Zoomlion ZCC2600CR User manual

Zoomlion Heavy Industry Science & Technology Co.,Ltd.
Address: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Changsha, Hunan Province, China Postcode: 410131
Website: http://www.zoomlion.com Email: [email protected]
Copyright © 2015 Zoomlion Heavy Industry Science&Technology Co., Ltd. All rights reserved
CRAWLER CRANE
OPERATOR’S MANUAL

Edition 1 July 2018
ZCC2600CR Crawler Crane
Operator’s Manual

Operator’s Manual for Crawler Crane
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
I

Operator’s Manual for Crawler Crane
The following terms that are used in these operating instructions "Danger", "Warning", "Caution" and
"Notice" are intended to point out certain important rules of conduct to all persons who work with the
crane. The meanings of the terms 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 tip or hint in the operation instructions.
Safety Instructions
II

Operator’s Manual for Crawler Crane
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 Component safety features..............................................................................................1-2
1.3 Features for operator safety.............................................................................................1-2
1.4 Environmental safety........................................................................................................1-2
1.5 Personnel protective equipment (PPE)............................................................................1-2
1.6 Measured noise level........................................................................................................1-3
1.7 Vibration levels.................................................................................................................1-3
1.8 Organizational safety measures.......................................................................................1-3
1.9 Personnel qualification, requirements and responsibilities ..............................................1-4
1.10 Safety advices regarding specific operation phases......................................................1-4
1.11 Special Hazards..............................................................................................................1-4
1.11.1 Electrical energy.................................................................................................1-4
1.11.2 Gas, dust, steam, smoke and noise...................................................................1-5
1.11.3 Welding or naked flames....................................................................................1-5
1.11.4 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 Intended use of the crane.....................................................................................2-1
2.1.3 Crane design calculation......................................................................................2-2
2.1.4 Engine type and its manufacturer.........................................................................2-3
2.2 Terminology......................................................................................................................2-4
2.2.1 Boom configurations.............................................................................................2-4
2.2.2 Description of crane components.........................................................................2-5
2.3 Product description...........................................................................................................2-7
2.3.1 Hoisting winches...................................................................................................2-7
2.3.2 Main boom derricking winch.................................................................................2-7
Contents
III

Operator’s Manual for Crawler Crane
2.3.3 Slewing mechanism..............................................................................................2-7
2.3.4 Travel gear............................................................................................................2-7
2.3.5 A-frame erecting mechanism................................................................................2-8
2.3.6 Operator’s cab movement-controlling mechanism...............................................2-8
2.3.7 Counterweight and its fitting & removal mechanism ............................................2-8
2.3.8 References...........................................................................................................2-8
2.3.9 Classification of the crane ....................................................................................2-8
2.3.10 Crane working environment................................................................................2-9
2.3.11 Overall dimensions.............................................................................................2-9
2.4 Technical data.................................................................................................................2-10
2.4.1 Main technical parameter...................................................................................2-10
2.4.2 Type of load hook and applicable rope reeving..................................................2-10
2.4.3 Hoisting rope reeving and specification of wire rope..........................................2-11
2.4.4 Lifting height .......................................................................................................2-14
2.4.5 Lifting capacity charts.........................................................................................2-16
Chapter 3 Safety Guidelines
3.1 Operational planning ........................................................................................................3-1
3.1.1 State-of-the-Art Technology..................................................................................3-2
3.1.2 Appropriate use of the crane................................................................................3-2
3.1.3 Results of inappropriate use.................................................................................3-2
3.1.4 Areas of responsibility ..........................................................................................3-3
3.1.5 Personal protective gear.......................................................................................3-4
3.1.6 Work area.............................................................................................................3-5
3.2 Safety technical notes ......................................................................................................3-6
3.2.1 Safety instructions for crane operator ..................................................................3-6
3.2.2 Selecting an operating site...................................................................................3-8
3.2.3 Slopes and trenches.............................................................................................3-8
3.2.4 Permissible ground pressure................................................................................3-9
3.2.5 Checking safety measures.................................................................................3-10
3.2.6 Electromagnetic influences.................................................................................3-10
3.2.7 Safety signs........................................................................................................3-11
3.2.8 Potential dangers existing in crane operation....................................................3-16
3.2.9 Injuries due to hydraulic energy .........................................................................3-18
3.2.10 Risk of chemical burns .....................................................................................3-19
3.2.11 Risk of fire and explosion..................................................................................3-20
3.2.12 Risk of poisoning and asphyxiation..................................................................3-22
3.2.13 Operating near energized lines........................................................................3-23
IV

