Zoomlion ZCC1100H Operators Manual
CRAWLER CRANE
Vision creates future
CRAWLER CRANE
Zoomlion Heavy Industry Science and Technology Co., Ltd
OPERATOR’S MANUAL
OPERATOR’S MANUAL
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.
Edition 1 5, 2014
ZCC1100H Crawler Crane
Operator’s Manual
Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
To Users
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.
I
Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
Contents
To Users ........................................................................................................................................ I
Safety Instructio ns ....................................................................................................................... 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 Safe ty 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 qual ification, requirem ents and responsibilities ............................................ 1-3
1.7 Safety advi c e 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 , sm ok e and noise .................................................................. 1-5
1.8.3 Welding or naked flames .................................................................................. 1-5
1.8.4 Hydrauli c equipm ent......................................................................................... 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 Int ended use of the crane ................................................................................. 2-2
2.1.4 Classif ic ation of the crane ............................................................................... 2-2
2.2 Terminology ................................................................................................................. 2-5
2.2.1 Crane modes ................................................................................................... 2-5
2.2.2 Descripti on of main components ....................................................................... 2-8
2.3 Product description .................................................................................................... 2-10
2.3.1 Cr
2.3.2 Crawler tr av el gear ......................................................................................... 2-10
2.3.3 Crane superstruct ur e...................................................................................... 2-10
ane working environment ............................................................................ 2-10
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Operator’s Manual for Crawler Crane
2.3.4 Over all dim ensi ons......................................................................................... 2-12
2.4 Techni c al data ............................................................................................................ 2-13
2.4.1 Main technic al parameter ............................................................................... 2-13
2.4.2 Specification of load hook and sel ec tion of rope reeving ................................. 2-15
2.4.3 Performance of wire rope and winch............................................................... 2-15
2.4.4 Lifti ng height .................................................................................................. 2-18
2.4.5 Lifti ng capacit y chart....................................................................................... 2-21
2.4.6 Lifti ng capacit y i n assembly m ode .................................................................. 2-57
Chapter 3 Safety Guideli nes
3.1 Operational planning .................................................................................................... 3-1
3.1.1 Correct use of the cr ane ................................................................................... 3-2
3.1.2 Possible c onsequence s resulting from im pr oper use of the cr ane ..................... 3-2
3.1.3 Responsibi lity of relevant personnel ................................................................. 3-3
3.1.4 Work area ........................................................................................................ 3-4
3.2 Safety technic al notes .................................................................................................. 3-5
3.2.1 Safety instructions for crane operator ............................................................... 3-5
3.2.2 The requir em ent for the crane operator during the whole operat ion .................. 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 pot ential 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 Ri sk of chemic al bur ns.................................................................................. 3-19
3.2.12 Risk of fir e and ex plosi on ............................................................................. 3-20
3.2.13 Risk of poi soni ng and asphyxiation ............................................................... 3-22
3.2.14 Endangering the environment ....................................................................... 3-23
3.3 S
IV
lings ........................................................................................................................ 3-24
3.3.1 Hooks ............................................................................................................ 3-24
3.3.2 Rigging introduction ....................................................................................... 3-24
3.3.3 Sli ngs i ntroduc tion .......................................................................................... 3-25
3.3.4 Sli ng safet y .................................................................................................... 3-25
3.3.5 Sli ng safet y gui de ........................................................................................... 3-26
3.3.6 Taglines ......................................................................................................... 3-26
3.3.7 Load center of grav ity ..................................................................................... 3-27
Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
3.4 Requirements for oper ating site ................................................................................. 3-28
3.4.1 Slopes and trenches....................................................................................... 3-28
3.4.2 Permissibl e gr ound pr essure .......................................................................... 3-29
3.4.3 Travel on level ground or slope wit hout a load ................................................ 3-30
3.4.4 Travel on level ground or slope wit h a load ..................................................... 3-30
3.4.5 The requir em ents for cr awler c r ane 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 Electric al safety.......................................................................................................... 3-33
3.6.1 Safety regulations for auxiliary power supply (220V AC) ................................ 3-33
3.7 Underground cabl es................................................................................................... 3-34
3.7.1 In undergr ound working, it is possible to damage: ......................................... 3-34
3.7.2 Safety prec autions and protectiv e measures when operating t he equipment near
underground cables ................................................................................................... 3-34
3.7.3 Notes in c onnec tion with gas pipes ................................................................. 3-35
3.7.4 The consequences of a gas pi pe’s damage .................................................... 3-35
3.7.5 Measures adopted if a gas pipe is damaged and the gas escapes, or a l eak is
suspected.................................................................................................................. 3-36
3.7.6 Measures adopted in the event of a gas fire ................................................... 3-36
3.7.7 Notes in c onnec tion with underground electri c cabl es ..................................... 3-37
3.7.8 The consequences of dam aging an underground cabl e .................................. 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 i nspect ion of the crane........................................................................... 3-39
3.8.2 Safety chec ki ng before crane operation .......................................................... 3-39
3.9 Crane operation with a load ....................................................................................... 3-40
3.9.1 Counterweight ................................................................................................ 3-40
3.9.2 Crane operat ion ............................................................................................. 3-41
3.10 Hand signals for controlling crane oper ations ........................................................... 3-53
Chapter 4 Crane operation
4.
