Qy130v633 Operation Manual

QY130V633 / F 20Y
ZOOMLION ® Truck Crane
ZLJ5550JQZ130V
QY130V633/20Y
QY130V633 / M20Y
Contents
0 Foreword …………………………………………………………………… 1145-000-00-20Y

1 Description of crane ………………………………………………………0063152-000-01-20Y
1.1 Model and name plate
1.2 Main components and configurations
1.3 Technical data
1.3.1 Dimensions
1.3.2 Lifting capacity
1.3.3 Weights
1.3.4 Speeds
1.3.5 Energy consumption and environmental protection
1.3.6 Lifting height chart
1.3.7 Lifting capacity table
2 Safety ……………………………………………………………………… 1145-000-02-20Y
2.1 Traffic regulations
2.2 Break-in instructions
2.3 Planning crane operation
2.4 General safety technical guidelines
2.4.1 Requirements of the crane operator and conductor
2.4.2 Selecting an operating site
2.4.3 Supporting
2.4.4 Working conditions
2.4.5 Points for attention
2.5 Signs on the crane
2.6 Hand signals
3 Operation - crane chassis ………………………………………………0063152-000-03-20Y
3.1 Vehicle operating and control instruments
3.1.1 Steering wheel
3.1.2 Display unit
3.1.3 Foot pedal (R): Engine control
3.1.4 Foot pedal (L): Service brake
3.1.5 Keyboard
3.1.6 Center console
3.1.7 Crane lighting
3.1.8 DVD reversing system
3.1.9 Door – driver's cab
3.1.10 Seats in driver's cab
3.1.11 Toolbox
3.2 Before starting up the vehicle
3.2.1 General checks before setting off
3.2.2 Axle suspension / axle locking system
3.3 Driving the crane
3.3.1 Crane driving conditions
3.3.2 Starting and turning off the engine
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QY130V633 / M20Y
3.3.3 Driving
3.3.4 Automated shift transmission
3.3.5 Important control instruments while driving
3.3.6 Off-road driving
3.3.7 Maneuvering
3.3.8 Towing
3.3.9 Finishing driving operations
3.4 Outrigger – operation
3.4.1 Installing and removing the outrigger pads
3.4.2 Extending and retracting the outriggers
3.5 The crane at the jobsite
3.5.1 Converting from driving mode to crane operation
3.5.2 Outrigger pad
3.5.3 Converting from crane operation to driving mode
3.5.4 Switching the axle locking off
3.5.5 Converting to driving mode
3.5.6 Supporting the crane with support control unit
3.5.7 Checking outriggers
3.5.8 Before leaving the work site
4 Operation – crane superstructure ………………………………………0063152-000-04-20Y
4.1 Control instruments and indicators
4.1.1 Operator's cab
4.1.2 Operator's seat
4.1.3 Right control box
4.1.4 Left control box
4.1.5 Instrument console
4.2 Computer system
4.2.1 General
4.2.2 Programs
4.3 Starting up the crane
4.3.1 Checks before starting up
4.3.2 Starting the engine
4.3.3 Computer system after engine start
4.4 Safety devices
4.4.1 General
4.4.2 Support control unit
4.4.3 Load moment limiter
4.4.4 Hoisting / lowering limit switch
4.4.5 Hydraulic safety valves
4.4.6 Bypass operation
4.4.7 Wind warning system
4.4.8 Emergency off switch
4.5 Crane operation
4.5.1 Preparations for crane operation
4.5.2 Derricking
4.5.3 Telescoping
4.5.4 Lifting / lowering
4.5.5 Slewing
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QY130V633 / M20Y
4.5.6 Rope reeving

4.5.7 Simultaneous crane movements
5 Equipment …………………………………………………………………0063152-000-05-20Y
5.1 Safety technical guidelines for assembly
5.2 Jib
5.2.1 General
5.2.2 Assembly
5.2.3 Angle settings
5.2.4 Removing
5.2.5 Electrical connections
5.2.6 Reeving in the auxiliary hoist rope
5.3 Assembly of the extension
5.3.1 Assembly of the extension below an angle of 0
5.3.2 Assembly of the extension and jib
5.3.3 Dismantling the extension
5.4 Rooster sheave
5.4.1 Assembly
5.4.2 Dismantling
5.5 Assembly of auxiliary winch
5.6 Counterweight
5.6.1 Counterweight and its assembly & disassembly mechanism
5.6.2 Assembly
6 Additional equipment …………………………………………………… 1145-000-06-20Y
6.1 Air conditioning in driver's cab
6.2 Air conditioning in operator's cab
6.3 Emergency control
6.3.1 Emergency operation – crane superstructure
6.3.2 Emergency operation – crane chassis
6.4 Interphone
7 Maintenance and service ………………………………………………… 0063152-000-07-20Y
7.1 General
7.2 Cleaning and care of the crane
7.3 Maintenance intervals
7.3.1 Crane chassis maintenance and inspection plan
7.3.2 Crane superstructure maintenance and inspection plan
7.4 Lubrication
7.4.1 Hydraulic oil
7.4.2 Gear oil
7.4.3 Lubricating grease
7.4.4 Engine oil
7.4.5 Cooling medium
7.4.6 Lubricating points
7.5 Adjusting, cleaning and replacing parts
7.5.1 Replacing the wire rope
7.5.2 Replacing the hook
7.5.3 Checking and replacing return-line filter
7.5.4 Replacing the hydraulic oil filter for closed slewing pump
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QY130V633 / M20Y
7.5.5 Cleaning and replacing the fuel filter