Operator’s Manual for Crawler Crane
3.2.14 Establishing the prohibited zone ......................................................................3-23
3.2.15 Electromagnetic influences ..............................................................................3-24
3.2.16 Endangering the environment..........................................................................3-25
3.3 Rigging ...........................................................................................................................3-26
3.3.1 Rigging introduction............................................................................................3-26
3.3.2 Rigging hardware...............................................................................................3-26
3.3.3 Hooks .................................................................................................................3-26
3.4 Slings..............................................................................................................................3-28
3.4.1 Slings introduction..............................................................................................3-28
3.4.2 Sling identification tags.......................................................................................3-28
3.5 Chain Hitches.................................................................................................................3-29
3.5.1 Sling hitches.......................................................................................................3-29
3.5.2 Angle of choke....................................................................................................3-30
3.5.3 D/d ratio..............................................................................................................3-30
3.5.4 Load angle factor................................................................................................3-31
3.5.5 Load share..........................................................................................................3-32
3.5.6 Load angle factor chart.......................................................................................3-32
3.5.7 Sling safety.........................................................................................................3-33
3.5.8 Sling safety guide...............................................................................................3-34
3.5.9 Taglines ..............................................................................................................3-34
3.5.10 Load center of gravity.......................................................................................3-35
3.5.11 Sling hook up center of gravity.........................................................................3-35
3.5.12 Estimating weights............................................................................................3-36
3.6 Ground conditions ..........................................................................................................3-37
3.6.1 Bearing pressure................................................................................................3-37
3.7 Snow and ice..................................................................................................................3-38
3.8 Lightning strikes..............................................................................................................3-39
3.9 Overhead power lines.....................................................................................................3-40
3.10 Underground cables.....................................................................................................3-49
3.11 Crane operation with a load..........................................................................................3-54
3.11.1 Counterweight...................................................................................................3-54
3.11.2 Travel without a load.........................................................................................3-55
3.11.3 Travel with a load..............................................................................................3-56
3.11.4 Requirements when transferring from the horizontal to the incline..................3-59
3.11.5 Crane operation ...........................................................................................3-61
3.12 Hand signals for controlling crane operations..............................................................3-78
V

Operator’s Manual for Crawler Crane
Chapter 4 Crane Operation
4.1 Operating and control instruments ...................................................................................4-1
4.1.1 Operator’s cab, overview......................................................................................4-1
4.1.2 Left control box.....................................................................................................4-3
4.1.3 Right control box...................................................................................................4-4
4.1.4 Control panel assy................................................................................................4-6
4.1.5 Right control panel................................................................................................4-8
4.2 Instruction for digital display system...............................................................................4-11
4.2.1 Load moment limiter...........................................................................................4-12
4.2.2 LCD screen of parameter monitor......................................................................4-12
4.3 Startup of the crane........................................................................................................4-18
4.3.1 Adjustment of crane operator’s seat...................................................................4-18
4.3.2 Checks before startup ........................................................................................4-21
4.3.3 Turn on power supply.........................................................................................4-22
4.3.4 Start the engine ..............................................................................................4-24
4.4 Safety devices ................................................................................................................4-25
4.4.1 Emergency stop button.......................................................................................4-25
4.4.2 Battery master switch.........................................................................................4-25
4.4.3 Load moment limiter...........................................................................................4-26
4.4.4 Boom angle indicator..........................................................................................4-29
4.4.5 Derrick limiter......................................................................................................4-30
4.4.6 Lowering limiter ..................................................................................................4-31
4.4.7 Hoisting limiter....................................................................................................4-33
4.4.8 Support cylinder locking device..........................................................................4-34
4.4.9 Relief valve.........................................................................................................4-34
4.4.10 Anemometer.....................................................................................................4-34
4.5 Crane operation..............................................................................................................4-35
4.5.1 Operation of travel gear......................................................................................4-39
4.5.2 Operation of crane winches................................................................................4-45
4.5.3 Operation of synchronizing A-frame and main boom derricking winch and
synchronizing reeving winch and working winch ...........................................................4-57
4.5.4 Operation of slewing mechanism.......................................................................4-60
4.5.5 Simultaneous operation......................................................................................4-63
4.5.6 Operator’s cab movement-controlling mechanism.............................................4-77
4.5.7 Auxiliary remote control box...............................................................................4-80
4.6 Rope reeving ..................................................................................................................4-86
4.6.1 Heavy duty boom (S)..........................................................................................4-88
VI

