Zoomlion QUY260 User manual

QUY260F/20.CY
ZOOMLION ® Crawler Crane
QUY260
QUY260/20.CY

Zoomlion Heavy Industry Science & Technology Co.,Ltd
13.10
QUY260S/20.1
CRAWLER CRANE
QUY260
Operating manual
QUY260CR/20.1
20
The operating manual is part of the crane！
Always keep on hand！
Comply with road travel and crane operating
regulations！

QUY260YM/20.1
I
Contents
0 Foreword .................................................................................. 0066340-200-00Y.C
1 Safety instructions................................................................... 0066340-200-01Y.C
2 Description of the crane.......................................................... 0066340-200-02Y.C
2.1 Product model
2.1.1 Product name plate and its position
2.1.2 Engine type and its manufacturer
2.2 Terminology
2.2.1 Boom configuration
2.2.2 Description of component parts
2.3 Product description
2.3.1 Crawler travel gear
2.3.2 Crane superstructure
2.3.3 Overall dimensions
2.4 Technical data
2.4.1 Main technical parameter
2.4.2 Type of load hook and applicable rope reeving
2.4.3 Hoisting rope reeving and specification of wire rope
2.4.4 Lifting height
2.4.5 Lifting capacity charts
3 Safety Guidelines......................................................................... 0066340-200-03Y.C
3.1 Operational planning
3.2 Safety—Technical Notes
3.2.1 Safety Instructions
3.2.2 Selecting an operating site
3.2.3 Slopes and trenches
3.2.4 Permissible ground pressure
3.2.5 Checking safety measures
3.2.6 Crane operation with a load
3.2.7 Electromagnetic influences
3.2.8 Safety signs

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3.2.9 Hand signals for controlling crane operations
4 Crane operation ......................................................................... 0066340-200-04Y.C
4.1 Operating and control instruments
4.1.1 Overview of crane operator’s cab
4.1.2 Left control box
4.1.3 Right control box
4.1.4 Control panel assy
4.2 Instruction for digital display system
4.2.1 Load moment limiter
4.2.2 Display of control system
4.3 Startup of crane
4.3.1 Adjustment of crane operator’s seat
4.3.2 Checks before startup
4.3.3 Turn on power supply
4.3.4 Start engine
4.4 Safety devices
4.4.1 Emergency stop button
4.4.2 Battery master switch
4.4.3 Load moment limiter
4.4.4 Boom angle indicator
4.4.5 Derrick limiter
4.4.6 Lowering limiter
4.4.7 Hoisting limiter
4.4.8 Support cylinder locking device
4.4.9 Overflow valve
4.4.10 Anemometer
4.5 Crane operation
4.5.1 Operation of traveling mechanism
4.5.2 Operation of crane winches
4.5.3 Operation of synchronizing A-frame and main boom derricking winch and

QUY260YM/20.1
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synchronizing reeving winch and working winch
4.5.4 Operation of slewing mechanism
4.5.5 Simultaneous operation
4.5.6 Operation of movements of crane operator’s cab
4.5.7 Auxiliary remote control box
4.5.8 Undercarriage remote control box
4.5.9 Operation of A-frame erection cylinder and mounting cylinder on A-frame
4.5.10 Emergency control box
4.6 Rope reeving
4.6.1 Heavy duty boom (S)
4.6.2 Light duty boom (SL)
4.6.3 Fixed jib on heavy duty boom (SF)
4.6.4 Luffing jib on heavy duty boom (SW)
4.6.5 Main boom derricking rope guidance and reeving
4.6.6 luffing jib derricking rope guidance and reeving
5 Assembly and dismantling................ ........................................ 0066340-200-05Y.C
5.1 Safety-technical notes
5.1.1 Notes on assembly
5.1.2 Checking safety measures
5.1.3 Inspection of wire rope, load hook, rope pulley and anchoring rods
5.1.4 Connecting or disconnecting the hydraulic lines with quick-release couplings
5.1.5 Setting-up and taking-down
5.2 A-frame
5.2.1 Connecting the hydraulic lines to mounting cylinder on A-frame
5.2.2 Operation of A-frame
5.3 Attaching the crawler carriers
5.3.1 Unloading of basic machine
5.3.2 Attaching the first crawler carrier
5.3.3 Attaching the second crawler carrier
5.3.4 Connecting the hydraulic lines to the crawler carrier
5.4 Attaching the central counterweight
5.5 Assembling the rear counterweight