7.5.6 Cleaning and replacing the air filter
7.5.7 Replacing the pressure filter
7.5.8 Adjusting the telescopic wire rope of sliding beam
7.5.9 Tires / wheels
7.6 Transportation and storage
8 Crane inspections ………………………………………………………… 1145-000-08-20Y
8.1 Re-inspections
8.2 Periodic crane inspections
8.2.1 Inspection during break-in period
8.2.2 Inspecting the rims
8.2.3 Inspecting the brake systems
8.2.4 Inspecting the hoist and slewing mechanisms
8.2.5 Inspecting the hooks
8.2.6 Inspecting the wire rope pulleys
8.2.7 Inspecting the crane wire ropes
8.2.8 Inspecting the tightness of load carrying components
8.2.9 Inspecting the oil and fuel reservoirs
8.2.10 Inspecting the hydraulic system
8.2.11 Inspecting the electrical system
8.2.12 Inspecting the safety devices
9 Diagnostics ……………………………………………………………………… 1145-000-09-20Y
9.1 Crane superstructure
9.1.1 Instruments
9.1.2 Load moment limiter and input / output condition of PLC controller
9.1.3 Telescoping errors
9.1.4 Superstructure, troubleshooting
9.2 Crane chassis
9.2.1 Instruments
9.2.2 Transmission
9.2.3 Chassis, troubleshooting
IV
1145-000-00-20Y
Foreword
Thank you for purchasing ZOOMLION crane. These operating instructions are intended to put
you in a position to operate the crane safely and utilize the reliable usage options that it
provides.
This product can be widely used in industrial and mining establishments, building sites, harbor,
oil field, storage, warehouse and so on to do lifting and hoisting work.
Before operating the crane, read these operating instructions carefully. Correctly
understanding and using these instructions will make it easier to become familiar with the
crane and avoid problems due to improper operation. Observing these operating instructions
can increase liability in use, prolong the service life of your crane and reduce repair costs and
downtime. The operating instructions must be read and used by all persons who are involved
in use, operation, assembly and maintenance of the crane. If there is anything the operating
instructions or the individual chapters that you do not understand, please contact us before
starting the relevant work. Additional information about the crane you received from us must
also be followed and kept with the operating instructions.
Always keep these operating instructions handy in the driver's or operator's cab. The
operating instructions belong with the crane.
 Safety Information
The accidents occurring during the crane operation are mostly caused by ignoring the
precautionary measures and safety regulations. Incorrect operation, service and maintenance
are all dangerous and might cause life-threatening hazards. Therefore, do read, understand
and master the precautionary measures and notes before starting your work. Operations,
checks and maintenance must be carried out carefully. Special attention must be paid to the
safety equipment built into the crane. The functionality of the safety equipment must be
monitored at all times. The crane must not be operated if the safety equipment is not working
or not working correctly. The operator’s motto must always be Safety first!
The contents concerning about safety are marked with " " and the safety information
involved in these operating instructions is only the routine one.
The following terms that are used in these operating instructions "Danger", "Warning", and
"Caution" 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:
The term "Danger" is used to provide a warning about life-threatening hazards or serious
damage to property.
Warning:
The term "Warning" is used to provide a warning about potentially serious personal injury or
damage to property.
Caution:
The term "Caution" is used to provide a warning about potential minor personal injury or
machinery failures.
Note:
The term "Note" is used to draw attention to certain matters.
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It's difficult to forecast every dangerous condition. However, operating the crane according to
these operating instructions can ensure your safety. Our company assumes no liability for any
accidents caused by crane operations which differ from the directions contained in these
operating instructions and warning labels.
Our product and technical documents are subject to technical improvements and changes
without notice. Therefore, please acquaint yourself with our updated technology information. If
there are differences between illustration and product, refer to the product.
These operating instructions have been translated to be best of one’s knowledge. Zoomlion
assumes no liability for translation errors. The Chinese version of the operating instructions is
solely applicable for factual accuracy. If you find any errors or if any misunderstandings arise
when reading these operating instructions, please contact Zoomlion immediately.
0-2
Chapter 1 Description of crane
0063152-000-01-20Y
1.1 Model and name plate
1.1.1 Model
z Model in auto industry: ZLJ5550JQZ130V

z Model in engineering industry: QY130V
1.1.2 Name plate
1.1.2.1 Installation location
The name plate is installed on the left side of operator's cab.
Name plate
1.1.2.2 Name plate
Note:
The above details must always be provided when requiring us to offer service work.
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0063152-000-01-20Y
1.1.3 Vehicle identification number (VIN) and its location
The VIN of ZLJ5550JQZ130V is L5E6H5D4×××××××××, and is stamped in the name

plate and on the right side longitudinal beam of the vehicle. Exact location is shown in the
following illustration:
VIN location
(On the right side L5E6H5D4×××××××××
longitudinal beam)
1.1.4 Engine model and its manufacturer
Engine model: OM501LA.Ⅲ/18 (for chassis)

Manufacturer: Mercedes – Benz
The first engine name plate can be found on the left rear part of the last cylinder, near the
flywheel. The exact location is shown in the following illustration:
The first engine name plate
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The second engine name plate is installed at the front end of the oil filter housing (engine left
side near the fan). The exact location is shown in following illustration:
The second engine

