normally.
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-2
1-3 Transport of hook block
T h e h o o k b l o c k s h o u l d n o t b e
suspended in front of the crane when the
crane travels on a highway, otherwise,
the field of vision of the driver may be
obstructed by the hook block, and driving
safety will be affected.
1. Transport of hook block for short
distance transfer
A hook block may be carried on board
when the crane is transferred for short distance
to another job site. The hook should be held
with an auxiliary cable and attached to the front
towing coupling.
2. Transport of hook block when the crane
is travelling on a highway
When the crane is travelling on a highway,
the hook block is not allowed on board, it
should be transported by another vehicle.
1-4 Crew
Only two persons are allowed in the
driver’s cab during travelling and no one is
permitted outside the cab.
1-5 Safety technical notes
1- Environment influence to cranes
1. Suitable working temperature for crane
operation is -20℃~+40℃. Beyond the range,
the working life of crane parts and operation
safety will be reduced. If the crane is to be
operated out of the temperature range, please
indicate the special application or auxiliary
parts, and grease needing to be added when you
order the machine.
2. The permissible maximum wind force
for crane operation is grade 5, i.e. wind velocity
is 14.1 m/s.
If ambient temperature is beyond the
normal working temperature, operator
has the right to stop operation on the
condition that there is no secondary
danger occurring.
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-3
The following should be met on job site:
1. Supports (outrigger floats) should be
extended in place stipulated in load charts;
2. All movements (e.g. slewing, lifting, and
elevating, etc.) should not be interfered by any
obstacle;
3. The crane must be set up on a firm and
level supporting surface, no risk of sinking
during operation. Otherwise, tipping of the
crane will occur.
The crane must be set up on a firm
and level supporting surface, no risk of
sinking during operation. Otherwise,
tipping of the crane will occur.
●Only when the outrigger beams
have been extended in place stipulated in
load charts can the crane be supported.
●Outrigger beams must be secured
by pins, i.e. outrigger beam pins must be
inserted fully so as to prevent outrigger
beams from retraction, which will cause
tipping.
●All tires should clear off the
ground. Otherwise, tipping will occur.
1-5-2 Job site requirements
1. It must be sure that the ground could bear
the pressure of outriggers during operation. Each
outrigger float must be located on the center of
each supporting wood or plate.
1-5-3 Set up crane
2. There are two working conditions
for operation of crane on outriggers, i.e.
fully extended outriggers and half extended
outriggers. During lifting operation, four
outrigger beams must be extended according
to the requirements stipulated in load charts. If
only the beams on the side that lifting operation
is to be carried out are extended, the following
will occur:
•The load will be transferred to the boom
and jib through wire rope. If abrupt unloading
or rope breaking occurs, the force applied on
boom head will be released, so the crane will tip
backward;
•The load may be moved to the side that
outrigger beams are not extended, and then
tipping of crane will be caused;
•The crane will tip backward due to the
effect of boom and counterweight.
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-4
If the crane operator does not possess
all necessary and required information,
it may prove impossible to carry out the
intended work, or he may be tempted to
improvise and accidents may be resulted.
As well as a fully functioning crane and
well qualified personnel, operational planning is
an important precondition for safe and reliable
crane operation.
The crane operator must be in possession
of or procure all the necessary information
before starting the crane operation, especially:
1. Natural condition of working site, such
as temperature and wind speed;
2. Site location (journey distance);
3. Route to be driven;
4. Height and side clearances;
5. Electrical overhead wires (complete with
voltage data);
6. Space requirements at the operating site;
7. Movement and operation restrictions due to
surrounding structures;
8. Weight and dimension of load(s) to be
lifted
9. Required lifting height and radius
10. Load-bearing capacity of soil or surface
to be operated upon
The crane operator can then use this
information to decide on the correct crane
operating equipment: hook blocks, jib, auxiliary
winch and super lifting device, as well as
counterweight, wood blocks and tools, etc.
1-5-4 Planning the job
1-6 “Ten don’t lifting”
Crane operator must refuse to perform lifting operation if any one of the following occurs:
1. Signal indefinite or command against rules;
2. Overloading;
3. Work-piece or load bound loosely;
4. There is person on the load to be lifted;
5. Safety devices incomplete or insensitive or failed;
6. Work-piece buried or stuck by structure or equipment;
7. Bad view due to darkness;
8. Load with sharp edges not being protected;
9. Side-loading;
10. Dangerous goods (e.g. oxygen cylinder, acetylene cylinder) without protective measures.
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-7 Operation precautions
1. Mistakes in calculating lifting capacity can cause accidents. So the following should be taken
into consideration:
•The lifting load listed in load chart includes the weight of the hook, rope and slings.
For example: the lifting load listed in load chart is 25000 kg，the weight of hook is 400 kg, the
weight of rope and slings is 100 kg, the actual lifting load of the crane should not be more than
25000-400-100=24500 kg.
•It is very dangerous trying to lift a load without knowing whether it is within the rated capacity, and this should
never be done.
•Operation must be done strictly according to the load charts, it is forbidden to overload.
•It is forbidden to calculate the lifting load by interpolation.
