Zoomlion ZCC1300 User manual

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Edition 1Jan 2020
Crawler Crane Maintenance Manual
ZCC1300
ZCC1800
ZCC2600

To Users
Maintenance 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.
Regular inspection and maintenance of crane are very important to make full use of crane
performance, ensure safe crane operation and extend the service life of crane. Therefore, we offer
you this MAINTENANCE MANUAL to facilitate your inspection and maintenance work.
This manual details the inspection and maintenance work of ZOOMLION crawler crane, and lists
some common problems that may occur and their solutions.
For safety’s sake, do not maintain the crane before you fully understand the contents in
MAINTENANCE MANUAL, OPERATOR’S MANUAL and other technical documents. If there is
anything in this manual you do not understand, please contact local service engineer of Zoomlion,
and they will provide you efficient technical support in time. Any risks associated with unspecified
and improper use are the sole responsibility of the crane’s owner, operator or user.
Unauthorized person is not allowed to dismantle or adjust the hydraulic elements during
maintenance. When the hydraulic system of crane fails or the components are damaged, please
contact local service engineer of Zoomlion.
The data (data, specifications, illustrations) in this manual is for cranes in production at the time of
this manual’s 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 MAINTENANCE 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.

Safety Instructions
Maintenance Manual for Crawler Crane
II
DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this
manual to show important instructions. In this manual, the labels follow the paragraph or item they
apply to. The markers are as follows:
DANGER
Refers to a dangerous situation which, if you do not prevent, will cause
death or injury.
WARNING
Refers to a possible dangerous situation which, if you do not prevent,
could cause death or injury.
CAUTION
Refers to a possible dangerous situation which, if you do not prevent, may
cause light or moderate injury.
NOTICE
Refers to a situation which, if you do not prevent, may cause property or
equipment damage.

