Zoomlion ZCC1100H User manual

Zoomlion Heavy Industry Science and Technology Co., Ltd.
OPERATOR’S MANUAL
Vision creates future
Add: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Economic and
Technological Development Zone, Changsha, Hunan Province, China.
PC: 410131
www.zoomlion.com
Zoomlion Heavy Industry Science and Technology Co., Ltd
CRAWLER CRANE
OPERATOR’S MANUAL
CRAWLER CRANE

Edition 1 5, 2014
ZCC1100H Crawler Crane
Operator’s Manual

Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
I
Zoomlion appreciates your selection of ZOOMLION crawler crane for your application.
No one should operate the crane unless they read and understand the information in this manual.
This manual contains the instructions and data on the safety and operation of the crawler crane.
Follow the operation procedures to make sure that your machine operates at MAXIMUM
EFFICIENCY. The operator must keep this manual in the cab of the crane.
If there is anything in the manual that is not clear or you do not understand, please contact our
service technician.We (Zoomlion) are NOT responsible for damages from an operator who does not
obey the instructions in the OPERATOR’S MANUAL.
The OPERATOR’S MANUAL is an important part of the crane. If the crane becomes the property of
a different person, make sure that the manual stays in the cab of the crane.
The data (data, specifications, illustrations) in this manual is for cranes in production at the time of
this manuals publication. We reserve the right to make changes to this manual at any time, without
obligation.
The manual has been translated to be best of our knowledge. Zoomlion assumes no liability for
translation errors. The Chinese version of the OPERATOR’S MANUAL is solely applicable for
factual accuracy.
Thank you!
Mobile Crane Branch Company of Zoomlion Heavy Industry Science and Technology Co., Ltd.
Copyright
Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any electronic
medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science
and Technology Co., Ltd.
Copyright © 20XX, Zoomlion Heavy Industry Science and Technology Co., Ltd.
All rights reserved.
To Users

Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
III
To Users ........................................................................................................................................I
Safety Instructions.......................................................................................................................II
Chapter 1 Safety
1.1 Important instructions...................................................................................................1-1
1.1.1 Notes...............................................................................................................1-1
1.1.2 Alarms and warnings........................................................................................1-1
1.2 Safety tips....................................................................................................................1-2
1.2.1 Safety precautions ...........................................................................................1-2
1.2.2 Precautions for operator safety.........................................................................1-2
1.3 Environmental safety ...................................................................................................1-2
1.4 Personnel protective equipment (PPE) .......................................................................1-2
1.5 Organizational safety measures...................................................................................1-3
1.6 Personnel qualification, requirements and responsibilities............................................1-3
1.7 Safety advice regarding specific operation phases.......................................................1-4
1.8 Special Hazards...........................................................................................................1-4
1.8.1 Electrical power................................................................................................1-4
1.8.2 Gas, dust, steam, smoke and noise..................................................................1-5
1.8.3 Welding or naked flames..................................................................................1-5
1.8.4 Hydraulic equipment.........................................................................................1-5
Chapter 2 Description of Crane
2.1 Product model .............................................................................................................2-1
2.1.1 Product name plate and its position..................................................................2-1
2.1.2 Engine type and its manufacturer.....................................................................2-2
2.1.3 Intended use of the crane.................................................................................2-2
2.1.4 Classification of the crane ...............................................................................2-2
2.2 Terminology.................................................................................................................2-5
2.2.1 Crane modes ...................................................................................................2-5
2.2.2 Description of main components.......................................................................2-8
2.3 Product description....................................................................................................2-10
2.3.1 Crane working environment............................................................................2-10
2.3.2 Crawler travel gear.........................................................................................2-10
2.3.3 Crane superstructure......................................................................................2-10
Contents

