XCMG XCT80 User manual

ＸＣＴ８０ Ｔｒｕｃｋ Ｃｒａｎｅ Ｏｐｅｒａｔｉｏｎ Ｍａｎｕａｌ
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XCT80 Truck Crane Operation Manual
Vehicle identification number (VIN)
Date of production
The product service manual is part of the product, and should always be placed handy for
future reference.
Please read the product service manual before using the product.
This product is designed and manufactured to comply with GB 6067.1-2010 “Safety
regulations of hoisting machine”,
GB 7258-2012 “Safety operation technical conditions of motor vehicles”, GB/T 6068-
2008 “Test specifications of truck crane and tyre crane”, JB/T 9738-2000 “Technical
requirements of truck crane and tyre crane”, and Q/320301JAF144 standard.
Xuzhou Construction Machinery Group Co., Ltd. Xuzhou Heavy Machinery Co., Ltd.
Address: No. 165Tongshan Road, Xuzhou City, Jiangsu Province, China
Tel: [phone] 83462350
Fax: [phone]
Post Code: 221004
Service Tel: [phone]
Service Fax: [phone]
Spare Parts Tel: [phone]
XCT80 Truck Crane Operation Manual
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XCT80 Truck Crane Operation Manual
I
Contents
Preface .........................................................................................................................................................Ⅸ
Chapter1 Properly use the product manual................................................................................................ 1-1
Chapter2 Crane logo .................................................................................................................................. 2-1
2-1 Composition and meaning of product models............................................................................. 2-1
2-2 Product nameplate ....................................................................................................................... 2-1
2-3 Chassis nameplate........................................................................................................................ 2-2
2-4 Crane performance label.............................................................................................................. 2-3
2-5 Indicating label ............................................................................................................................ 2-3
2-6 Warning label............................................................................................................................... 2-3
Chapter3 Basic safety instructions............................................................................................................. 3-1
3-1 Properly use the crane.................................................................................................................. 3-1
3-1-1 Abnormal use of the crane .................................................................................................... 3-1
3-1-2 General requirements of the crane safety operation ............................................................. 3-2
3-2 Personnel selection and qualification .......................................................................................... 3-4
3-2-1 Assignment personnel .......................................................................................................... 3-4
3-2-2 Crane operator....................................................................................................................... 3-4
3-2-3 Slingers ................................................................................................................................. 3-5
3-2-4 Command personnel ............................................................................................................. 3-6
3-2-5 Installation personnel............................................................................................................ 3-7
3-2-6 Maintenance personnel ......................................................................................................... 3-7
3-3 Personnel safety equipment......................................................................................................... 3-8
3-4 Safety passage and emergency escape......................................................................................... 3-8
3-5 Crane driving safety instructions................................................................................................. 3-9
3-5-1 Road traffic rules................................................................................................................... 3-9
3-5-2 Hook transportation .............................................................................................................. 3-9
3-5-3 Passengers on driving crane................................................................................................ 3-10
3-5-4 New crane running.............................................................................................................. 3-10
3-6 Crane operation safety instructions ........................................................................................... 3-10
Chapter4 Construction instructions............................................................................................................ 4-1
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XCT80 Truc k Cr an e Op er at ion Manual
II Contents
4-1 Planning....................................................................................................................................... 4-1
4-2 Crane operation management ...................................................................................................... 4-2
4-2-1 Safe working system............................................................................................................. 4-2
4-2-2 Crane operation plan ............................................................................................................ 4-3
4-2-3 Faults and accidents report .................................................................................................. 4-3
4-3 Crane settings .............................................................................................................................. 4-3
4-3-1 Crane supporting conditions ................................................................................................ 4-3
4-3-2 Obstacles around crane ........................................................................................................ 4-6
4-3-3 Wind load inuence ............................................................................................................. 4-8
4-3-4 Crane grounding ................................................................................................................ 4-10
4-4 Multiple cranes lifting operation ............................................................................................... 4-10
4-5 lifting weight.............................................................................................................................. 4-11
4-6 Disaster Treatment and Emergency Measures........................................................................... 4-12
4-6-1 Natural disaster ................................................................................................................... 4-12
4-6-2 Accident disaster ................................................................................................................. 4-13
4-7 Operation instructions for the crane in out-of-service condition............................................... 4-14
Chapter 5 Main characteristics and technical parameters.......................................................................... 5-1
5-1 Main purposes and characteristics............................................................................................... 5-1