Maintenance Manual for Crawler Crane
To Users ..............................................................................................................................................I
Safety Instructions............................................................................................................................II
Chapter 1 About this Manual
1.1 General.............................................................................................................................1-1
1.2 Product identification........................................................................................................1-2
1.3 Illustration and symbols....................................................................................................1-3
Chapter 2 Safety Guidelines and Environmental Protection
2.1 Safety guidelines..............................................................................................................2-1
2.1.1 General.................................................................................................................2-1
2.1.2 Qualification and selection of the personnel ........................................................2-2
2.1.3 Potential risks.......................................................................................................2-2
2.1.4 Preparations before maintenance and service work............................................2-4
2.1.5 Instructions about maintenance work...................................................................2-6
2.1.6 Notes for long-term storage..................................................................................2-6
2.2 Environmental protection..................................................................................................2-7
Chapter 3 Description of Crane
3.1 Description of main components under different boom configurations............................3-1
3.1.1 “Main boom” configuration....................................................................................3-1
3.1.2 “Main boom with fixed jib” configuration...............................................................3-2
3.1.3 “Main boom with luffing jib” configuration.............................................................3-3
3.2 Description of main components of basic machine..........................................................3-4
3.2.1 Basic machine of ZCC1300 crawler crane...........................................................3-4
3.2.2 Basic machine of ZCC1800 crawler crane...........................................................3-5
3.2.3 Basic machine of ZCC2600 crawler crane...........................................................3-6
Chapter 4 Maintenance
4.1 General.............................................................................................................................4-1
4.1.1 Aims of maintenance and service........................................................................4-1
4.2 Precautions.......................................................................................................................4-1
4.2.1 General precautions.............................................................................................4-1
4.2.2 Safety precautions..............................................................................................4-2
Contents
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4.3 Inspection of the crane.....................................................................................................4-6
4.4 Explanation of maintenance interval ................................................................................4-7
4.5 Maintenance plan .............................................................................................................4-8
4.6 Power system.................................................................................................................4-12
4.6.1 Engine.................................................................................................................4-12
4.6.2 Fuel system ........................................................................................................4-14
4.6.3 Cooling system...................................................................................................4-17
4.6.4 Air intake system................................................................................................4-19
4.6.5 Exhaust system..................................................................................................4-21
4.7 Hoisting winch and derricking winch...............................................................................4-22
4.7.1 Inspection of oil level of winch reducer...............................................................4-22
4.7.2 Change of gear oil of winch reducer...................................................................4-22
4.7.3 Inspection of tightening bolts of winch reducer ..................................................4-23
4.7.4 Inspection of brakes of the winch reducer..........................................................4-26
4.7.5 Inspection of hoisting winch reducer and derricking winch reducer...................4-27
4.7.6 Theoretical service life of winches......................................................................4-28
4.8 Maintenance of the slewing reducer and slewing ring....................................................4-33
4.8.1 Slewing reducer..................................................................................................4-33
4.8.2 Slewing ring........................................................................................................4-37
4.9 Crawler and traveling reducer ........................................................................................4-40
4.9.1 Crawler carrier assy............................................................................................4-40
4.9.2 Travelling reducer...............................................................................................4-42
4.10 Maintenance of hydraulic system.................................................................................4-45
4.10.1 Routine inspection of hydraulic system............................................................4-45
4.10.2 Hydraulic oil tank..............................................................................................4-47
4.10.3 Exhaust of hydraulic system.............................................................................4-51
4.10.4 Inspection of hydraulic pipes for damage.........................................................4-52
4.10.5 Inspection of hydraulic cylinder........................................................................4-52
4.10.6 Inspection of hydraulic hoses...........................................................................4-53
4.10.7 Safe connection and dismantling of quick-release coupling in hydraulic pipes4-55
4.11 Maintenance of the electrical system............................................................................4-57
4.11.1 Inspection of the illumination system................................................................4-57
4.11.2 Inspection of hoisting limit switch......................................................................4-57
4.11.3 Inspection of battery master switch ..................................................................4-57
4.11.4 Inspection of cable joints and dust caps...........................................................4-57
4.11.5 Maintenance of the battery...............................................................................4-57
4.11.6 Prevention of electrical parts or cables from catching fires..............................4-59
4.11.7 Circuit breaker...................................................................................................4-60
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Maintenance Manual for Crawler Crane
4.12 Maintenance of load hooks and pulleys.......................................................................4-61
4.12.1 Daily inspection and maintenance of load hook...............................................4-61
4.12.2 Inspection of load hook ....................................................................................4-62
4.12.3 Inspection of pulley...........................................................................................4-63
4.12.4 Pulley lubrication ..............................................................................................4-64
4.13 Maintenance of wire ropes...........................................................................................4-65
4.13.1 Inspection of wire ropes ...................................................................................4-65
4.13.2 Maintenance of wire ropes...............................................................................4-65
4.13.3 Take-down criteria............................................................................................4-66
4.13.4 Comprehensive introduction of wire ropes.......................................................4-68
4.14 Maintenance of air conditioning....................................................................................4-73
4.14.1 Daily maintenance............................................................................................4-73
4.14.2 Maintenance of air conditioning in slack season..............................................4-73
4.15 Operator’s cab..............................................................................................................4-74
4.15.1 Inspection of the windshield wiper and cleaning solution in the operator’s cab4-60
4.15.2 Inspection of the sliding door of the operator’s cab .........................................4-74
4.15.3 Inspection of the operator’s cab video monitoring system...............................4-74
4.16 Lubrication system........................................................................................................4-75
4.16.1 Lubrication of boom pin....................................................................................4-76
4.17 Key structural member .................................................................................................4-77
4.17.1 Visual inspection...............................................................................................4-77
4.17.2 Periodic inspection...........................................................................................4-79
4.17.3 Inspection of structural members.....................................................................4-79
4.17.4 Inspection of counterweight..............................................................................4-95
4.17.5 Other inspection ...............................................................................................4-96
4.18 Inspection and maintenance under special working environments................................4-97
4.18.1 Working in mud, snow and rain...........................................................................4-97
4.18.2 Working at seaside..............................................................................................4-97
4.18.3 Dusty environment..............................................................................................4-97
4.18.4 Environment with many rocks.............................................................................4-97
4.18.5 Environment with falling rocks ............................................................................4-97
4.18.6 Cold environment................................................................................................4-97
4.18.7 Other working environment.................................................................................4-97
Chapter 5 Troubleshooting
5.1 Troubleshooting of mechanical drive................................................................................5-1
5.2 Troubleshooting of power system ....................................................................................5-2
5.3 Troubleshooting of hydraulic system................................................................................5-7
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Maintenance Manual for Crawler Crane
5.4 Troubleshooting of electrical system..............................................................................5-11
5.4.1 Troubleshooting of cab electrics.........................................................................5-11
5.4.2 Troubleshooting of slewing table electrics..........................................................5-12
5.4.3 Troubleshooting of boom electrics......................................................................5-13
5.4.4 Troubleshooting of load moment limiter.............................................................5-14
5.5 Troubleshooting of air conditioning system....................................................................5-15
Chapter 6 Oil and Medium Application
6.1 Antifreeze coolant.............................................................................................................6-1
6.2 Lubricating oil....................................................................................................................6-2
6.3 Diesel oil...........................................................................................................................6-2
6.4 Lubricating grease............................................................................................................6-3
6.5 Hydraulic oil......................................................................................................................6-4
6.6 Gear oil of reducer............................................................................................................6-5
6.7 Oil change interval and lubricating interval.......................................................................6-6
Chapter 7 Appendix
7.1 Tightening torque of threaded parts..................................................................................7-1
7.2 Tightening torque of threaded parts at pipe orifices.........................................................7-7
7.3 Attached tools...................................................................................................................7-8
7.4 Checklist for periodic inspection.....................................................................................7-10
VI