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2.3.4 Overall dimensions......................................................................................... 2-12
2.4 Technical data............................................................................................................2-13
2.4.1 Main technical parameter............................................................................... 2-13
2.4.2 Specification of load hook and selection of rope reeving................................. 2-15
2.4.3 Performance of wire rope and winch............................................................... 2-15
2.4.4 Lifting height .................................................................................................. 2-18
2.4.5 Lifting capacity chart....................................................................................... 2-21
2.4.6 Lifting capacity in assembly mode.................................................................. 2-57
Chapter 3 Safety Guidelines
3.1 Operational planning....................................................................................................3-1
3.1.1 Correct use of the crane...................................................................................3-2
3.1.2 Possible consequences resulting from improper use of the crane..................... 3-2
3.1.3 Responsibility of relevant personnel ................................................................. 3-3
3.1.4 Work area........................................................................................................3-4
3.2 Safety technical notes..................................................................................................3-5
3.2.1 Safety instructions for crane operator...............................................................3-5
3.2.2 The requirement for the crane operator during the whole operation ..................3-5
3.2.3 Safety instructions for the rigger....................................................................... 3-6
3.2.4 Safety instructions for the signalman................................................................ 3-7
3.2.5 Safety instructions for crane operating crew .....................................................3-7
3.2.6 Electromagnetic influences............................................................................... 3-8
3.2.7 Safety signs.....................................................................................................3-9
3.2.8 The potential dangers existing in crane operation........................................... 3-17
3.2.9 Injuries due to hydraulic energy...................................................................... 3-18
3.2.10 Scald ........................................................................................................... 3-19
3.2.11 Risk of chemical burns.................................................................................. 3-19
3.2.12 Risk of fire and explosion ............................................................................. 3-20
3.2.13 Risk of poisoning and asphyxiation............................................................... 3-22
3.2.14 Endangering the environment....................................................................... 3-23
3.3 Slings........................................................................................................................3-24
3.3.1 Hooks............................................................................................................3-24
3.3.2 Rigging introduction ....................................................................................... 3-24
3.3.3 Slings introduction.......................................................................................... 3-25
3.3.4 Sling safety.................................................................................................... 3-25
3.3.5 Sling safety guide........................................................................................... 3-26
3.3.6 Taglines ......................................................................................................... 3-26
3.3.7 Load center of gravity..................................................................................... 3-27

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Operator’s Manual for Crawler Crane
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3.4 Requirements for operating site ................................................................................. 3-28
3.4.1 Slopes and trenches.......................................................................................3-28
3.4.2 Permissible ground pressure..........................................................................3-29
3.4.3 Travel on level ground or slope without a load................................................ 3-30
3.4.4 Travel on level ground or slope with a load.....................................................3-30
3.4.5 The requirements for crawler crane with attachments on uphill slopes ............ 3-30
3.5 Operation weather .....................................................................................................3-32
3.5.1 Snow and ice .................................................................................................3-32
3.5.2 Lightning Strikes.............................................................................................3-32
3.6 Electrical safety..........................................................................................................3-33
3.6.1 Safety regulations for auxiliary power supply (220V AC) ................................3-33
3.7 Underground cables...................................................................................................3-34
3.7.1 In underground working, it is possible to damage: .........................................3-34
3.7.2 Safety precautions and protective measures when operating the equipment near
underground cables...................................................................................................3-34
3.7.3 Notes in connection with gas pipes................................................................. 3-35
3.7.4 The consequences of a gas pipe’s damage....................................................3-35
3.7.5 Measures adopted if a gas pipe is damaged and the gas escapes, or a leak is
suspected..................................................................................................................3-36
3.7.6 Measures adopted in the event of a gas fire ................................................... 3-36
3.7.7 Notes in connection with underground electric cables.....................................3-37
3.7.8 The consequences of damaging an underground cable.................................. 3-37
3.7.9 The measures taken when the machine damages an underground cable ....... 3-37
3.8 Checking safety measures.........................................................................................3-39
3.8.1 Daily inspection of the crane...........................................................................3-39
3.8.2 Safety checking before crane operation.......................................................... 3-39
3.9 Crane operation with a load ....................................................................................... 3-40
3.9.1 Counterweight................................................................................................3-40
3.9.2 Crane operation.............................................................................................3-41
3.10 Hand signals for controlling crane operations...........................................................3-53
Chapter 4 Crane operation
4.1 Operating and control instruments................................................................................4-1
4.1.1 Operator’s cab, overview..................................................................................4-1
4.1.2 Operating console............................................................................................4-3
4.1.3 Control lever.....................................................................................................4-4
4.1.4 Left control panel..............................................................................................4-7
4.1.5 Right control panel...........................................................................................4-8