name plate
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1.2 Main components and configurations
11
12
10
13
9
14
7
6 15
5 4 3 2 1
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26
25
24
23
22
21
20
19
18
17
16
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1.2.1 Main components
The numbers stand for the following components of the crane.
1.2.1.1 Crane chassis
1 Chassis
2 Tires – axles 1, 2 and 5 are equipped with single tires and axles 3 and 4 are equipped
with double tires
3 Outrigger pad
4 Sliding beam – two sections extendable simultaneously
5 Driver's cab
6 Engine
1.2.1.2 Crane superstructure
7 Counterweight
8 Auxiliary hoist mechanism
9 Main hoist mechanism
10 Slewing table
11 Hook block
12 Derricking mechanism
13 Engine
14 Operator's cab
15 Slewing mechanism
16 Basic boom
17 Telescopic boom section 1
22 Adaptor I
23 Adaptor II
24 Extension (Optional)
25 Jib section 1
26 Jib section 2
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1.2.2 Product description
1.2.2.1 Crane chassis
z Frame
Distortion-resistant box structure welded from high-strength steel.
z Engine
V-type, 6-cylinder diesel, manufactured by Benz, model OM501LA, intercooled.
Performance: 320 KW at 1800 rpm
Maximum torque: 2100 Nm at 1080 rpm
Fuel tank: 400 L
z Sliding beams
2-section sliding beams, completely and intermediately extendable simultaneously.
z Transmission
ZF 12-speed transmission system with automatic switching system AS-TRONIC.
z Transfer case
Single-stage power distribution, with longitudinal differential and differential locks.
z Axles
Axles 1, 2 and 5 are steered.
Axles 2, 4 and 5 are driven.
Axles 1 and 5 with transversal differential and differential locks.
Axle 4 with transversal / longitudinal differential and differential locks.
z Suspension
Axles 1 and 2 with hydro-pneumatic suspension and hydraulically lockable, making axle’s
height adjustable. Axles 3, 4 and 5 are with leaf spring suspension.
z Tires
The steered wheels are equipped with single tire and the non-steered wheels are
equipped with double tires.
Tire size: 12.00R24
z Steering system
Hydraulic steering gear, dual circuit system.
z Brake system
It consists of service brake, parking brake (emergency brake) and auxiliary brake.
Service brake: acting on all wheels
Parking brake: acting on axles 3, 4, and 5
Auxiliary brake: consisting of engine compressed air brake and exhaust brake
z Driver's cab
Spacious cab made of thin metal plate, with safety glass, operating and control
instruments, luxury equipment
z Electrical system
24 Volt DC, 2 batteries, each with 195 AH current.
Lighting system complies with national standards
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1.2.2.2 Crane superstructure
z Main boom
1 basic boom and 5 telescopic sections. All telescopic boom sections are hydraulically
extendable independently of each other via 1 telescopic cylinder with hydraulic
interlocking device.
Telescopic boom length: 12.8 m to 57.5 m
z Slewing table
High-tailed, distortion-resistant box structure, providing unlimited horizontal rotation for
superstructure components.
z Engine
In-line 6-cylinder diesel, manufactured by Benz, model OM906LA, intercooled.
Performance: 190 KW at 2200 rpm
Maximum torque: 1000 Nm at 1200 rpm
Fuel tank: 220L
z Crane drive
Diesel hydraulic with 2 axial plunger pumps with servo control and power control, 1 gear
pump.
Hydraulic pump in a compact design is flanged directly onto the diesel engine.
z Controls
Modern CAN bus technology, computer integrated controls, engine load-limit controls,
computer diagnosis, electron pedal, optional GPS.
Variable hydraulic system for open and closed circuit with electro-hydraulic proportional
controls.
Two 4-way joysticks, self-centering, realize infinitely variable control of all crane
movements by adjusting the hydraulic pumps, additional speed control when adjusting
the diesel engine RPM.
z Operator's cab
All superstructure switches and display unit are arranged in it, equipped with safety glass.
The cab can be tilted backwards for 20°.
z Safety system
Load moment limiter overload system, safety valves to prevent pipe and hose breakage,
hoisting limit switch / lowering limit switch for winches.
z Hoist mechanism
It consists of two hoist mechanisms: main / auxiliary hoist mechanism
Hydraulic motor.
Hoist mechanism with planetary reducer and brake.
Main hoist mechanism is driven by variable motor and auxiliary hoist mechanism is
driven by fixed displacement motor.
Wire rope diameter: φ19mm
z Derricking mechanism
1 telescopic cylinder with a balance valve lifts and lowers the boom from -1.5° to 82°.
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z Slewing mechanism
Slewing drive device, fixed displacement motor, planetary reducer, and brake.
The crane is equipped with 2 slewing mechanisms, symmetrically arranged.
z Electrical system
24 Volt DC, 2 batteries, each with 185 AH current.
z Counterweight
5 moveable combination counterweight plates can be assembled and disassembled by
the counterweight handler on the tail of slewing table.
Total weight: 45 ton
Weight variants: 0 ton, 10 ton, 24 ton, 32 ton, 45 ton
z Hook block
5 hooks.
The maximum lifting capacity in various reevings: 130 ton, 90 ton, 55 ton, 20 ton, 7 ton (1
reeving)
Hooks 130T (optional) and 90T are straight shank hooks with two points.
z Central lubricating system
All the lubricating points are automatically supplied with the correct grease quantity.
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1.2.2.3 Additional equipment
z Jib
2-section reducing lattice jib, can be attached below 0° or 30° in relation to the main
boom via adaptor I and adaptor II.
Length of jib section 1: 11 m
Length of jib section 1 + jib section 2: 18.6 m
Jib section 2 cannot be used individually.
z Jib extension
8 m long lattice component, of which 8 m are a higher coupling point for the jib. Jib
extension is optional.
z Rooster sheave
Inserted at the boom head of telescopic boom section 5, 1 reeving.
This option is set up for rapid hoists over the boom nose to improve the working efficiency
when the loads are light.
z Air conditioning
Both the drive's cab and operator's cab are all equipped with special air conditioning and
heater for vehicle.
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1.2.3 Boom
Including main boom, jib and extension.
1.2.3.1 Main boom
1 basic boom and 5 telescopic sections.

Boom length: 12.8 m to 57.5 m
L=57.5 m
L=12.8 m
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1.2.3.2 Main boom + 11 m jib (jib section 1)
Fully extended main boom with jib (2 offsets: 0°, 30°)

Boom length: 57.5 m+11 m=68.5 m
Jib S=11 m
Main boom M=57.5 m
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1.2.3.3 Main boom + 18.6 m jib (jib section 1 + jib section 2)
Fully extended main boom with jib (2 offsets: 0°, 30°)

Boom length: 57.5 m+18.6 m=76.1 m
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1.2.3.4 Main boom + 18.6 m jib (jib section 1 + jib section 2) + extension
Fully extended main boom with jib and extension (2 offsets: 0°, 30°)
Boom length: 57.5 m+18.6 m+8 m = 84.1 m
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1.3 Technical data
1.3.1 Dimensions
1.3.1.1 Overall view (Unit: Metric mm)
1.3.1.2 Rope diameter & length
Rope diameter
Type of rope Rope length (m)
(mm)
Main hoist rope φ19 300
Auxiliary hoist rope φ19 190
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1.3.2 Lifting capacity
Max. rated lifting Max. load Max. load Max. load moment of 84.1 m
capacity (kg) moment of 12.8 m moment of 57.5 m boom (kN.M)
main boom (kN.M) main boom (kN.M)
130000 4860 2080 743.1
1.3.3 Weights
1.3.3.1 Axle loads
- Crane in driving position

- For driving condition, please refer to Chapter 3.3.4.
Axle 1 2 3 4 5 Total
weight
Weight (kg) 9950 9950 12485 12485 9800 54670
1.3.3.2 Lifting equipment
Max. reeving
Load (t) Pulleys Weight (kg)
numbers
130 8 16 1410
90 7 14 830
55 4 8 540
20 1 3 300
7 0 1 200
1.3.3.3 Max. support strength per outrigger
Front (kN) Rear (kN)
950 1100
1.3.4 Speeds
1.3.4.1 Driving speeds (km/h)
Road 1 2 3 4 5 6 7 8 9 10 11
gear
Speed 4.7 6.1 7.8 10.1 12.8 16.4 21.6 27.8 35.8 45.9 58.3
Road 12 R Maximum gradeability

gear
Speed 74 5.1 40%
Minimum braking distance: ≤ 10 m (Driving speed = 30 km/h)

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1.3.4.2 Crane speeds
The drives on crane superstructure can realize infinitely variable control.
Drives Speeds Remarks