5-1-1 Main purpose and scope ....................................................................................................... 5-1
5-1-2 Main characteristics of XCT80 truck crane.......................................................................... 5-1
5-2 Conditions of use......................................................................................................................... 5-1
5-3 XCT80 truck crane technical parameters and rated lifting weight chart..................................... 5-1
5-4 Crane main structure performance parameters.......................................................................... 5-29
Chapter6 Components and functions of lower crane portion ................................................................... 6-1
6-1 General overview......................................................................................................................... 6-1
6-1-1 Power system ........................................................................................................................ 6-1
6-1-2 Transmission system ............................................................................................................. 6-1
6-1-3 Driving system...................................................................................................................... 6-1
6-1-4 Operating system .................................................................................................................. 6-1
6-1-5 Cab and covering parts ......................................................................................................... 6-1
6-1-6 Hydraulic system .................................................................................................................. 6-1
6-1-7 Air conditioning system ........................................................................................................ 6-1
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XCT80 Truck Crane Operation Manual
III
6-1-8 Electrical system ................................................................................................................... 6-1
6-1-9 Auxiliary system ................................................................................................................... 6-1
6-2 Main components introduction.................................................................................................... 6-3
6-3 Cab and protective device............................................................................................................ 6-4
6-3-1 The cab interior equipments.................................................................................................. 6-4
6-3-2 Main function introduction of meters, switches and lights in the cab ................................ 6-15
6-3-3 Other device........................................................................................................................ 6-20
6-3-4 Protective devices ............................................................................................................... 6-22
Chapter 7 Traveling Status on Highway ................................................................................................... 7-1
7-1 Preparations before traveling....................................................................................................... 7-1
7-1-1 Crane traveling mode on highway ........................................................................................ 7-1
7-1-2 Inspection of vehicle condition............................................................................................. 7-1
7-1-3 The use of air conditioning ................................................................................................... 7-4
7-2 Operation of lower crane portion engine..................................................................................... 7-6
7-2-1 Check before starting the engine .......................................................................................... 7-6
7-2-2 Start lower crane portion engine........................................................................................... 7-9
7-2-3 Inspection after the engine startup ...................................................................................... 7-10
7-2-4 Flameout of engine ............................................................................................................. 7-10
7-3 General operation ...................................................................................................................... 7-11
7-3-1 Starting and gear shift ......................................................................................................... 7-11
7-3-2 Trail operation..................................................................................................................... 7-13
7-3-3 Clutch operating.................................................................................................................. 7-13
7-3-4 Steering system ................................................................................................................... 7-14
7-3-5 Braking system ................................................................................................................... 7-16
7-4 Driving cranes in winter ............................................................................................................ 7-17
7-4-1 Cooling system ................................................................................................................... 7-17
7-4-2 Braking device .................................................................................................................... 7-18
7-4-3 Battery................................................................................................................................. 7-18
Chapter8 Components and functions of upper crane portion .................................................................... 8-1
8-1 General overview......................................................................................................................... 8-1
8-1-1 Lifting device........................................................................................................................ 8-1
8-1-2 Safety device......................................................................................................................... 8-1
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XCT80 Truc k Cr an e Op er at ion Manual
IV
8-1-3 Upper crane portion control room and rotary bearing system .............................................. 8-1
8-1-4 Upper crane hydraulic system............................................................................................... 8-1
8-1-5 Upper crane portion electric system ..................................................................................... 8-2
8-2 Main component introduction ..................................................................................................... 8-3
8-3 Operating cab............................................................................................................................... 8-5
8-3-1 Electric device....................................................................................................................... 8-6
8-3-2 Instrument panel ................................................................................................................... 8-7
8-3-3 Control handle..................................................................................................................... 8-10
8-3-4 Relay .................................................................................................................................. 8-10
8-3-5 Electric system manual ....................................................................................................... 8-11