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4.1.6 Control panel on the roof of operator’s cab....................................................... 4-9
4.2 Instruction for digital display system........................................................................... 4-12
4.2.1 Load moment limiter....................................................................................... 4-12
4.2.2 Electrical system............................................................................................ 4-13
4.3 Startup of the crane ...................................................................................................4-19
4.3.1 Adjustment of crane operator’s seat ............................................................... 4-19
4.3.2 Checks before startup.................................................................................... 4-21
4.3.3 Turn on power supply..................................................................................... 4-22
4.3.4 Operation of air conditioning in operator’s cab................................................ 4-24
4.3.5 Horn............................................................................................................... 4-24
4.3.6 Start of engine................................................................................................4-25
4.4 Safety device............................................................................................................. 4-27
4.4.1 Emergency stop button .................................................................................. 4-27
4.4.2 Battery master switch..................................................................................... 4-28
4.4.3 Flashing light..................................................................................................4-29
4.4.4 Load moment limiter....................................................................................... 4-29
4.4.5 Boom angle indicator ..................................................................................... 4-31
4.4.6 Derricking limiter ............................................................................................ 4-32
4.4.7 Lowering limiter..............................................................................................4-33
4.4.8 Hoisting limiter ............................................................................................... 4-34
4.4.9 Anemometer.................................................................................................. 4-35
4.4.10 Crane inclinometer....................................................................................... 4-35
4.4.11 Checklist of safety device............................................................................. 4-36
4.5 Crane operation.........................................................................................................4-40
4.5.1 Preparation for operation................................................................................ 4-40
4.5.2 Inspection during operation............................................................................ 4-40
4.5.3 Valid area of control lever............................................................................... 4-41
4.5.4 Setting of work mode ..................................................................................... 4-42
4.5.5 Operation of travel gear.................................................................................. 4-42
4.5.6 Operation of crane winches............................................................................ 4-46
4.5.7 Operation of slewing mechanism.................................................................... 4-51
4.5.8 Auxiliary remote control box ........................................................................... 4-55
4.6 Rope reeving............................................................................................................. 4-57
4.6.1 Hoisting rope guidance and reeving ............................................................... 4-57
4.6.2 Derricking rope reeving.................................................................................. 4-61
4.6.3 Fixation of rope end point............................................................................... 4-63

Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
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Chapter 5 Assembly and Dismantling
5.1 Safety-technical notes..................................................................................................5-1
5.1.1 Notes on assembly...........................................................................................5-1
5.1.2 Checking safety measures ...............................................................................5-1
5.1.3 Checking wire rope, load hook, rope pulley and anchoring rod..........................5-3
5.2 Assembly of basic machine..........................................................................................5-5
5.2.1 Unloading of basic machine..............................................................................5-5
5.2.2 Self-assembly and dismantling of crawler carrier (optional).............................5-10
5.2.3 Extending and retracting of crawler carrier......................................................5-16
5.2.4 Assembly of central counterweight ................................................................. 5-22
5.2.5 Self-assembly and dismantling of counterweight.............................................5-26
5.2.6 Fixation of mounting cylinder.......................................................................... 5-32
5.3 Available boom configurations....................................................................................5-34
5.4 Boom configuration....................................................................................................5-37
5.4.1 Main boom (S-1)............................................................................................5-37
5.4.2 Main boom with fixed jib (SF-1) ......................................................................5-50
5.5 Assembly and dismantling of main boom ...................................................................5-59
5.5.1 Preparations for assembly..............................................................................5-59
5.5.2 Assembly of main boom.................................................................................5-59
5.5.3 Electrical connection to main boom ................................................................ 5-66
5.5.4 Erecting main boom .......................................................................................5-68
5.5.5 Lowering and dismantling main boom.............................................................5-70
5.6 Assembly and dismantling of main boom with fixed jib................................................5-71
5.6.1 Preparation for assembly................................................................................5-71
5.6.2 Assembly of fixed jib.......................................................................................5-71
5.6.3 Electrical connection to fixed jib......................................................................5-76
5.6.4 Erecting main boom with fixed jib ...................................................................5-78
5.7 Assembly and dismantling of tip boom .......................................................................5-81
5.8 Transport weights and dimensions of main components............................................. 5-82
5.9 Transport means and safety precautions for transport................................................ 5-85
5.9.1 Safety precautions for transport...................................................................... 5-85
5.9.2 Other requirements ........................................................................................5-85