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5.6 Available boom configurations for crawler crane QUY260
5.7 Boom configuration
5.7.1 Heavy duty boom (S)
5.7.2 Light duty boom (SL)
5.7.3 Fixed jib on heavy duty boom (SF)
5.7.4 Heavy fixed jib on heavy duty boom (SFV)
5.7.5 Luffing jib on heavy duty boom (SW)
5.8 Assembly and dismantling of heavy duty boom (S)
5.8.1 Preparations for assembly
5.8.2 Assembling main boom
5.8.3 Connect electrics to main boom
5.8.4 Erecting main boom
5.8.5 Lowering and disassembling the main boom
5.9 Assembly and dismantling of main boom with luffing jib (SW)
5.9.1 Preparations for assembling luffing jib
5.9.2 Assembling main boom with luffing jib
5.9.3 Connect electrics to luffing jib
5.9.4 Erection and set-down of main boom with luffing jib
5.10 Assembly and dismantling of light duty boom (SL)
5.11 Assembly and dismantling of main boom with fixed jib (SF)
5.11.1 Preparations
5.11.2 Assembling main boom with fixed jib
5.11.3 Connect electrics to fixed jib
5.11.4 Erecting and lowering main boom with fixed jib
5.12 Assembly and dismantling of main boom with heavy fixed jib (SFV)
5.13 Assembly and dismantling of tip boom
5.14 Transport dimensions and weights of main components
5.15 Requirement for crane transport
6 Maintenance .............................................................................. 0066340-200-06Y.C
6.1 General
6.1.1 Crane maintenance
6.1.2 Requirements for crane inspection
6.1.3 Attached tools for maintenance
6.2 Superstructure maintenance and inspection plan

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6.2.1 Maintain and inspect superstructure every day or every 5 hours
6.2.2 Maintain and inspect superstructure every month or every 100 hours
6.2.3 Maintain and inspect superstructure every 3 months or every 250 hours
6.2.4 Maintain and inspect superstructure every 6 months or every 600 hours
6.3 Undercarriage maintenance and inspection plan
6.3.1 Maintain and inspect undercarriage every day or every 5 hours
6.3.2 Maintain and inspect undercarriage every month or every 100 hours
6.3.3 Maintain and inspect undercarriage every 3 months or every 250 hours
6.3.4 Maintain and inspect undercarriage every 6 months or every 600 hours
6.4 Boom frame maintenance and inspection plan
6.5 Maintenance and inspection for engine
6.6 Instructions for lubrication and oil change
6.6.1 Hydraulic oil
6.6.2 Gear oil
6.6.3 Lubricating grease
6.6.4 Engine oil
6.6.5 Fuel
6.6.6 Coolant
6.6.7 Lubrication and maintenance of crane in irregular conditions
7 Crane inspections ..................................................................... 0066340-200-07Y.C
7.1 General
7.2 Inspection of steel bearing structures
7.3 Inspection of hosting and luffing winches
7.3.1 Inspections
7.3.2 Requirements for monitoring the winches
7.4 Inspection of load hook
7.5 Inspection of rope pulleys
7.6 Inspection and maintenance of anchoring rods
7.7 Inspection and maintenance of wire rope
7.7.1 Handling and transport of wire rope

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7.7.2 Inspection of wire rope
7.7.3 Discard of wire rope
7.7.4 Maintenance and care of wire rope
7.8 Inspection of oil and fuel tanks
7.9 Inspection of load bearing components
7.10 Inspection of engine
8 Additional equipment. ............................................................... 0066340-200-08Y.C
8.1 Air conditioning
8.1.1 Control panel for air conditioning
8.1.2 Methods for operating air conditioning
8.1.3 Maintenance of air conditioning system
8.2 Media Player
9、Crane inspection log

0066340-200-00-20CY
Foreword
Thank you for purchasing ZOOMLION crawler crane produced by Changsha Zoomlion Heavy
Industry Science & Technology Development Co., Ltd. We are glad to provide high quality and
high-efficiency service for you.
The operating manual are intended to put you in a position to operate the crane safely and utilize
its capabilities to the fullest extend possible.
Certain terms are used in the operating manual, and in order to avoid misunderstandings while
operating, these terms should be used consistently.
Danger: Only qualified and especially trained personnel are permitted to work on the crane!
If this is not assured, the chance of causing a serious accident is greatly
increased!
All regulations and guidelines applicable to the job site, such as accident prevention regulations
and all guidelines and regulations stated in the Operating Manual must be strictly adhered to.
All accident prevention and operating guidelines and regulations, etc. assume that the crane is
strictly used for lifting and transporting of loads, which are not stuck. Any other application or use
does not constitute specified and proper use.
Any risks associated with unspecified and improper use are the sole responsibility of the crane’s
owner, operator or user.
Using this instructions in the manual:
·makes it easier to become familiar with the crane
··avoids malfunctions due to improper operation
Observing these instructions in the manual：
·increases reliability in operations
·extends the service life of the crane
·reduces repair costs and down-time
Always keep the operating manual handy in the driver’s and crane cab-it is an integral part of the
crane. Operate this crane if you are well familiarized with the capabilities and limitations of the
crane, and always follow these operating instructions.
If you have received additional information about the crane from us, e.g. in the form of technical
information letters, then this information must also be followed and kept with the operating manual.
If there is anything in the operating manual or the individual chapters that you do not understand,
please do no hesitate to ask us or our agents before you begin operation.
No parts of the operating manual may be copied or distributed, nor used for competitive purposes.