8-4 Safety device.............................................................................................................................. 8-12
8-4-1 Lifting torque limiter .......................................................................................................... 8-12
8-4-2 Three-coil protector (counter)............................................................................................. 8-12
8-4-3 Length and angle sensor ..................................................................................................... 8-13
8-4-4 Groove jumping device (rope block) .................................................................................. 8-14
8-4-5 Level ................................................................................................................................... 8-14
8-4-6 Horn .................................................................................................................................... 8-14
8-4-7 Safety control switch .......................................................................................................... 8-15
8-4-8 Hydraulic unloading valve.................................................................................................. 8-16
8-4-9 Hydraulic oil filter blocking alarm lamp............................................................................. 8-16
8-4-10 Rotary table lock device ................................................................................................... 8-17
Chapter9 Crane accessory.......................................................................................................................... 9-1
9-1 Crane accessory selection............................................................................................................ 9-1
9-2 Mounting and dismounting of auxiliary lifting mechanism ........................................................ 9-1
9-2-1 Operating Precautions........................................................................................................... 9-1
9-2-2 Mounting auxiliary lifting mechanism ................................................................................. 9-2
9-2-3 Dismounting auxiliary lifting mechanism ............................................................................ 9-3
9-3 Mounting and dismounting of auxiliary crane arm ..................................................................... 9-4
9-3-1 Operating Precautions........................................................................................................... 9-4
9-3-2 Component name of auxiliary crane arm.............................................................................. 9-5
9-3-3 Mounting auxiliary crane arm............................................................................................... 9-7
9-3-4 Mounting angle adjustment of auxiliary crane arm ............................................................ 9-13
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XCT80 Truck Crane Operation Manual
V
9-3-5 Auxiliary crane arm storage................................................................................................ 9-15
9-4 Mounting and dismounting of balance weight .......................................................................... 9-16
9-4-1 Operating Precautions......................................................................................................... 9-16
9-4-2 Balance weight combination............................................................................................... 9-16
9-4-3 Mounting balance weight.................................................................................................... 9-17
9-4-4 Dismounting balance weight .............................................................................................. 9-20
9-5 Mounting and dismounting of arm end single pulley................................................................ 9-20
9-5-1 Operating precautions ......................................................................................................... 9-20
9-5-2 Mounting arm end single pulley ......................................................................................... 9-21
9-5-3 Storing arm end single pulley ............................................................................................. 9-23
9-5-4 Crane performance of arm end single pulley...................................................................... 9-23
9-6 Hook and steel wire rope ........................................................................................................... 9-24
9-6-1 Hook selection .................................................................................................................... 9-24
9-6-2 Hook basic structure ........................................................................................................... 9-24
9-6-3 Steel wire rope magnification conversion........................................................................... 9-25
9-6-4 Crossing and winding method of steel wire rope ............................................................... 9-28
9-6-5 Crossing and winding of steer wire rope precautions ........................................................ 9-31
Chapter10 Crane operation ...................................................................................................................... 10-1
10-1 Crane operation preparations................................................................................................... 10-1
10-1-1 Check before crane runing................................................................................................ 10-1
10-1-2 Crane operation conditions check..................................................................................... 10-1
10-1-3 Air conditioning equipment use........................................................................................ 10-2
10-1-4 Operating cab seat adjustment .......................................................................................... 10-5
10-1-5 Check the winch steel wire rope position ......................................................................... 10-7
10-1-6 Check safety device .......................................................................................................... 10-7
10-2 Engine operation...................................................................................................................... 10-9
10-3 Power take-off operation ....................................................................................................... 10-10
10-4 Outrigger system operation .................................................................................................. 10-13
10-4-1 Operating precautions ..................................................................................................... 10-13
10-4-2 Outrigger operation composition .................................................................................... 10-14
10-4-3 Fold and unfold foot plate............................................................................................... 10-18
10-4-4 Fold and unfold horizontal outrigger .............................................................................. 10-18
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XCT80 Truc k Cr an e Op er at ion Manual
VI
10-4-5 Fold and unfold vertical outrigger .................................................................................. 10-18
10-4-6 Leveling crane................................................................................................................. 10-19
10-5 Throttle operation .................................................................................................................. 10-19
