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
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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
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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
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XCT80 Truc k Cr an e Op er at ion Manual
VIII
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