0066340-200-00-20CY
All rights are expressly reserved in accordance with copyright laws.
The content with respect to the safety is marked with“ ”, the safety instructions involved in the
book are only the conventional contents.
The operating manual must be read and the regulations in it must be observed by all persons
operating, maintaining, or otherwise working in any capacity on this crane.
The employer shall comply with the manufacturer's specifications and limitations applicable to
the operation of any and all cranes and derricks. Where manufacturer's specifications are not
available, the limitations assigned to the equipment shall be based on the determinations of a
qualified engineer competent in this field and such determinations will be appropriately
documented and recorded. Attachments used with cranes shall not exceed the capacity, rating, or
scope recommended by the manufacturer.
A thorough, annual inspection of the hoisting machinery shall be made by a competent
person, or by a government or private agency recognized by the U.S. Department of Labor. The
employer shall maintain a record of the dates and results of inspections for each hoisting machine
and piece of equipment.
Notes:
The following terms that are used in the operating manual “Note”, “Caution”, and “Danger” are
intended to point out certain important rules of conduct to all persons who work with the crane.
The term “Note” is used whenever the observance of certain instructions or notes is economically
meaningful to the utilization of the crane.
The term “Caution” is used whenever damage to the crane can occur if the operating instruction(s)
is not observed and adhered to.
The term “Danger” is used whenever the nonobservance of the warning given may insure or lead
to the death of persons and damaged to the crane.
Safety device
The safety devices built into the crane system deserve your special attention. They must always
be checked to see that they are functioning properly. If they do not function or function incorrectly,
the crane may not be operated. Your motto must always be Safety First.
Caution:
When welding work is conducted on crane, the operator should unplug all power source plugs of
controllers, otherwise, he should bear all consequences incurred.

Chapter1 Safety instructions

0066340-200-01Y.C
1.1 Notes
a) Read this manual and familiarize yourself with any associated documentation before
operating this product.
b) Ensure that a copy of this manual is available for any persons installing, using,
maintaining or repairing this equipment.
Training should be provided to ensure safe working practices.
Initial commissioning and staring must only be undertaken by a competent person who
has read and fully understands the information provided in the manual pack.
c) To avoid the risk of electric shock always isolate this equipment from the supply prior to
carrying out any maintenance adjustment or removing any guards or covers.
d) Always follow the procedures outlined in the operating and maintenance instruction.
e) If in doubt ask, do not take personal risk.
f) Only trained personal can be allowed to install, set, operate, maintain, and decommission
this equipment.
1.2 Alarms and warnings
a) You can be injured if you do not obey the safety instructions as indicated on warning
stickers.
b) Ensure that safety instructions and warnings attached to the plant are always complete
and perfectly legible
c) Keep warnings and instruction labels clean.
d) Replace unreadable or missing labels with new ones before operating the plant. Make
sure replacement parts include warning or instruction labels where necessary.
Caution:
To assure personnel safety, all safety instructions and warnings should be observed; for the
position of labels and warnings, please refer to Chapter 3 “Safety Guidelines”
1.3 Component Safety Features
a) Do not use this equipment with guards removed or incorrectly fastened.
b) Do not use this equipment with safety devices maladjusted or removed.
c) Do not use this equipment before the portable fire extinguisher with a basic minimum
extinguisher rating of 5 BC is installed in the cab and minimum 10 BC outside the cab.
1.4 Features for Operator Saf
a) Safety components – crane emergency stop buttons. Ensure all Guards are bolted down.