履带起重机操作手册
第一章 安全操作说明
Operator’s Manual for Crawler Crane
Chapter 1 Safety

履带起重机操作手册
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Operator’s Manual for Crawler Crane
Safety
Operator’s Manual for Crawler Crane
ZCC1100H Crawler Crane 1-1
Chapter 1 Safety
1.1 Important instructions
1.1.1 Notes
a) Read thismanual and familiarize yourself with any associated documents before operating
this crane.
b) Ensure that a copy of this manual is available to any person installing, using, maintaining
or repairing this equipment. Training should be provided to ensure safe working practices.
c) To avoid the risk of electric shock, always isolate this equipment from the power supply
prior to carrying out any maintenance adjustment or removing any guards or covers.
d) Always follow the procedures outlined in the Operator’s Manual and Maintenance Manual.
e) If in doubt, do not take personal risk.
f) Only trained personnel can be allowed to install, set, operate, maintain, and commission
this equipment.
g) End-user (the owner) should follow the restrictions of using the crane and all the relevant
parameters specified by the manufacturer. If technical parameters can not be obtained
clearly, experienced and qualified engineer should judge the restrictions of using, which
should be recorded in the archive. Do not exceed the rated capacity specified in the
documents associated with the crane.
h) End-user should comply with requirements in 29CRS, OSHAabout CC section.
1.1.2 Alarms and warnings
a) As to the persistent danger mentioned in this manual, affix the warning symbols in proper
positions of the crane.
b) Alarm symbols
1) You can be injured if you do not obey the safety instructions as indicated on warning
stickers.
2) Ensure that safety instructions and warnings attached to the crane are always
complete and perfectly legible.
3) Keep warnings and instruction labels clean.
4) Replace unreadable or missing labels with new ones before operating the crane.
Make sure the replacement parts include warning or instruction labels where
necessary.
CAUTION
(1) Follow the warnings and instructions for the sake of personal safety.
(2) For the position of warnings and instruction labels, please see chapter 3 "Safety
Guidelines".

Operator’s Manual for Crawler Crane
Safety
1-2 ZCC1100H Crawler Crane
1.2 Safety tips
1.2.1 Safety precautions
a) Do not use this equipment with guards removed or incorrectly fastened.
b) Do not use this equipment with safety devices maladjusted or removed.
1.2.2 Precautions for operator safety
a) Safety component –crane emergency stop button. Ensure all safety components are in
place.
b) Support plates, handrails, tread plates and fixed guards are provided to assist the
personnel to climb on the crane.
1.3 Environmental safety
a) A regular service should be taken on the crane strictly in accordance with maintenance
procedures to ensure that engine emission is close to a minimum value.
b) Consumable materials
1) Diesel spillages must be dealt with immediately.
2) Only use the lubricating oil recommended in the maintenance manual.
3) Local regulations must be observed strictly when disposing of waste.
4) Improper disposal of waste will affect the ecological environment, which is also illegal.
5) Potentially harmful waste used on this crane includes such items as hydraulic oil, fuel,
coolant, filters and batteries, etc.
6) Use leak-proof containers for draining fluids. Do not use food or beverage containers
that may mislead someone into drinking or eating them.
7) Do not pour waste into the ground, into sewer system or into any water source.
8) Ensure that all consumable and replaced parts are disposed of safely and with
minimum environmental impact.
c) Machine disposal. This machine must only be disposed of by a special machine breaker.
1.4 Personnel 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 other tools
that will enable parts of your body away from the moving parts.
c) For reasons of safety, long hair must be tied back or otherwise secured. Garmentsmust be
close fitting and no jewellery such as rings may be worn.
d) Correctly wear personnel protective equipment.
e) Recommended personnel protective equipment includes:

履带起重机操作手册
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Operator’s Manual for Crawler Crane
Safety
Operator’s Manual for Crawler Crane
ZCC1100H Crawler Crane 1-3
-Hard hat
-Safety glasses/Goggles
-Hearing protection device
-Close fitting overalls
-Safety boots
-Industrial gloves
-High visibility vest or jacket
1.5 Organizational safety measures
a) The crane must only be operated by a suitably qualified operator who holds a current
license in line with construction site or international legislation.
b) Understand the service procedure before doing work. Keep working area clean and dry.
c) Never lubricate, clean or adjust crane while it is moving (excluding central lubrication).
d) Keep hands, feet and clothing clear of power driven parts or 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. Remove grease, oil and debris in time.
f) Disconnect battery ground cable and power supply before making adjustments on
electrical systems.
g) Disconnect battery ground cable, switch off the engine 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 changes 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, lock it immediately and report the malfunction to the
relevant authority / person.
1.6 Personnel qualification, requirements and responsibilities
a) Any work on and / or with the crane 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 crane.
c) Work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.