Max. hoist rope speed 115 m / min Drum 4th layer
(main winch)
Max. hoist rope speed 70 m / min Drum 3rd layer
(auxiliary winch)
Slewing mechanism 0-1.5 r / min
Approx. 80 sec. -1.5°
Derricking mechanism
to 82° boom position
Approx. 600 sec. for
Suppose engine running at Max.
Telescoping mechanism main boom length
theoretical RPM
from 12.8 m – 57.5m
1.3.5 Energy consumption and environmental protection
1.3.5.1 Engine
Limits for exhaust pollutants and

Engine Oil consumption
smoke
70 L/100 km (lowest oil
Chassis GB3847-2005 GB17691-2005 Tier 3
consumption)
Superstructure GB3847-2005 GB17691-2005 Tier 2
1.3.5.2 Workplace-related emission value
Sound pressure level at Stationary noise (db)
nominal RPM Left ear Right ear
Driver's cab, driver's side 90 90
Driver's cab, passenger’s 90

side
Operator's cab 90 90
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1.3.6 Lifting height chart
1.3.6.1 Main boom
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1.3.6.2 Main boom + 11 m jib
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1.3.6.3 Main boom + 18.6 m jib (jib section 1 + jib section 2)
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1.3.6.4 Main boom + 18.6 m jib (jib section 1 + jib section 2) + 8 m extension
Note:
(1) The outriggers are completely extended and all counterweight plates are installed;
(2) All above charts do not include deflection of boom and jib.
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1.3.7 Lifting capacity table
1.3.7.1 Notes for the lifting capacity table
1) The lifting capacity table indicates the maximum load which can be lifted by this crane in
different working conditions provided it is level and standing on firm and load-bearing
ground. The unit of the rated lifting capacity is metric ton;
2) The values as given in the tables include the mass of the hook and slings;
3) The values given in the lifting capacity table are suitable to 360° full range;
4) The working radius in lifting capacity table refers to the level distance from hook center
to slewing center. Its unit is metric meter;
5) The boom extension length must be equivalent to the value given in the lifting capacity
table. The numbers, I, II, III, IV and V, in the table indicate the corresponding telescopic
section (highest number = furthest telescopic section). The numbers, 1, 2, 3 and 4,
display the boom status of the telescope. 1 represents the telescope extends 0%,
2 represents the telescope extends 46%, 3 represents the telescope extends 92% and 4
represents the telescope extends 100%;
6) If the actual working radius is between two adjacent values given in the lifting capacity
table, the bigger one should be referred to;
7) The working radius of the crane must be strictly limited in the range of the lifting capacity
table. If the working radius is above or below the range, the crane will topple over even
without load;
8) Before operating the crane, the outriggers must be extended according to the lifting
capacity table and secured;
9) Before the lifting work, all wheels must be away from the ground;
10) Before lifting work, the crane must be leveled with the support control units. And checks
must be done during crane operation to ensure the crane in level position;
11) The rated lifting capacities for the rooster sheave are equivalent to the rated lifting
capacities for the telescopic boom to a maximum of 7 ton. If the rated lifting capacity for
the telescopic boom checked from the table is above 7 ton, the maximum lifting capacity
is also 7 ton;
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12) The rated lifting capacity for the telescopic boom is the value without jib assembled.
When using the boom with jib assembled, 2400 kg plus the mass of hook block and
slings should be subtracted from the rated lifting capacities;
13) The telescoping percentage of boom under any working conditions should be referred
to the lifting capacity table;
14) Load moment limiter is just a vital equipment to ensure safe operation of the crane. But
consequences for not paying attention to the safe operation are also rest with the
crane operator.
15) Never telescope with load.
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1.3.7.2 Lifting capacity table
Table 1 - 1 Unit: Metric ton
Working Main boom (m)