0066340-200-01Y.C
b) Steps, handrails, tread plates and fixed guards are provided where personnel are
required to climb on the machine.
1.5 Environmental safety
a) It is essential that the service intervals detailed in the maintenance procedures are
followed to ensure that engine emission are kept to a minimum.
b) Consumable materials
1) Diesel spillages must be dealt with immediately.
2) Only use the Lubricating Oils recommended in the maintenance schedule.
3) Local and National regulations must be observed when disposing of waste.
4) Improperly disposing of waste can threaten the environment and ecology and is
illegal.
5) Potentially harmful waste used on this equipment includes such items as oil, fuel,
coolant, filters and batteries, ect.
6) Use leak proof containers when draining fluids. Do not use food or beverage
containers that may mislead someone into drinking from them.
7) Do not pour waste onto the ground, down a drain or into any water source.
8) Ensure that all consumables and replaced parts are disposed of safely and with
minimum environmental impact.
c) Machine disposal. This machine must only be disposed of at a specialist machine
breaker.
1.6 Personal protective Equipment (PPE)
a) Loose or baggy clothing can get caught in running machinery.
b) Where possible when working close to engines or machinery, only do so when they are
stopped. If this is not practical, remember to keep tools, test equipment and all other parts
of your body well away from the moving parts.
c) For reasons of safety, long hair must be tied back or otherwise secured, garments must
be close fitting and no jewellery such as rings may be worn.
d) Always wear correctly fitting personal protective equipment.
e) Recommended personal protective equipment includes:
1) Hard Hat
2) Safety Glasses/Goggles
3) Hearing Protection
4) Close Fitting Overalls
5) Safety Boots

0066340-200-01Y.C
6) Industrial Gloves
7) High Visibility Vest or Jacket
1.7 Measured Noise Level
The product and local conditions will affect the noise levels.
The sound pressure level and sound power level, measured using EN13000 Annex G and
2000/14/ EC standards is respectively 73.9dB (A) and 107dB (A)
The sound pressure level measured using ISO 7731 at the position 3′3″away from the warning
device is 97.7dB(A).
1.8 Vibration Levels
Suitable seating has been installed to reduce the risk of whole body vibrations, in line with
current industry standards.
The crane body vibrations, measured using ISO 2631－1 under normal operating condition, is A(1):
1.3m/s2，A(4)：0.6m/s2，A(8)：0.4m/s2
1.9 Organizational Safety Measures
a) This vehicle must only be driven and the crane operated by a suitably qualified operative
who holds a current license in line with National/ International legislation.
b) Understand the service procedure before doing work. Keep area clean and dry.
c) Never lubricate, clean, service or adjust machinery while it is moving(excluding central
lubrication).
d) Keep hands, feet and clothing clear of power driven parts and in running nip-points.
e) Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Removed any build up of grease, oil and
debris.
f) Disconnect battery ground cable before making adjustments on electrical systems.
g) Disconnect battery ground cable and ECM connecting cable and unplug all plugs of
controllers before welding on machine.
h) During maintenance only use the correct tool for the job.
i) Never make any modifications, additions or conversions which might affect safety without
the manufacturer’s approval.
j) In the event of safety relevant modifications or changes in the behavior of the machine
during operation, stop the machine and lock out immediately and report the malfunction
to the competent authority/ person.
k) No modifications or additions which affect the capacity or safe operation of the equipment
shall be made by the employer without the manufacturer's written approval. If such
modifications or changes are made, the capacity, operation, and maintenance instruction

0066340-200-01Y.C
plates, tags, or decals, shall be changed accordingly. In no case shall the original safety
factor of the equipment be reduced.
1.10 Personnel Qualification, Requirements and Responsibilities
a) Any work on and/ or with the machine must be executed by trained, reliable and
authorized personnel only.
b) Maintenance work must only be undertaken by suitable qualified engineers with specialist
knowledge of this equipment.
c) Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
1.11 Safety Advice Regarding Specific Operational Phases
a) Standard operation
1) Take necessary precautions to ensure that the machine is used only when in a safe
and reliable state.
2) Operate the machine only for it’s designed purpose and only if all guarding, protective
and safety orientated devices, emergency shut-off equipment, sound proofing
elements and exhausts, are in place and fully functional.
3) Ensure that any local barriers erected to stop unauthorized entry to this equipment
are in place.
4) Before starting the engine ensures it is safe to do so.
b) Malfunction
In the event of any malfunction or operational difficulty, stop the machine immediately.
c) Unguarded areas
1) In-running nip points on moving machinery can cause serious injury or even death.
2) Do not reach into unguarded machinery. Your arm could be pulled in and amputated.
3) Switch off the machine before removing any safety devices or guarding.
4) Limit access to the machine and its surrounds where appropriate erect barrier guards
to reduce the risk of residual mechanical hazards, falling lifted loads.
1.12 Machine maintenance and repairs
Observe the adjusting, maintenance and intervals set out in these operating instructions,
except where:
1) Warning, horn/ light/ gauge or indicator calls for immediate action.
2) Adverse conditions necessitate more frequent servicing.
3) Always read instructions supplied with replacement of parts and equipment. Ensure