Operator’s Manual for Crawler Crane
Safety
1-4 ZCC1100H Crawler Crane
1.7 Safety advice regarding specific operation phases
a) Standard operation
1) Take necessary precautions to ensure that the crane is used in a safe and reliable
state.
2) This crane is a conventional assembly & dismantling machine. Do not apply the crane
for other purpose. Operate the crane only for its designed purpose and only if all
guarding, protective and safety-orientated devices, emergency shut-off equipment,
sound proofing element 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, ensure it is safe to do so.
b) Malfunction
In the event of any malfunction or operational difficulty, stop the crane 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) Stop the crane before removing any safety devices or guarding devices.
4) Limit access to the machine and its surrounding where barrier guards are
appropriately erected to reduce the risk of potential mechanical hazards, such as
falling lifted loads.
1.8 Special Hazards
1.8.1 Electrical power
a) External considerations and hazards
When working with the crane, maintain a safe distance from the overhead electric lines. If
overhead lines are in the immediate vicinity, a risk assessment must be completed prior to
operating this crane.
If your machine comes into contact with a live wire:
-Vacate the area
-Warn others against approaching and touching the crane.
-Report the incident and have the live wire de-energized.
b) Machine –Electrical
-The electrical equipment of the crane must be inspected at regular intervals. Defects
such as loose connections, 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.

履带起重机操作手册
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Operator’s Manual for Crawler Crane
Safety
Operator’s Manual for Crawler Crane
ZCC1100H Crawler Crane 1-5
-This crane is wired on a negative earth. Always observe correct polarity.
c) Battery
-Always disconnect battery leads before carrying out any maintenance to the electrical
system.
-Recharge the battery in a well ventilated area.
-The battery contains sulphuric acid, an electrolyte which can cause severe burns and
produce explosive gases. Avoid contact with the skin, eyes or clothing.
-No smoking when maintaining battery.
-Wear appropriate PPE.
1.8.2 Gas, dust, steam, smoke and noise
a) Always operate internal combustion engines out of doors or in a well ventilated area.
b) If a crane is operated for maintenance purposes in an enclosed area, ensure that there is
sufficient ventilation.
c) Observe the rules and regulations at different working sites.
d) Dust found on the crane or produced during work on the crane must not be removed by
blowing with compressed air.
e) Toxic dust / waste must only be handled by authorized persons, dampened, placed in a
sealed container and marked, to ensure safe disposal.
1.8.3 Welding or naked flames
a) Welding, flame cutting and grinding work on the crane must only be carried out if this has
been expressly authorized, as there may be a risk of explosion and fire.
b) No welding that will affect its structural integrity should be undertaken on this crane.
c) Avoid all naked flames in the vicinity of this crane.
d) Only when a fire extinguisher with a specification of no less than 10BC is equipped in the
operator’s cab, can the crane work.
1.8.4 Hydraulic equipment
a) Work on hydraulic system must be carried out by persons having special knowledge and
experience of hydraulic system.
b) Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Sprayed oil may cause personal injury and fire.
c) Always relieve pressure from the hydraulic system before carrying out any kind of
maintenance or adjustment work.
d) Depressurize all system components and pressure pipes (such as hydraulic system,
compressed air system) to be removed in accordance with the specific instructions for the
unit concerned before carrying out any repair work.

Operator’s Manual for Crawler Crane
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1-6 ZCC1100H Crawler Crane
e) Hydraulic lines and compressed air lines must be laid and fitted properly. Ensure that no
connections are interchanged. The fittings, lengths and quality of the hoses must comply
with the technical requirements.
f) Only fit replacement components of a type provided by the manufacturer.
g) Always keep hydraulic elements clean.
h) Hydraulic fluid under pressure can penetrate the skin and cause serious injury.
i) Once the fluid is injected under/into the skin, seek medical help immediately.