1 Operating and cont r ol instr um ents................................................................................ 4-1
4.1.1 Operator’s cab, overvi ew .................................................................................. 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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Operator’s Manual for Crawler Crane
4.1.6 Control panel on the roof of operator’s cab ....................................................... 4-9
4.2 Instructi on 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 Adj ustm ent of crane operator ’s seat ............................................................... 4-19
4.3.2 Checks bef or e 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 Safe ty d evice ............................................................................................................. 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 Derricki ng lim iter ............................................................................................ 4-32
4.4.7 Lowering limiter .............................................................................................. 4-33
4.4.8 Hoisting lim iter ............................................................................................... 4-34
4.4.9 Anemometer .................................................................................................. 4-35
4.4.10 Crane i ncli nom eter ....................................................................................... 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 operati on ............................................................................ 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 r ope guidance and reeving ............................................................... 4-57
4.6.2 Derricki ng r ope r eeving .................................................................................. 4-61
4.6.3 Fixation of rope end point ............................................................................... 4-63
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Operator’s Manual for Crawler Crane
Operator’s Manual for Crawler Crane
Chapter 5 Assembly and Di smantling
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 pull ey and anchoring r od .......................... 5-3
5.2 Assembly of basic m ac hine .......................................................................................... 5-5
5.2.1 Unloading of basic machine.............................................................................. 5-5
5.2.2 Self-assembly and dismantling of crawler c ar ri er (opt ional) ............................. 5-10
5.2.3 Ext ending and r etracting of crawler carrier ...................................................... 5-16
5.2.4 Assembl y of central c ounterweight ................................................................. 5-22
5.2.5 Self-assembl y and dismantling of counterweight ............................................. 5-26
5.2.6 Fixation of mounting cylinder .......................................................................... 5-32
5.3 Available boom confi gur ations.................................................................................... 5-34
5.4 Boom configur ation .................................................................................................... 5-37
5.4.1 Main boom (S-1) ............................................................................................ 5-37
5.4.2 Main boom wit h 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 Assembl y of main boom ................................................................................. 5-59
5.5.3 Elect ri c al c onnec tion to main boom ................................................................ 5-66
5.5.4 Erecting main boom ....................................................................................... 5-68
5.5.5 Lowering and di smantling main boom ............................................................. 5-70
5.6 Assembly and dismantling of main boom with fix ed jib ................................................ 5-71
5.6.1 Preparation for assembly ................................................................................ 5-71
5.6.2 Assembl y 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 m ain c om ponents ............................................. 5-82
ransport means and safet y precautions for transport ................................................ 5-85
5.9 T
5.9.1 Safety prec autions for transport ...................................................................... 5-85
5.9.2 Other requirements ........................................................................................ 5-85
VII
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
安
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Operator’s Manual for Crawler Crane
Safety
Operator’s Manual for Crawler Crane
CAUTION
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 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, OSHA about 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.
(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".
ZCC1100H Crawler Crane 1-1
Operator’s Manual for Crawler Crane
Safety
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. 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:
1-2 ZCC1100H Crawler Crane
履带起重机操作手册
安
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Operator’s Manual for Crawler Crane
Safety
Operator’s Manual for Crawler Crane
- 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.
ZCC1100H Crawler Crane 1-3
Operator’s Manual for Crawler Crane
Safety
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.
1-4 ZCC1100H Crawler Crane
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Operator’s Manual for Crawler Crane
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Operator’s Manual for Crawler Crane
- 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.
ZCC1100H Crawler Crane 1-5
Operator’s Manual for Crawler Crane
Safety
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.