radius 0 t counterweight, outriggers completely extended, over full range
(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 115.0 95.0
3.5 105.0 95.0 85.0 70.0
4.0 95.0 90.0 80.0 64.0 55.0
4.5 88.0 80.0 70.0 59.0 55.0 45.0
5.0 81.0 70.0 62.0 56.3 50.0 43.5
6.0 54.5 55.6 48.4 48.0 45.8 41.0 35.0
7.0 39.0 38.7 38.3 38.0 36.5 34.5 31.0 26.0
8.0 29.0 29.0 28.0 28.0 27.6 26.6 25.0 25.0 22.5
9.0 22.0 22.0 21.0 21.0 21.0 21.0 21.0 21.0 19.5 18.0
10.0 18.0 18.6 17.8 18.2 20.0 20.3 19.7 19.8 16.0 15.5 15.0
12.0 12.6 11.7 12.8 13.2 14.7 13.6 13.7 12.0 12.0 12.5 11.0
14.0 8.5 7.7 8.6 9.6 10.6 9.8 9.8 9.0 9.0 9.5 9.5
16.0 5.0 5.9 6.8 7.8 7.2 7.2 6.6 7.0 7.0 7.2
18.0 3.1 4.0 4.9 5.8 5.2 5.2 5.0 5.2 5.6 5.8
20.0 2.5 3.4 4.3 3.7 3.7 3.8 4.2 4.5 4.5
22.0 1.4 2.3 3.1 2.5 2.6 2.7 3.2 3.5 3.5
24.0 1.4 2.2 1.6 1.7 1.9 2.3 2.5 2.6
26.0 1.2 1.6 2.0 2.0
28.0 1.4 1.4
30.0
32.0
34.0
36.0
38.0
40.0
42.0
44.0
46.0
48.0
50.0
52.0
Reeving 16 14 13 10 10 7 6 4 4 3 3 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
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(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 117.0 95.0
3.5 110.0 95.0 85.0 70.0
4.0 100.0 90.0 80.0 64.0 55.0
4.5 95.0 81.0 75.0 59.0 55.0 45.0
5.0 86.0 75.5 70.0 57.5 50.0 45.0
6.0 70.0 65.0 60.0 53.0 48.5 41.0 35.0
7.0 52.0 50.0 46.0 46.0 45.0 38.0 33.0 26.0
8.0 40.0 39.0 37.0 37.0 37.0 36.5 31.5 25.5 23.0
9.0 31.0 31.0 31.4 32.5 33.0 35.0 30.0 25.0 22.0 18.0
10.0 26.0 26.0 25.5 26.0 28.0 28.2 28.6 23.0 20.0 16.0 15.0
12.0 18.2 17.5 18.4 20.0 21.0 20.0 20.0 18.0 15.0 14.0 12.0
14.0 14.3 12.5 14.0 14.8 16.0 15.4 15.4 15.0 14.0 12.5 11.0
16.0 10.0 10.7 11.6 12.5 12.0 12.0 12.3 12.0 11.5 10.0
18.0 7.5 8.3 9.1 10.0 9.5 9.5 9.8 10.0 10.0 9.0
20.0 6.5 7.3 8.1 7.6 7.6 7.9 8.3 8.7 8.0
22.0 5.0 5.8 6.6 6.1 6.1 6.4 6.8 7.2 7.0
24.0 4.5 5.4 4.8 4.8 5.1 5.5 6.0 6.0
26.0 3.5 4.2 3.8 3.8 4.1 4.5 4.9 5.0
28.0 3.2 2.9 2.9 3.2 3.6 4.0 4.1
30.0 2.2 2.2 2.2 2.5 2.9 3.2 3.3
32.0 1.6 1.6 1.9 2.3 2.6 2.7
34.0 1.1 1.3 1.7 2.0 2.1
36.0 1.2 1.5 1.6
38.0 1.1 1.2
40.0
42.0
44.0
46.0
48.0
50.0
52.0
Reeving 16 14 13 10 10 7 6 5 4 3 3 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
1 - 25
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 120.0 95.0
3.5 115.0 95.0 85.0 70.0
4.0 105.0 90.0 80.0 65.0 55.0
4.5 100.0 83.0 75.0 60.0 55.0 45.0
5.0 92.0 76.0 70.0 58.5 51.0 45.0
6.0 78.0 68.0 63.0 54.0 50.0 42.0 35.0
7.0 66.0 60.0 57.0 50.0 46.5 40.0 33.5 26.0
8.0 55.0 55.0 55.0 45.5 44.0 37.0 32.5 25.5 23.0
9.0 44.0 44.6 43.7 41.8 40.0 35.0 31.0 25.0 22.0 18.0
10.0 37.0 36.8 36.0 36.0 35.0 32.8 30.0 24.0 20.0 16.5 15.0
12.0 26.6 26.0 27.8 28.5 29.7 25.0 23.0 19.0 15.2 14.0 12.0
14.0 20.0 20.0 21.3 22.1 22.5 21.0 20.0 17.2 14.0 13.0 11.0
16.0 16.0 16.0 17.2 17.7 17.0 17.0 16.0 12.8 12.0 10.5
18.0 12.5 13.5 13.7 14.4 14.8 14.8 14.0 12.0 11.0 9.5
20.0 11.0 11.0 12.0 12.2 12.1 12.3 11.5 10.5 9.0
22.0 9.0 9.0 10.0 10.1 10.0 10.2 10.0 10.0 8.5
24.0 7.5 8.3 8.4 8.3 9.0 9.0 9.0 8.0
26.0 6.2 7.0 7.0 7.0 7.6 8.0 8.0 7.5
28.0 6.0 6.0 6.0 6.5 7.0 7.0 7.0
30.0 5.0 5.0 5.3 5.0 6.0 6.0 6.2
32.0 4.0 4.5 4.5 5.0 5.0 5.6
34.0 3.3 3.8 4.0 4.0 4.2 4.8
36.0 3.0 3.0 3.2 3.6 4.2
38.0 2.0 2.5 2.6 3.0 3.6
40.0 1.7 2.2 2.5 3.1
42.0 1.2 1.6 2.0 2.6
44.0 1.2 1.6 2.1
46.0 1.0 1.3 1.7
48.0 1.0 1.2
50.0 1.0
52.0
Reeving 16 14 13 10 10 7 6 5 4 3 3 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
1 - 26
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 125.0 95.0
3.5 117.0 95.0 85.0 70.0
4.0 110.0 90.0 83.0 65.0 55.0
4.5 100.0 85.0 78.0 60.0 55.0 45.0
5.0 96.0 83.5 75.0 59.0 51.0 45.0
6.0 80.0 78.0 68.0 55.0 50.0 42.0 35.0
7.0 66.0 65.0 60.0 51.5 46.5 40.0 33.5 26.0
8.0 56.0 55.0 55.0 46.8 44.0 37.0 32.5 25.5 23.0
9.0 48.0 48.0 48.0 42.8 40.0 35.0 31.0 25.0 22.0 18.0
10.0 43.0 43.0 43.0 38.2 35.0 33.8 30.0 24.0 20.0 16.5 15.0
12.0 32.0 31.5 32.0 33.0 30.0 25.0 23.0 19.0 15.2 14.0 12.5
14.0 24.5 24.0 25.0 25.0 26.2 21.8 20.4 17.2 14.0 13.0 11.0
16.0 19.0 20.0 20.5 20.4 20.0 18.0 16.0 12.8 12.0 10.5
18.0 15.0 16.2 16.0 17.2 17.0 16.0 14.5 12.0 11.0 10.0
20.0 13.0 13.0 13.5 14.3 14.0 13.0 11.5 10.5 9.5
22.0 10.5 11.0 11.0 11.8 12.0 11.8 10.5 10.0 8.5
24.0 9.0 9.7 10.0 10.0 10.0 9.5 9.0 8.0
26.0 8.0 8.0 9.3 8.7 8.8 9.0 8.0 7.7
28.0 6.4 8.0 7.8 7.5 8.0 7.5 7.0
30.0 5.5 6.7 6.0 6.2 6.7 7.0 6.5
32.0 5.6 5.3 5.5 6.0 6.0 6.2
34.0 4.6 4.6 4.5 5.5 5.2 5.4
36.0 3.8 3.8 5.0 4.7 5.0
38.0 2.5 3.1 4.5 4.0 4.0
40.0 2.6 3.0 3.5 3.6
42.0 2.0 2.7 3.0 3.0
44.0 2.4 2.5 2.5
46.0 2.0 2.0 2.0
48.0 1.6 1.7
50.0 1.4
52.0 1.2
Reeving 16 14 13 10 10 7 6 5 4 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
1 - 27
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 130.0 105.0
3.5 125.0 102.0 90.0
4.0 115.0 98.0 90.0 75.0
4.5 105.0 91.0 85.0 72.0 60.0
5.0 97.0 85.0 77.0 68.5 56.0 48.0
6.0 81.0 78.0 69.5 62.0 54.0 45.0 38.0
7.0 66.0 66.0 63.0 56.5 50.5 43.0 37.0 27.0
8.0 56.0 56.0 57.0 52.0 47.4 40.0 35.0 26.5 23.0
9.0 48.0 48.0 48.0 48.0 45.8 37.0 32.5 26.0 22.0 18.5
10.0 43.0 43.0 43.0 43.0 41.0 34.0 30.0 25.0 20.0 16.5 15.0
12.0 38.0 38.6 38.5 35.8 30.0 25.0 23.0 19.0 15.2 14.0 12.5
14.0 30.0 29.0 30.7 31.6 26.2 22.8 20.0 18.0 14.5 13.0 11.0
16.0 23.0 24.7 24.5 24.0 20.0 18.0 16.0 14.0 12.0 10.5
18.0 19.0 19.3 20.0 20.2 18.0 16.0 14.5 13.0 11.0 10.0
20.0 16.0 16.7 17.5 16.0 14.0 13.0 12.0 10.5 9.5
22.0 13.3 14.0 14.8 14.0 12.8 11.8 10.8 10.0 9.0
24.0 11.4 12.6 12.4 11.5 10.5 9.8 9.0 8.5
26.0 10.0 11.0 11.0 10.0 9.5 9.0 8.0 8.0
28.0 9.0 10.0 9.0 8.5 8.2 7.6 7.3
30.0 8.0 8.6 8.0 8.0 7.6 7.0 6.8
32.0 7.5 7.0 7.0 7.0 6.5 6.2
34.0 6.6 6.5 6.0 6.5 6.0 5.8
36.0 5.5 5.4 5.8 5.6 5.4
38.0 5.0 5.0 5.0 5.0
40.0 4.4 4.5 4.8 4.5
42.0 3.5 4.0 4.2 4.3
44.0 3.4 3.7 3.8
46.0 3.2 3.3
48.0 3.0 3.0
50.0 2.8
52.0 2.5
Reeving 16 14 13 10 8 7 6 5 4 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
1 - 28
0063152-000-01-20Y