Operator’s Manual for Crawler Crane
4.6.2 Light duty boom (SL)..........................................................................................4-91
4.6.3 Fixed jib on heavy duty boom (SF).....................................................................4-92
4.6.4 Luffing jib on heavy duty boom (SW) .................................................................4-93
4.6.5 Derricking rope guidance and reeving ...............................................................4-94
4.6.6 Luffing rope guidance and reeving.....................................................................4-95
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...................................................................................5-2
5.1.3 Inspection of wire rope, load hook, rope pulley and anchoring rods....................5-3
5.1.4 Connecting or disconnecting the hydraulic lines with quick-release couplings....5-4
5.1.5 Erecting and lowering the boom...........................................................................5-4
5.2 A-frame.............................................................................................................................5-6
5.2.1 Connecting the hydraulic lines to mounting cylinder onA-frame.........................5-7
5.2.2 Operation of A-frame............................................................................................5-9
5.3 Attaching crawler carriers...............................................................................................5-13
5.3.1 Unloading of basic machine...............................................................................5-13
5.3.2 Attaching the first crawler carrier........................................................................5-16
5.3.3 Attaching the second crawler carrier..................................................................5-18
5.3.4 Connecting the hydraulic lines to the crawler carrier.........................................5-19
5.4 Attaching the central counterweight...............................................................................5-22
5.5 Assembling the rear counterweight................................................................................5-24
5.6 Available boom configurations of ZCC2600 crawler crane............................................5-27
5.7 Boom configuration.........................................................................................................5-34
5.7.1 Heavy duty boom (S)..........................................................................................5-34
5.7.2 Light duty boom (SL)..........................................................................................5-43
5.7.3 Fixed jib on heavy duty boom (SF).....................................................................5-58
5.7.4 Heavy fixed jib on heavy duty boom (SFV)........................................................5-69
5.7.5 Luffing jib on heavy duty boom (SW) .................................................................5-80
5.8 Assembly and dismantling of heavy duty boom(S)........................................................5-96
5.8.1 Preparations for assembly..................................................................................5-96
5.8.2 Assembling main boom......................................................................................5-96
5.8.3 Connect electrics to main boom.......................................................................5-105
5.8.4 Erecting main boom .........................................................................................5-108
5.8.5 Lowering and disassembling main boom......................................................... 5-111
5.9 Assembly and dismantling of main boom with luffing jib (SW).....................................5-111
5.9.1 Preparations for assembling lufing jib..............................................................5-112
VII

Operator’s Manual for Crawler Crane
5.9.2 Assembling main boom with luffing jib..............................................................5-112
5.9.3 Connect electrics to luffing jib...........................................................................5-126
5.9.4 Erecting and lowering main boom with luffing jib..............................................5-134
5.10 Assembly and dismantling of light duty boom (SL).......................................................5-142
5.11 Assembly and dismantling of main boom with fixed jib (SF).........................................5-144
5.11.1 Preparations.....................................................................................................5-144
5.11.2 Assembling main boom with fixe jib..................................................................5-144
5.11.3 Connect electrics to fixed jib.............................................................................5-153
5.11.4 Erecting and lowering main boom with fixed jib................................................5-156
5.12 Assembly and dismantling of main boon with heavy fixed jib (SFV).............................5-159
5.13 Assembly and dismantling of tip boom.........................................................................5-160
5.14 Transport weights and dimensions of main components..............................................5-161
5.15 Requirement on crane transport...................................................................................5-169
Chapter 6 Appendix
6.1 Description of special heavy fixed jib on heavy duty boom..............................................6-1
6.1.1 Terminology ..........................................................................................................6-1
6.2 Assembly of special heavy fixed jib on heavy duty boom..............................................6-14
6.2.1 Preparations .......................................................................................................6-14
6.2.2 Assembly of rear counterweight.........................................................................6-14
6.2.3 Assembly of special heavy fixed jib on heavy duty boom (SFV-D)....................6-15
6.2.4 Connect electrics to special heavy fixed jib........................................................6-21
6.2.5 Erecting, lowering and dismantling special heavy fixed jib heavy duty boom
(SFV-D) ..........................................................................................................................6-21
6.3 Description of special heavy fixed jib for SFV-D boom...................................................6-22
6.3.1 Description of special heavy fixed jib for S boom...............................................6-22
6.3.2 Description of special heavy fixed jib SFV-D boom............................................6-24
6.3.3 Description of special heavy fixed jib for SFV-D boom used to turning over the
shield tunneling machine................................................................................................6-26
6.3.4 Lifting capacity charts of shield tunneling machine............................................6-26
6.4 Computer Control ...........................................................................................................6-29
6.5 How to turn over the shield tunneling machine ..............................................................6-34
VIII