1-6 ZCC1100H Crawler Crane
履带起重机操作手册
第二章 起重机的描述
Operator’s Manual for Crawler Crane
Chapter 2 Description of Crane
Operator’s Manual for Crawler Crane
Description of Crane
Operator’s Manual for Crawler Crane
Figure 2-1 Position of product name plate
Figure 2-2 Product name plate
Position of product name plate
Chapter 2 Description of Crane
2.1 Product model
2.1.1 Product name plate and its position
ZCC1100H Crawler Crane 2-1
Operator’s Manual for Crawler Crane
Description of Crane
CAUTION
2.1.2 Engine type and its manufacturer
QSL9-C 280, American Cummins (Imported)
2.1.3 Intended use of the crane
This crawler crane is designed for lifting loads!
It is prohibited to transport people with this equipment! In many cases, there have been serious
injuries when people have been transported using this equipment (or even on the hook or on
loads). Under such circumstances, they have no control over the crane movements and are not
protected against bumps or falls. Even the smallest error can cause vital injury! In exceptional
cases, please consult the responsible authorities concerning safety regulations.
It is expressly forbidden to use the crane for jumps with rubber ropes (bungee jumping)! Using
the crane for such jumps represents a misuse of the crane and entails extreme danger for life
and limb!
The crane is designed exclusively for assembly operation, i.e. lifting loads, non-continuous use
of crane. Any other type of use or otherwise use which goes beyond its limits specified, such as
handling of general cargo or grab operation, are not classified as intended use. The
manufacturer shall not be liable for any damage caused. The operator bears full responsibility
for this type of misuse.
The use of two hoisting winches for lifting loads (twin hook operation) is only permitted following
consultation with the crane manufacturer.
The intended use also includes the observation of Operator’s Manual and Maintenance
Manual.
2.1.4 Classification of the crane
2.1.4.1 General
The crane has been constructed using state of the art technology and in accordance with
recognized safety regulations. Nevertheless, its use can lead to hazards for the life and limb of
2-2 ZCC1100H Crawler Crane
the operator and third parties, and/or damage to the machine and other objects.
Use the crane only when it is in full working order and only for its intended use, paying attention
at all times to safety and potential hazards, and in observance of the Operator’s Manual and
Maintenance Manual.
Have any malfunctions which might impair safety rectified immediately.
Operator’s Manual for Crawler Crane
Description of Crane
Operator’s Manual for Crawler Crane
No.
Working
mechanism
Operating class
Load collective
class
Crane group
1
Hoisting winch
T3/T5
L2/L3
M4/M6
2
Slewing
mechanism
T2
L2
M2
3
Derricking
mechanism
T2
L2
M2
4
Travel gear
T2
L1
M1
Note:
Among hoisting winches, the group of winch with free-fall function is M6, and group of normal winch is M4.
125.0
p
K
3
maxQ
Qi
T
i
P
P
P
C
C
K
2.1.4.2 Classification of the crane
The crane group of the crane is A1, operating class is U2 and the load collective class is Q1.
All important components of the crane are designed and manufactured for normal assembly
operation. Operating conditions or types of use other than assembly operation require the
permission of the manufacturer and normally lead to a reduction in the lifting capacities.
Otherwise, the life of the crane will reduce. The classification of various mechanisms is shown
in table 2-1.
Table 2-1 Classification of various mechanisms
2.1.4.3 Service life
Classification of the crane is based on a total operating life (service life) of 20 years under the
following conditions:
a) The crane is operated as an assembly crane. The load capacity charts specified for the
crane are for assembly operation only. General cargo handling or grab operation can only
be permitted following express permission from the manufacturer under suitable
conditions.
b) The entire number of the crane’s load cycles
A “load cycle” encompasses processes which begin when a load is lifted and end when the
crane is ready to lift the next load, including the time of crane operation and normal break.
The entire number of the crane’s load cycles with operating class U2 is 32000 – 63000 (for
example: 8 – 20 strokes / day on 200 days / year).
c) The load collective class of the crane
The load spectrum coefficient of the crane with load collective class Q1
the rated load rarely, but the medium-duty load frequently), the calculation of load
spectrum coefficient is expressed as follows:
(lift
ZCC1100H Crawler Crane 2-3
Operator’s Manual for Crawler Crane
Description of Crane
Qi
P
maxQ
P
i
C
Qi
P
T
C
CAUTION
Where,
is the i value appearing in the whole service life of the crane.
is the max. load value appearing in the crane’s entire service life.
is the crane’s load cycles corresponding to
load in the crane’s entire service life.
is the entire number of the crane’s load cycles in the crane’s service life.