0066340-200-01Y.C
only properly trained personnel undertake these tasks.
a) Isolation
When undertaking maintenance and repair work, the plant must be first made safe.
1) Switch off the engine and remove the ignition key.
2) Attaching a warning sign(s) to the plant in appropriate positions.
b) Maintenance site conditions
Prior to staring any maintenance work, ensure the machine is positioned on stable and
level ground and has been secured against inadvertent movement and bucking.
c) Replacement and removal of components
1) Always observe handling instructions itemized in this manual, the Original Equipment
Manufacturer’s Manuals or the Spare Parts Supplier’s instructions.
2) Never allow untrained staff to attempt to remove or replace any part of the plant.
3) The removal of large or heavy components without adequate lifting equipment is
prohibited.
4) To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured. Use
only suitable and technically adequate lifting gear supplied or approved by the
supplier.
5) Never work or stand under suspended loads.
6) Limit access to the machine and its surrounds where appropriate erect barrier guards
to reduce the risk of residual mechanical hazards, falling lifted loads.
d) Climbing, falling
1) Falling from and/ or onto this machine could cause injury or even death.
2) Never climb on the machine whilst it is in operation.
3) Always keep the area around the machine clear of debris and trip hazards.
4) Beware of moving equipment in the vicinity of the machine.
5) For carrying out overhead assembly work always use specially designed or otherwise
safety-oriented ladders and working platforms.
6) Only use any walkway/ platforms provided on the machine or on an approved safe
and secure platform.
7) Only use CE certified safety harness when reaching any points 3′3″or more above
the ground level.
8) Keep all handles, steps, handrails, platforms, landing and ladders free from dirt, oil,

0066340-200-01Y.C
snow and ice.
e) Safety consideration during advanced maintenance
1) Prior to undertaking all but normal planned maintenance activities, it is essential that
a method statement regarding safe working practices for the job in hand is produced.
2) Restrict access to the maintenance area to essential staff only. Where appropriate
erect barrier guards and post warnings.
3) The fastening of loads and instructing of crane operators should be entrusted to
qualified persons only.
4) If a marshal is used to provide instructions, the marshal must be within sight or sound
of the operator with an all round view of the operation.
5) Always ensure that any safety fitment such as locking wedges, securing chains, bars
or struts are utilized as indicated in the operating instructions.
6) Particularly make sure that any part of the plant raised for any reason is prevented
from falling by securing in a safe reliable manner.
7) Never work under unsupported equipment.
8) Never work alone.
f) Safety consideration during cleaning
1) This equipment must be isolated prior to cleaning.
2) Do not direct power washers near or into control boxes and devices.
3) After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found must be rectified without
delay.
g) Removal of safety devices and guards
1) All safety devices (control device or guard) temporarily removed for set-up,
maintenance or repair purposes must be refitted and checked immediately upon
completion of the maintenance and repair work prior to operation.
2) Never operate the machine with safety devices and guards removed or unsecured.
3) Always report any defects regarding guards, safety device or control devices.
h) Safety when refilling
1) Only refuel with diesel from approved storage and supply equipment.
2) Diesel fuel is flammable.
3) Never remove the filler cop, or refuel, with the engine running.
4) Never add gasoline or any other fuels mixed to diesel because of increased fire or

0066340-200-01Y.C
explosion risks and damage to the engine.
5) Do not carry out maintenance on the fuel system near naked lights or sources of
sparks, such as welding equipment or whilst smoking.
6) To avoid spillages use drip trays.
7) Immediately clear up spilt fuel and dispose of correctly to minimize any environmental
impact.
1.13 Special Hazards
1.13.1 Electrical energy
a) External considerations and hazards
When working with the machine, maintain a safe distance form overhead electric lines.
If overhead cables are in the vicinity a risk assessment must be completed prior to
operating this equipment.
If your machine comes into contact with a live wire:
1) Vacate the area.
2) Warn others against approaching and touching the machine.
3) Report the incident and have the live wire de-energized.
b) Machine - Electrical
The electrical equipment of the plant is be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be
rectified immediately. Use only original fuses with the specified current rating. Switch off
the machine immediately if trouble occurs in the electrical system.
This plant is wired on a negative earth. Always observe correct polarity.
c) Battery
1) Always disconnect battery leads before carrying out any maintenance to the electrical
system.
2) Recharge the battery in a well ventilated area.
3) The battery contains sulphuric acid, an electrolyte which can cause severe burns and
produce explosive gases.
4) Avoid contact with the skin, eyes or clothing.
5) No smoking when maintaining battery.
6) Wear appropriate PPE.