Chapter 1 Safety
Operator’s Manual for Crawler Crane

起
重
机
说
明
Safety
Operator’s Manual for Crawler Crane
Chapter 1 Safety
1.1 Important instructions
1.1.1 Notes
a) Read this manual 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 crane.
c) Training should be provided to ensure safe working practices.
d) To avoid the risk of electric shock, always isolate this crane from the power supply prior to
carrying out any maintenance and adjustment work or removing any guards or covers.
e) Always follow the procedures outlined in the Operator’s Manual and Maintenance Manual.
f) If in doubt, do not take personal risk.
g) Only trained personnel can be allowed to install, set, operate, maintain, and commission
this crane.
1.1.2 Alarms and warnings
a) As to the potential 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 warnings and instruction labels 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 warnings or instruction labels where
necessary.
CAUTION
(1) Follow the warnings and instruction labels for the sake of personal safety.
(2) For the positions of warnings and instruction labels, please see Chapter 3 "Safety
Guidelines".
1-1

Safety
Operator’s Manual for Crawler Crane
1.2 Component safety features
a) Do not use this crane with guards removed or incorrectly fastened.
b) Do not use this crane with safety devices maladjusted or removed.
1.3 Features 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.
1.4 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) The spilling diesel must be dealt with immediately.
2) Only use the lubricating oil recommended in the Maintenance Manual.
3) Local and national regulations must be observed strictly when disposing of the waste.
4) Improper disposal of the waste is illegal, as it will undermine the environment.
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 the fluids. Do not use food or beverage
containers that may mislead someone into drinking or eating them.
7) Do not pour the 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.
1.5 Personnel protective equipment (PPE)
a) Loose or baggy clothing can get caught in running machinery.
b) Where possible when working close to the engine or machine, 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 away from the moving parts.
c) For reasons of safety, long hair must be tied back or otherwise secured. The garments
must be close fitting and no jewellery such as rings may be worn.
d) Correctly wear personnel protective equipment.
e) Recommended personnel protective equipment includes:
1) Hard hat
1-2

起
重
机
说
明
Safety
Operator’s Manual for Crawler Crane
2) Safety glasses/Goggles
3) Hearing protection device
4) Close fitting overalls
5) Safety boots
6) Industrial gloves
7) High visibility vest or jacket
1.6 Measured noise level
The condition of working site may affect the noise levels.
According to EN13000 Annex G and 2000/14/ EC standards, the sound pressure level and
sound power level measured in the operator’s cab are 73.9 dB(A) and 107 dB(A) respectively.
The sound pressure level measured according to ISO 7731 standard at the position 1 m away
from the warning device is 97.7 dB(A).
1.7 Vibration levels
Suitable seating has been installed to reduce whole body vibrations, in line with current industry
standards.
According to ISO 2631-1 standard, the crane body vibrations areA (1): 1.3 m/s2, A(4): 0.6 m/s2,
A (8): 0.4 m/s2under normal operating condition.
1.8 Organizational safety measures
a) The crane must only be operated by a suitably qualified operator who holds a current
license in line with national or international legislation.
b) Understand the service procedure before doing work. Keep working area clean and dry.
c) Never lubricate, clean or adjust the crane while it is moving (excluding central lubrication).
d) Keep hands, feet and clothing clear of power driven parts and 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 ECM and unplug all plugs of the 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.
1-3

Safety
Operator’s Manual for Crawler Crane
1.9 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) The maintenance work must only be undertaken by suitable qualified engineers with
specialist knowledge of this crane.
c) The work on the hydraulic system must be carried out only by personnel with special
knowledge and experience of hydraulic equipment.
1.10 Safety advices 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
protective and safety-orientated devices, emergency shut-off equipment, warning
devices and exhaust devices are in place and fully functional.
3) Erect barrier guards in proper positions to stop unauthorized entry to this crane.
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 blind spots on the crane can cause serious injury or even death.
2) Do not reach into unguarded components.
3) Stop the crane before removing any safety devices.
1.11 Special Hazards
1.11.1 Electrical energy
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 the crane comes into contact with a live wire:
1) Vacate the area
2) Warn others against approaching and touching the crane.
3) Report the incident and have the live wire de-energized
4) Switch off the electrical system
b) Battery
1) Always disconnect battery leads before carrying out any maintenance to the electrical
1-4

起
重
机
说
明
Safety
Operator’s Manual for Crawler Crane
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. Therefore, avoid contact with the skin, eyes or clothing.
1.11.2 Gas, dust, steam, smoke and noise
a) Always operate internal combustion engine out of doors or in a well ventilated area.
b) If the 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) The 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 dampened by authorized persons, placed in a sealed
container and marked, to ensure safe disposal.
1.11.3 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 should be undertaken on this crane as it will affect its structural integrity.
c) Avoid all naked flames in the vicinity of this crane.
1.11.4 Hydraulic equipment
a) The 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 to be removed in accordance
with the specific instructions for the unit concerned before carrying out any repair work.
e) Hydraulic 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) If the high-pressure hydraulic fluid leaks, it can cause serious injury to personnel nearby.
Once it happens, seek medical help immediately.
1-5