The examples of load spectrum coefficient are as follows:
10% of crane’s load cycles in the crane’s entire service life is under the maximum load.
40% of crane’s load cycles in the crane’s entire service life is under 40% of the maximum
load.
50% of crane’s load cycles in the crane’s entire service life is under 10% of the maximum
load.
“Load” is to be understood in this connection as the sum total of load, load handling
devices and lifting tackle (e.g.: load + load hook + sling rope).
Under these circumstances, assuming that maintenance work is carried out properly, the
theoretical service life can be more than 20 years. Harder operating conditions lead to a
reduction in the service life.
If the user uses the crane according to other operating class and load collective class, the
corresponding entire number of crane’s load cycles and load spectrum coefficient are
adjusted, which result in a change of crane service life.
Some components (for example, wire rope, pulley and bearing) are not designed for the
entire service life of the crane, but must be replaced after a certain amount of time.
2-4 ZCC1100H Crawler Crane
Operator’s Manual for Crawler Crane
Description of Crane
Operator’s Manual for Crawler Crane
Configuration
no.
Description
Length of main boom
Length of fixed jib
Remarks
S-1
Main boom
42’8”(13m)-219’10”(67m)
No
The load is attached
onto main boom.
S-2
Main boom
with fixed jib
101’9”(31m)-180’5”(55m)
19’8”(6m)-59’(18m)
The load is attached
onto main boom.
S-3
Main boom
with tip boom
42’8”(13m)-200’2”(61m)
No SF-1
Main boom
with fixed jib
101’9”(31m)-180’5”(55m)
19’8”(6m)-59’(18m)
The load is attached
onto fixed jib.
SF-2
Main boom
with fixed jib
101’9”(31m)-180’5”(55m)
19’8”(6m)-59’(18m)
Main boom is
attached with a load
hook. However, the
load is attached onto
fixed jib.
2.2 Terminology
2.2.1 Crane modes
2.2.1.1 Working mode
The boom configurations of ZCC1100H crawler crane in working mode are shown in the table
2-2.
Table 2-2 Boom configurations of ZCC1100H crawler crane in working mode
ZCC1100H Crawler Crane 2-5
Operator’s Manual for Crawler Crane
Description of Crane
Figure 2-3 Boom configurations
DANGER
S-1 S-2 S-3 SF-1 SF-2
The boom configurations are shown in the figure 2-3.
It’s prohibited to lift a load by use of two hooks (twin hook operation) without the
permission of the manufacturer under the boom configurations S-2, S-3, SF-2, otherwise,
the crane may topple over.
2.2.1.2 Assembly mode
There exists an assembly mode for ZCC1100H crawler crane, which is used for crane
self-assembly and dismantling during crane conversion. During crane self-assembly and
dismantling operation, mounting cylinder is used to lift a load. The maximum lifting capacity of
mounting cylinder is 26460lb (12t). The assembly mode of crane is shown in figure 2-4,
however, when the crane is attached with crawler carriers, the mounting cylinder can also be
used to lift a load. At this time, the assembly mode in load moment limiter is SA.
2-6 ZCC1100H Crawler Crane
Operator’s Manual for Crawler Crane
Description of Crane
Operator’s Manual for Crawler Crane
Note: L is the working radius in assembly mode.
Figure 2-4 Assembly mode
CAUTION
L
Whenever using mounting cylinder on the boom to lift the load, be sure to make the
crane in assembly mode.
According to actual requirements, there are five working modes and an assembly mode
available for this crawler crane. For the details, please refer to relevant documents of load
moment limiter.
ZCC1100H Crawler Crane 2-7
Operator’s Manual for Crawler Crane
Description of Crane
Figure 2-5 Components on slewing table
No.
Names of the components
No
Names of the components
1
Rear counterweight
9
Slewing mechanism
2
Counterweight lifting cylinder
10
Fuel tank
3
Hydraulic oil tank
11
Hoisting winch 1
4
Hoisting winch 2
12
Engine
5
Main valve
13
Hoisting winch 3 (optional)
6
Battery box
14
Derricking winch
7
Tool box
15
Counterweight assembly
8
Operator’s cab
1 3 4 5 6 7 8 9 10
12
13
14 2 15
11
2.2.2 Description of main components
2.2.2.1 Components on superstructure
The positions of components on slewing table are shown in the figure 2-5, and the description
of components is shown in the table 2-3.
2-8 ZCC1100H Crawler Crane
Table 2-3 Description of components on slewing table
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