10-5-1 Operating precautions ..................................................................................................... 10-19
10-5-2 Operating method ........................................................................................................... 10-20
10-6 Lifting mechanism operation................................................................................................. 10-21
10-6-1 Operating precautions ..................................................................................................... 10-21
10-6-2 Main lifting mechanism operation (right handle) ........................................................... 10-21
10-6-3 Auxiliary lifting mechanism operation (left control handle) .......................................... 10-22
10-6-4 Free trackslip operation .................................................................................................. 10-23
10-7 Main crane boom stretching operation .................................................................................. 10-23
10-7-1 Operating precautions ..................................................................................................... 10-23
10-7-2 Operating method ........................................................................................................... 10-24
10-8 Main crane boom luffing operation ....................................................................................... 10-25
10-8-1 Operating precautions ..................................................................................................... 10-25
10-8-2 Main crane boom luffing operation (right control handle) ............................................. 10-26
10-8-3Relations between main crane boom elevation angle and total crane weight and working radius ............... 10-27
10-9 Slewing operation.................................................................................................................. 10-27
10-9-1 Operating precautions ..................................................................................................... 10-27
10-9-2 Slewing operation (left control handle) .......................................................................... 10-28
10-10 Combined action instructions .............................................................................................. 10-29
Chapter11 Oil and Grease ........................................................................................................................ 11-1
11-1 Fuel and engine oil................................................................................................................... 11-1
11-2 Hydraulic oil ............................................................................................................................ 11-1
11-3 Gear oil .................................................................................................................................... 11-2
11-4 Grease ...................................................................................................................................... 11-4
11-5 Domestic and foreign grease comparison................................................................................ 11-7
11-6 Coolant..................................................................................................................................... 11-8
11-7 Waste oil, antifreeze processing............................................................................................... 11-8
Chapter 12 Crane inspection and maintenance........................................................................................ 12-1
12-1 Overview ................................................................................................................................. 12-1
12-2 Inspection items....................................................................................................................... 12-1
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XCT80 Truck Crane Operation Manual
VII
12-2-1 Inspection of steel structure bearing weight ..................................................................... 12-7
12-2-2 Daily inspection ................................................................................................................ 12-8
12-2-3 Weekly inspection ............................................................................................................. 12-8
12-2-4 Inspection for unusual use ................................................................................................ 12-9
12-2-5 Test requirements .............................................................................................................. 12-9
12-3 Wire rope inspection.............................................................................................................. 12-10
12-4 Hook inspection..................................................................................................................... 12-17
12-5 Drum, pulley and brake inspection....................................................................................... 12-18
12-5-1 Drum ............................................................................................................................... 12-18
12-5-2 Pulley .............................................................................................................................. 12-18
12-5-3 Brake............................................................................................................................... 12-18
Chapter 13 Crane Transportation and Storage ......................................................................................... 13-1
13-1 Crane transportation mode....................................................................................................... 13-1
13-1-1 Highway transportation..................................................................................................... 13-1
13-1-2 Rail transportation............................................................................................................. 13-1
13-1-3 Shipping transportation..................................................................................................... 13-1
13-2 Lorry shipping parts................................................................................................................. 13-3
13-2-1 Balance weight transportation .......................................................................................... 13-3
13-2-2 Hook transport .................................................................................................................. 13-3
13-3 Crane storage ........................................................................................................................... 13-4
Chapter 14 Appendix ............................................................................................................................... 14-1
14-1 Terms ....................................................................................................................................... 14-1
14-2 Lifting commanding gestures diagram.................................................................................... 14-3
14-2-1 Universal gesture signal.................................................................................................... 14-3
14-2-2 Special gesture signal........................................................................................................ 14-5
Contents
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XCT80 Truc k Cr an e Op er at ion Manual
VIII
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XCT80 Truck Crane Operation Manual
IX
Preface
Cordially thanks to the trust and recognition of XCMG brands, and the use of the truck crane
produced by XCMG heavy machinery Co., Ltd.