Chapter 1 About this Manual
Maintenance Manual for Crawler Crane

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AboutthisManual
Maintenance Manual for Crawler Crane
Chapter 1 About this Manual
1.1General
This manual is compiled for the users to guide crane maintenance and service work.
Read and understand the content in this manual before crane maintenance and service work.
Perform the crane maintenance and service work in accordance with the requirements
stipulated in this manual, especially the information about CAUTION, WARNING and
DANGER.
Violation of these regulations may cause damage to the crane, even death to personnel, which
is the sole responsibility of the operator or user.
This manual is compiled according to the working status of the current crane. However, it may
be different from the actual status of the crane due to technical improvements. Therefore, you
can contact us if you want to know about more accurate information about the crane.
CAUTION
If you find any cracks in the steel structure of the crane, please contact with “customer
service department” of Zoomlion and describe the position and shape of the crack.
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About this Manual
Maintenance Manual for Crawler Crane
1.2 Product identification
Figure 1-1 Position of the name plate
The crane name plate is located in a prominent position at the outside of the cab. The above
figure shows the detailed position of the name plate.
The user can distinguish this crane from others directly via the name plate. The information on
it ishelpful for crane maintenance and service. Please keep it in a good condition within the
service life of crane.
The serial number on the name plate is for crane identification. The users can confirm the
crane components and relevant technical data by this serial number. Forexample, the
serial number of the crane is ZCC1300-001.
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Maintenance Manual for Crawler Crane
1.3 Illustration and symbols
This manual has a mass of illustrations, which are schematic. The meanings of illustrations are
as follows:
a) Position of working mechanism to be operated on the crane;
b) Sequence of operation;
c) Correct operating way;
d) Unpermitted or dangerous operating way
The illustrations in this manual may be different from the actual condition of crane. However,
this does not hinder the user from understanding the meanings of illustrations.
1-3

Chapter 2 Safety Guidelines and Environmental Protection
Maintenance Manual for Crawler Crane