radius 10 t counterweight, outriggers intermediately extended, over full range
(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 90.0 80.0 75.0
3.5 85.0 75.0 70.0 65.0
4.0 75.0 70.0 65.0 60.0 55.0
4.5 60.0 55.0 52.0 50.0 45.0 40.0
5.0 50.0 45.0 43.0 42.0 40.0 36.0
6.0 35.0 33.0 31.0 30.5 30.0 30.0 29.0
7.0 25.0 24.0 22.0 22.0 22.5 23.0 23.0 23.0
8.0 20.0 20.0 18.0 18.5 19.0 20.0 19.5 19.0 19.0
9.0 15.0 15.0 14.5 15.0 16.0 17.0 16.5 16.5 16.0 16.5
10.0 12.0 12.5 12.0 13.0 13.5 14.5 14.0 14.0 14.0 14.5 14.0
12.0 10.0 9.0 9.5 10.0 10.5 10.0 10.5 10.5 10.5 11.0 11.0
14.0 7.0 6.0 7.0 7.5 8.0 7.5 7.5 8.0 8.2 8.5 8.5
16.0 4.0 5.0 5.5 6.0 6.0 5.6 6.0 6.5 6.7 6.5
18.0 2.5 3.0 4.0 5.0 4.3 4.2 4.5 5.0 5.5 5.5
20.0 2.2 3.0 3.5 3.2 3.0 3.4 3.8 4.2 4.3
22.0 1.3 1.7 2.5 2.0 2.2 2.5 2.8 3.2 3.4
24.0 1.2 2.0 1.5 1.5 1.7 2.0 2.5 2.5
26.0 1.2 1.0 1.2 1.5 1.8 2.0
28.0 1.0 1.3 1.4
30.0
32.0
34.0
36.0
38.0
40.0
42.0
44.0
46.0
48.0
50.0
52.0
Reeving 14 13 12 10 8 7 5 4 3 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 90 t 55 t 20 t
1 - 29
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 90.0 85.0 80.0
3.5 85.0 80.0 78.0 75.0
4.0 80.0 78.0 75.0 70.0 55.0
4.5 75.0 74.0 72.0 65.0 55.0 45.0
5.0 70.0 65.0 65.0 60.0 50.0 42.0
6.0 52.0 50.0 48.0 46.0 45.0 40.0 35.0
7.0 40.0 40.0 38.0 38.0 37.0 37.0 32.0 28.0
8.0 33.0 33.0 31.0 31.0 31.5 31.5 28.0 26.0 25.0
9.0 27.0 27.0 26.0 26.0 26.5 27.0 26.0 23.0 20.0 18.0
10.0 22.0 23.0 22.0 22.2 22.8 23.0 22.0 20.0 18.0 17.0 15.0
12.0 17.0 16.0 16.0 17.0 17.5 17.0 16.2 16.5 16.5 14.0 12.0
14.0 12.0 11.5 12.0 13.0 13.5 13.0 13.0 13.5 13.5 12.0 11.0
16.0 9.0 9.5 10.0 11.0 10.5 10.3 10.5 11.0 11.0 10.0
18.0 7.0 7.5 8.0 8.5 8.0 7.8 8.2 9.0 9.5 9.5
20.0 6.0 6.3 6.5 6.5 6.5 7.0 7.5 7.5 8.0
22.0 4.5 5.2 6.0 5.5 5.6 6.0 6.3 6.5 6.5
24.0 4.0 5.0 4.5 4.5 5.0 5.2 5.5 5.5
26.0 3.0 3.5 3.0 3.5 4.0 4.2 4.8 4.8
28.0 3.0 2.5 3.0 3.0 3.5 4.0 4.0
30.0 2.5 2.0 2.3 2.5 2.8 3.0 3.2
32.0 1.5 1.5 2.0 2.0 2.5 2.8
34.0 1.0 1.2 1.5 1.5 2.2 2.2
36.0 1.0 1.2 1.5 1.5
38.0 1.2 1.2
40.0 1.0 1.0
42.0
44.0
46.0
48.0
50.0
52.0
Reeving 14 13 12 10 8 7 5 4 4 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 90 t 55 t 20 t
1 - 30
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 90.0 85.0 80.0
3.5 85.0 83.0 78.0 75.0
4.0 80.0 80.0 75.0 70.0 55.0
4.5 75.0 75.0 72.0 65.0 55.0 45.0
5.0 70.0 65.0 65.0 62.0 53.0 43.0
6.0 60.0 58.0 56.0 56.0 50.0 42.0 35.0
7.0 45.0 43.5 43.0 42.0 42.0 40.0 33.0 28.0
8.0 40.0 38.0 37.0 37.0 37.0 35.0 31.0 27.0 25.0
9.0 32.0 32.0 31.0 31.0 31.5 31.0 30.0 25.0 24.0 18.0
10.0 26.0 27.0 26.5 27.0 27.5 27.0 26.0 23.0 22.0 17.0 15.0
12.0 20.0 19.0 20.0 20.3 20.5 19.5 19.0 19.0 16.5 14.0 12.0
14.0 15.0 14.6 15.5 16.0 16.5 16.0 16.0 16.5 16.0 13.5 11.0
16.0 11.5 12.0 12.0 12.5 13.0 12.5 13.0 13.0 13.0 10.0
18.0 8.5 9.0 9.5 9.7 10.5 10.4 10.6 11.0 11.0 9.5
20.0 7.5 7.6 7.8 8.5 8.2 8.5 9.0 9.0 9.0
22.0 6.0 6.5 6.8 7.0 7.0 7.5 7.4 7.6 7.8
24.0 4.5 5.0 5.5 5.6 5.8 6.0 6.5 6.5
26.0 3.5 4.0 4.5 4.5 4.7 5.0 5.4 5.5
28.0 3.0 3.5 3.6 3.8 4.0 4.2 4.5
30.0 2.5 2.8 3.0 3.2 3.3 3.5 3.7
32.0 2.2 2.2 2.5 2.7 3.0 3.2
34.0 1.8 1.8 2.0 2.2 2.5 2.5
36.0 1.5 1.8 2.0 2.2 2.2
38.0 1.5 1.5 1.8 2.0
40.0 1.0 1.3 1.6 1.6
42.0 1.0 1.3 1.4
44.0 1.0 1.2
46.0
48.0
50.0
52.0
Reeving 14 13 12 10 8 7 5 4 4 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 90 t 55 t 20 t
1 - 31
0063152-000-01-20Y