The operating service manual is applicable to XCT80 truck crane.
The operation service manual describes the operation, inspection and adjustment methods for XCT80
truck cranes (crane for short), and the installation and transportation methods for the crane attachments.
The hoisting operation is a dangerous work. Therefore, in order to ensure the use safety and at the same
time play the best performance of the crane, please carefully read this manual before operation, master
and use the contents in the manual, and operate in strict accordance with the requirements of the manual.
The operator should pay special attention to the contents labeled "danger", "warning", "caution" and
"check" in the manual.
Before leaving the factory, the crane should be tested rigorously, and all control elements should pass
rigorous adjustment and calibration. Tor your safety, please do not arbitrarily adjust by yourself.
Only trained personnel obtaining a qualification certificate and passing an examination
can operate the crane.
Please pay special attention to regularly inspect the crane safety devices, which should not be used
when any failure or abnormality exists. You must comply with the highest criteria: safety rst.
The operating manual and other vehicle technical documents are part of the crane. Please preserve
properly them within the life period of the product. This manual serves as the necessary basis for your
operation and use of the crane. Our company will not be responsible for any adverse consequences due to
operation not complying with this manual. For safe lifting in special circumstances, please contact with
our company. We will provide you with a timely and effective technical support.
Our products have passed the national "3C" certification. To ensure "3C" product
conformance requirements in the maintenance process, parts with the same manufacturer, same model
and the original product configuration must be used when the user replaces the main supporting parts.
Otherwise, our company will not assume the resulting loss.
Our company reserves the right to modify the contents of the "operating manual" due to technological
improvements. The products are subject to changes without notice, and we hope you understand. In this manual
some figures may be inconsistent with the practical products, but do not affect your use. The real product
represents the state.
Version 1 in November, 2012
Preface
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XCT80 Truc k Cr an e Op er at ion Manual
X
Signs and their meanings:
——The warning word "Danger" indicates the impending dangerous situation. If
not avoided, it could result in death or serious injury.
——The warning word "Warning" indicates the potentially hazardous situation. If
not avoided, it could result in death or serious injury.
——The warning word "Caution" indicates the potentially hazardous situation. If
not avoided, it could result in minor or moderate damages.
——Carry out relevant checks according to the requirements.
Preface
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XCT80 Truck Crane Operation Manual
1-1
Properly use the product manual
Chapter 1 Properly use the product manual
1. Product instruction is a component of the product. Please safekeeping it for use in the product
life period.
2. When you transfer this crane, product instruction together with the product should be
simultaneously transferred to the new customer.
3. Before operating the crane, all documents along with the crane should be read and the inspection
and maintenance requirements in the repair manual should be obeyed.
4. Before operating the crane, operators should read product instruction at first and then operate
the lifting work to avoiding the unnecessary accidents happening due to the wrong operation.
5. In order to ensure that no mechanical damage accidents or casualties happen, you should
continuously read product instruction until completely understand and know well the content of this
book. If the method that not specifically recommended or allowed in this product instruction is adopted,
it is your responsibility to take necessary arrangements to ensure the safety.
●This manual is not provided of training manual for the crane driver! All operating
instructions are aimed at professionals who have already received for crane driving training.
●This manual is just for reference: Also provides simple or detailed operation steps for
trained drivers.