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SafetyGuidelines and
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Maintenance Manual for Crawler Crane
Chapter 2 Safety Guidelines and Environmental
Protection
2.1 Safety guidelines
2.1.1 General
a) Since various dangerous factors exist during maintenance and service of the crane, this
section will talk about the safety guidelines for service technician to maintain and service
crane.
b) These safety guidelines will be involved in the relevant chapter about lubrication and
maintenance and explained in detail if necessary. Read and understand these safety
guidelines before maintenance and service work.
c) The maintenance work must be done by qualified personnel who have received training in
crane technology, especially in electrical and hydraulic systems of crane.
d) No unauthorized personnel are accessible to crane during maintenance and service work.
e) Make sure that the handles, footsteps, the housing parts that can be walked on, platforms
and ladders are free from dust, snow and ice.
f) The service technician must wear tight-fitting protective clothing when servicing the crane,
together with the correct personal protective gear such as safety goggles, breathing mask
for the particular activity.
g) Correctly use auxiliary equipment and set up working platform before performing
high-level operation.
h) The maintenance and service work should be done in time and spare parts should be
changed according to the plan.
i) The customer must use original spare parts which meet technical requirements specified
by manufacturers.
j) Without the permission of our “customer service department”, welding is prohibited.
Unprofessional welding maintenance may cause damage, which is the sole responsibility
of the operator.
k) Do not perform any maintenance work if the service technician is tired, or he has drunk, or
he has taken medicine which may affect the work.
l) Do not reach into moving parts of the crane. The service technician must remove the
ignition start key and hang the “Prohibition” sign on the cab or control device before
operating these parts.
m) Do not touch hot components, hot pipelines, hot liquid and engine body when the engine
just stops. Only when the engine is cooled down for more than one hour, can the relevant
maintenance work be carried out.
n) Cut off the grounding terminal of battery and turn off mast power switch before dismantling
of the battery and welding operation on the crane.
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Safety Guidelines and
Environmental Protection
Maintenance Manual for Crawler Crane
WARNING
Follow the safety guidelines about maintenance and service before conducting any
maintenance and service work.
2.1.2 Qualification and selection of the personnel
Only professionals can conduct maintenance and service work.
This regulation is especially applicable for electrical system, hydraulic system, engine system
and brake system of crane.
2.1.3 Potential risks
2.1.3.1 Dangers caused by squeezing/shearing
Figure 3-1 Danger signs – squeezing and shearing
Parts involved:
a) Main boom, fixed jib, luffing jib, FA-frame, WA-frames 1 and 2
b) A-frame
c) Pinion gear of slewing reducer
d) Drive sprocket and driven sprocket
2.1.3.2 Dangers caused by tangling and dragging
Figure 3-2 Danger sign – tangling and dragging
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Maintenance Manual for Crawler Crane
Parts involved:
a) Wire ropes/rope pulleys/load hooks/slings
b) All winches
c) Crawler travel gear
2.1.3.3 Dangers caused by slipping, stumbling and falling
Figure 3-3 Danger sign – slipping, stumbling and falling
Only use specified thoroughfare and ladders, because the thoroughfare adopts anti slipping
design and has handrails to help you keep balance.
2.1.3.4 Dangers caused by heat
Figure 3-4 Danger sign – heating
Parts involved:
a) Engine with exhaust system
b) Working hydraulic system
2.1.3.5 Gas, dust and smoke
Make sure enough ventilation before refueling.
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Safety Guidelines and
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Maintenance Manual for Crawler Crane
2.1.3.6 Dangers caused by the residue energy in the hydraulic system
When hydraulic elements such as pipe, hose and hydraulic valve are damaged, the crane will
stop working. However, some part of the system will still bear pressure and the pressure may
be not released. At this time, please pay attention to the danger caused by residue pressure.
2.1.4 Preparations before maintenance and service work
2.1.4.1 Precautions
CAUTION
(1) Inform the operator, and assign a supervisor.
(2) The maintenance work must be done by qualified personnel who have received
training in crane technology, especially in electrical and hydraulic systems of crane.
(3) Shut down the diesel engine.
(4) Only keep diesel engine running when needing to use diesel engine to maintain and
lubricate the crane.
(5) Stop the crane on the ground (make sure that the ground has enough load-bearing
capacity) and take measures to prevent it from moving (for example, use wedges to
fasten the track pads).
(6) No unauthorized personnel are permitted to start the crane (the operator must take
out the ignition key and lock the door of the cab when leaving it) and set a warning
board.
(7) Correctly use auxiliary equipment and set up working platform before performing
high-level operation.
(8) Clean the crane before maintenance and service work, especially removing
lubrication oil, fuel oil or any additive in joints and couplings. Do not use corrosive
cleaning agent, but use non-fibre cleaning cloth.
(9) Before using water, vapor injection (high-pressure cleaning agnent) or any other
cleaning agent, cover or tie those openings which will be affected by water, vapor or
cleaning agent (considering safety or function, for exampel, install a power
distribution cabinet).
(10) Remove the cover or strap after cleaning the crane, and check if there is water in
theses areas.
(11) Check whether all fuel pipes, engine oil pipes and hydraulic oil pipes leak, and
check pipe fittings for tight fit, crack or damage after cleaning. If any faults are
found, please fix or change them immediately.
(12) Prepare proper container and adhesive in advance because the lubrication oil may
overflow during the maintenace and assembly process.
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