(m) 12.8 16.9 21.0 25.1 29.2 33.3 37.4 41.5 45.6 49.7 53.8 57.5
3.0 110.0 90.0 85.0
3.5 100.0 90.0 80.0 75.0
4.0 90.0 85.0 78.0 70.0 55.0
4.5 80.0 80.0 75.0 65.0 55.0 45.0
5.0 75.0 73.0 72.0 62.0 53.0 45.0
6.0 68.0 66.0 63.0 58.0 51.0 42.0 35.0
7.0 53.0 52.0 50.0 50.0 45.0 40.0 33.0 28.0
8.0 42.0 41.0 40.5 41.0 38.0 36.0 31.0 27.0 25.0
9.0 34.0 34.0 33.0 33.5 33.5 33.8 30.0 26.0 24.0 18.5
10.0 28.0 29.0 27.0 28.0 28.5 28.5 28.0 24.0 22.0 17.0 15.0
12.0 21.0 20.0 21.0 22.0 22.0 21.0 21.0 19.0 16.5 14.0 12.5
14.0 16.0 15.0 16.0 17.0 17.2 17.0 16.5 16.8 16.0 13.5 11.0
16.0 12.0 12.5 13.0 14.0 13.5 13.5 14.0 14.0 13.0 10.5
18.0 9.0 9.5 10.0 10.5 10.5 10.5 11.0 11.5 11.8 10.0
20.0 7.8 8.0 8.5 9.0 8.8 9.0 9.5 10.0 9.5
22.0 6.5 7.0 7.5 8.0 7.5 7.8 8.0 8.5 8.5
24.0 6.0 6.3 7.0 6.5 6.8 7.0 7.5 8.0
26.0 4.5 4.8 5.2 5.0 5.2 5.5 6.0 6.5
28.0 3.5 4.0 4.2 4.5 5.0 5.4 6.0
30.0 3.0 3.2 3.5 3.8 4.2 4.5 5.0
32.0 2.5 3.0 3.2 3.5 4.0 4.5
34.0 2.0 2.5 2.8 3.0 3.5 4.0
36.0 2.0 2.2 2.5 3.0 3.5
38.0 1.5 1.8 2.0 2.5 2.8
40.0 1.5 1.8 2.2 2.5
42.0 1.0 1.7 2.0 2.2
44.0 1.4 1.5 1.8
46.0 1.0 1.3 1.5
48.0 1.0 1.2
50.0
52.0
Reeving 16 14 13 10 8 7 5 4 4 3 2 2
I 1 1 2 2 2 2 3 3 3 3 3 4
II 1 2 2 2 2 2 2 3 3 3 3 4
III 1 1 1 2 2 2 2 2 3 3 3 4
IV 1 1 1 1 2 2 2 2 2 3 3 4
V 1 1 1 1 1 2 2 2 2 2 3 4
Hook 130 t 90 t 55 t 20 t
1 - 32
0063152-000-01-20Y
Table 1-10 Unit: Metric ton
Main boom (m) + jib (m)
24 t counterweight, outriggers intermediately extended, over full range
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
Offset Offset Offset
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 5.8 4.4 3.8 2.0 2.5 1.3
78 5.5 4.3 3.7 1.9 2.4 1.3
76 5.0 4.2 3.6 1.8 2.3 1.2
74 4.5 4.1 3.5 1.7 2.2 1.2
72 4.0 4.0 3.2 1.6 2.0 1.1
70 3.5 3.5 3.0 1.5 1.8 1.1
68 3.0 3.0 2.8 1.4 1.6 1.0
66 2.8 2.5 2.6 1.3 1.4 1.0
64 2.4 2.0 2.3 1.2 1.2 1.0
62 2.0 1.5 2.0 1.1 1.0 0.9
60 1.5 1.2 1.5 1.0
58 1.0 1.0 1.0 0.9
56
54
52
50
Reeving 1 1 1 1 1 1
1 - 33
0063152-000-01-20Y
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 5.8 4.4 3.8 2.1 2.6 1.4
78 5.5 4.3 3.7 2.0 2.5 1.3
76 5.0 4.2 3.6 1.9 2.4 1.3
74 4.8 4.1 3.5 1.8 2.3 1.2
72 4.4 4.0 3.2 1.7 2.2 1.2
70 4.2 3.9 3.0 1.6 2.1 1.1
68 4.0 3.8 2.8 1.5 1.9 1.1
66 3.8 3.5 2.6 1.4 1.8 1.1
64 3.5 3.0 2.4 1.3 1.6 1.0
62 2.5 2.4 2.2 1.2 1.5 1.0
60 2.3 2.2 1.8 1.1 1.3 1.0
58 2.0 1.8 1.5 1.0 1.1 0.9
56 1.6 1.5 1.3 0.9 1.0
54 1.3 1.2 1.2
52 1.0 1.0
50
Reeving 1 1 1 1 1 1
1 - 34
0063152-000-01-20Y
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 6.0 4.5 4.0 2.2 2.7 1.4
78 5.8 4.4 3.8 2.1 2.6 1.3
76 5.4 4.3 3.7 2.0 2.5 1.3
74 5.0 4.2 3.5 1.9 2.4 1.2
72 4.5 4.1 3.2 1.8 2.3 1.2
70 4.3 4.0 3.0 1.8 2.3 1.2
68 4.2 3.9 2.8 1.8 2.2 1.1
66 4.0 3.8 2.7 1.7 2.2 1.1
64 3.8 3.6 2.5 1.7 1.9 1.1
62 3.5 3.2 2.4 1.6 1.8 1.0
60 3.0 2.8 2.2 1.6 1.7 1.0
58 2.6 2.5 2.1 1.6 1.6 1.0
56 2.3 2.0 2.0 1.5 1.3 0.9
54 2.0 1.8 1.8 1.4 1.2
52 1.5 1.3 1.5 1.3 1.0
50 1.2 1.0 1.2 1.0
Reeving 1 1 1 1 1 1
1 - 35
0063152-000-01-20Y
10 t counterweight, outriggers completely extended, over full range
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.5 1.2
80 5.8 4.4 3.9 2.0 2.4 1.2
78 5.5 4.3 3.8 1.9 2.3 1.1
76 5.0 4.2 3.6 1.8 2.2 1.1
74 4.7 4.1 3.5 1.7 2.1 1.1
72 4.5 3.9 3.1 1.6 2.0 1.0
70 4.0 3.5 3.0 1.5 1.9 1.0
68 3.5 3.0 2.8 1.4 1.7 1.0
66 2.8 2.4 2.4 1.3 1.5 0.9
64 2.4 2.0 1.8 1.2 1.2
62 1.8 1.5 1.5 1.1 1.0
60 1.4 1.2 1.2 1.0
58 1.0
56
54
52
50
Reeving 1 1 1 1 1 1