Chapter 1
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XCT80 Truc k Cr an e Op er at ion Manual
1-2
LOG
Chapter 1
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XCT80 Truck Crane Operation Manual
2-1
Chapter 2 Crane logo
2-1 Composition and meaning of product models
2-2 Product nameplate
Product nameplate is installed on the control room gate outside ( see 2-1)
The product nameplate is marked with vehicle identification code (VIN code), name, model, rated
crane weight, manufacturing date, manufacturers, engine manufacturing number, engine model etc.
Figure 2-1 Product nameplate and crane performance label installation position
Crane logo
Enterprise custom code
Special purpose vehicle use feature code: truck crane
Structure feature code: crane lifting truck
Product serial number: successively using the number 0,
1, 2 ... for representation
Main parameter code: vehicle driving state total weight
(unit, t)
Vehicle category code: special purpose operation
vehicle category
En te r p r i s e n a me cod e: XC M G Xuz ho u he av y
machinery limited company
XZJ 5 50 1 J QZ 80K
Chapter 2
Upper crane
portion control
room
Crane performance
label
Product nameplate
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XCT80 Truc k Cr an e Op er at ion Manual
2-2
Figure 2-2 Chassis plate and VIN codes installation location
The chassis nameplate is mounted on the right side front of the chassis frame, and VIN code is
located on the product nameplate and under the chassis nameplate(see figure 2-1 and 2-2 )
2-3 Chassis nameplate
Chapter 2
VIN code
Chassis nameplate
Crane logo
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XCT80 Truck Crane Operation Manual
2-3
The crane performance label （Performance of being equipped with 3.5t balance weight）is
installed on the right side in control room so that it is convenient to observe for the operator (see figure
2-1). The crane performance label is an important basis for the crane operation, please strictly perform
the crane operation in accordance with numerical values marked on the crane performance label, and
the overload is forbidden.
The main content of crane performance label is:
1. Auto crane rated crane capability table;
2. Auto crane hoisting height curve;
3. Auto crane operation position area map.
Before lifting the weight, operators must choose proper operating working conditions after
knowing about the weight of objects and working range, strictly prohibited beyond the numerical value
in the table. When the amplitude and arm length are between two adjacent numerical values, one should
determine the crane operation based on the smaller one of the two values.
2-4 Crane performance label
The crane indicating label is located on the reducer and other maintenance positions. Indicating
label content includes the type, oil mass, replacing time and precautions of lubricating oil used for the
reducer or the transfer box.
There are various warning labels on the important positions of the crane arm, balance weight and
other to guide the operator for safety use and avoid damage, and the specific installation position and
the warning content are as follows.
2-5 Indicating label
2-6 Warning label
Chapter 2
Crane logo
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XCT80 Truc k Cr an e Op er at ion Manual
2-4
Figure2-3 Warning label positions schematic
Pay attention to safety within working radius
No pushing and
pulling!
Chapter 2
Crane logo
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XCT80 Truck Crane Operation Manual
2-5
No Graphical sign
1
2
3
4
Instruction
When operating the slewing, please
keep a certain safety distance away
f r o m t h e m a c h i n e t o a v o i d t h e
extrusion.
Table 2-1 Warning label instructions
When entering or going out the control
room, strictly prohibit the push and
the pull of the handle and the handle
control box
In order to prevent crane dangerous
actions caused by wrongly touching
the control handle when the operation
personnel in and out of control room,
one must close the switch before
the formal operation just be able to
establish the normal working pressure
of hydraulic system, otherwise the
crane can not work normally, and
after finishing the operation, one must
be close the switch when leaving the
control room
Dangerous area, and forbidden for
person standing under the crane arm
to avoid hurting people by the falling
weight
PAY ATTENTION TO
SAFETY WITHIN
WORKING RADIUS
NO PUSHING AND
PULLING!
Chapter 2
Crane logo
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XCT80 Truc k Cr an e Op er at ion Manual
2-6
LOG
Chapter 2
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