2. During lifting operation, pay attention to the following:
•Safety protective equipments (safety belt, helmet) should be worn when work on structural parts;
•No person and objects piled are permitted within slewing radius;
•Never use the crane as a lifter for transferring person;
•It is not allowed to interrupt common operation by using emergency stop device;
•The crane operation is forbidden whenever the thundering happens;
•The engine running should strictly obey the requirements in Engine technical documents;
•Safe distance between the hook block and boom head must be kept. Lower the hook while extending
the telescopic booms so as to avoid them blocking each other;
•Make sure no person is within the working areas before moving the hook, boom, load or
outriggers;
•Keep window clean to ensure enough vision of view for operator. Dirty windows, darkness,
bright sunlight, fog, rain and other conditions can make it difficult for the operator to see, and
consequently influence the safety of operation;
•Carelessness in getting on and off equipment can result in serious injuries. Always wait until the
machine has stopped. Do not jump on or off. Always use both hands and make sure you have good footing.
Slippery floors and steps, tools, trash, or other loose items can cause falls;
•Always place the boom point directly above the load when lifting. The load will swing out of
control if it is not directly beneath the boom point when lifted. This can side load the boom and may
cause the crane to tip or collapse.
1-5
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-6
1-8 Operation under special working conditions
Safe distance D is measured from the
foot of the trench T and depends on the
specific site conditions.
1-8-1 Slopes and trenches
The crane must not be set up too close to
slopes or trenches, and depending on the type
of soil, a safe distance must always be kept
from them.
•Soft or backfilled soil: D2=2×T;
•Hard or grown soil: D1=T
1-8-2 Working near transmitters
If there is a transmitter near the job site, strong electro-magnetic fields may exist. In any case,
before working with the crane near transmitters, contact related representative or consult a high
frequency specialist. These electro-magnetic fields can pose direct or indirect danger to persons or
objects, for example:
•Effect on human organs due to temperature increase;
•Danger of burns or inflammation due to temperature increase;
•Spark or electric arc formation;
•Effect on LMI and other electric components of the crane due to electro-magnetic interference.
The high frequency rays from a transmitter require an increased working protection and special
guidelines for crane operator and crane personnel.
1. Every crane must be “totally”grounded. Check visually or with a simple tester to ensure that
ladder and cab, etc. are grounded;
2. All persons working on the crane or on larger metal parts must carry special protective gloves
without metal connectors and suitable protective suits to protect them from burns while working;
3. When moving the crane, do not allow it to touch other crane loads. Since burn nicks reduce the
load carrying capacity of the cables significantly, contact your supervisor any time such a contact has
occurred, so that the cables can be checked and inspected;
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-7
4. An insulator must always be between the load hook of the crane and the tackle, and it is
prohibited to remove the insulator;
5. If possible, transport larger loads in horizontal direction, to reduce high frequency absorption;
6. Before carrying out any necessary manual work, ground the loads first or insulate them;
7. The temperature of the tool can be checked with a suitable tester. If, for example 500V can be
measured on a tool at a distance of 1 to 2 cm, then the tool may not be touched with bare hands.
8. Handling explosive matter (such as refueling) may only be done at least 6 m away from the
place where sparks could form due to handling of larger metal parts.
9. All accidents or special occurrences must be reported immediately to the local construction
supervisor and the safety engineer.
When performing crane operation in strong
wind, utmost cautions are required according
to the wind velocity, machine condition and
working environment. The wind velocity on
the ground is different with that in the high air.
It is also different on flat ground and in city
air. Always considering these conditions and
taking proper measures to meet the situation.
The wind velocity mentioned here means the
instantaneous wind speed. Measure the wind
velocity with the anemometer provided on the
boom head. The instantaneous wind speed also
can be approximated by the table of Wind Speed
Description.
Prior to operation, operator must obtain
the wind information such as wind velocity,
pressure from a weather report. Operation
should not be carried out if it exceeds rated
value, otherwise, danger will occur.
1-8-3 Influence of wind
Influence of the wind on the machine
becomes larger in proportion to the size of a
load lifted, lifting height, and boom length.
Esp ecially, the f ollowing cases ar e very
dangerous, so utmost care is necessary for
operation.
1. When lifting a load of wide area, against
which the wind blows hard, the wind could
cause the overturn of the machine and damage
to the boom. The wind could also blow the load
against the boom, and could cause damage.
2. When the boom is fully raised without a
load, the wind could blow the boom backward
resulting in an overturn of the machine.
When the wind velocity exceeds grade
5, i.e. 14.1m/s, stop the work and lower the
load onto the ground and release hook block.
Retract the boom fully and position it on
boom rest and stop engine.
General safe operating practices
Chapter 1
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QAY220 All Terrain Crane Operation Manual
1-8
1-9 Safety information
Voltage of power lines V/kV
Table 1-1
＜1
1.5
1～20
2
330
7
35～110
4
154
5
220
6
When operate crane near power electrical lines, the safe clearances keeping any part of
crane from the lines should comply with those shown in table 1-1, otherwise serious injury
or death will occur, and then consequent power failure accidents such as civil electricity,
electricity for hospital endangering patient, civil airport and traffic chaos and factory stopping
work.
1-9-1 Minimum distance between any part of the crane and electrical overhead wires
When operate crane near power electrical lines, the safe clearances keeping boom, slings, auxiliary
tool, rope, tag line and load from the lines should comply with those shown in table 1-1.
Min. distance /m
General safe operating practices
Chapter 1
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