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0063152-000-01-20Y
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 5.8 4.5 4.0 2.1 2.6 1.4
78 5.5 4.3 3.9 2.0 2.5 1.3
76 5.0 4.2 3.8 2.0 2.5 1.3
74 4.8 4.1 3.5 1.9 2.4 1.3
72 4.6 4.0 3.2 1.8 2.3 1.2
70 4.2 3.8 3.0 1.8 2.2 1.2
68 3.8 3.5 2.8 1.8 2.1 1.2
66 3.2 3.0 2.5 1.7 2.0 1.1
64 3.0 2.8 2.3 1.7 1.9 1.1
62 2.8 2.5 2.1 1.6 1.8 1.1
60 2.5 2.3 2.0 1.5 1.7 1.0
58 2.2 2.0 2.0 1.4 1.6 1.0
56 2.0 1.9 1.8 1.3 1.5 0.9
54 1.8 1.6 1.6 1.2 1.2
52 1.5 1.4 1.4 1.1 1.0
50 1.2 1.1 1.1 1.0
Reeving 1 1 1 1 1 1
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0063152-000-01-20Y
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 6.0 4.5 4.0 2.2 2.7 1.4
78 5.8 4.4 3.9 2.1 2.6 1.4
76 5.6 4.3 3.8 2.0 2.6 1.3
74 5.4 4.2 3.5 1.9 2.5 1.3
72 5.2 4.1 3.2 1.9 2.4 1.3
70 5.0 4.0 3.0 1.8 2.3 1.2
68 4.8 3.9 2.8 1.8 2.2 1.2
66 4.6 3.8 2.7 1.7 2.1 1.2
64 4.2 3.7 2.5 1.7 2.0 1.1
62 3.8 3.6 2.4 1.6 1.9 1.1
60 3.6 3.4 2.3 1.6 1.8 1.1
58 3.4 3.0 2.2 1.6 1.7 1.0
56 3.0 2.8 2.1 1.6 1.6 1.0
54 2.8 2.4 2.0 1.5 1.5 0.9
52 2.5 2.0 1.8 1.5 1.4
50 2.0 1.8 1.5 1.3 1.3
45 1.5 1.3 1.2 1.1 1.0
40 1.2 1.1 1.1 1.0
Reeving 1 1 1 1 1 1
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0063152-000-01-20Y
Derrick angle
57.5 m+11 m 57.5 m+18.6 m 57.5 m+26.6 m
(0)
00 300 00 300 00 300
82 6.0 4.5 4.0 2.2 2.7 1.4
80 6.0 4.5 4.0 2.2 2.7 1.4
78 5.8 4.4 3.9 2.1 2.6 1.4
76 5.6 4.3 3.8 2.0 2.6 1.3
74 5.4 4.2 3.5 1.9 2.5 1.3
72 5.2 4.1 3.2 1.9 2.4 1.3
70 5.0 4.0 3.0 1.8 2.3 1.2
68 4.8 3.9 2.8 1.8 2.3 1.2
66 4.6 3.8 2.7 1.7 2.2 1.2
64 4.5 3.7 2.5 1.7 2.0 1.1
62 4.0 3.6 2.4 1.7 1.9 1.1
60 3.8 3.4 2.3 1.6 1.8 1.1
58 3.6 3.2 2.2 1.6 1.7 1.0
56 3.4 3.0 2.1 1.6 1.6 1.0
54 3.0 2.8 2.0 1.5 1.5 1.0
52 2.8 2.5 1.9 1.5 1.4 0.9
50 2.5 2.4 1.6 1.4 1.3
45 2.0 1.8 1.4 1.3 1.2
40 1.5 1.4 1.3 1.2 1.0
35 1.3 1.2 1.2 1.1
30 1.1 1.1
Reeving 1 1 1 1 1 1
1 - 39
Chapter 2 Safety
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2.1 Traffic regulations
The crane is approved for road travel when used in accordance with national and regional
traffic regulations. No person is allowed to stay in operator’s cab during driving. The crane
must be made to comply with the relevant local traffic regulations, before it is driven on public
streets, roads and other places. The weights, axle loads and dimensions specified in the
permits must be maintained.
The technically feasible axle loads may be different from those permitted by local road traffic
regulations. In countries where EEC specifications apply, axle loads greater than 12 t are not
permitted for road and highway traffic.
Danger:
(1) If the axle loads or total weight exceed the permits, any increase in axle load and total
weight reduces braking performance in direction proportion to the excess weight;
(2) Brake lining wear is greater and risk of brake overheating in higher;
(3) The steering system, driving brake, parking brake and reducer will not comply with the
relevant regulations;
(4) Lives of all components such as brakes, axles, rims, suspension cylinders as well as
bearings are shortened;
(5) No person is allowed to stay in operator’s cab during driving.
A hook block may only be transported at the front of driver’s cab if:
a) It has been reeved no more than four times;
b) It has been lashed using the auxiliary rope provided on the front towing coupling.
Danger:
Do not allow the hook block to impair the driver’s field of vision when driving the
crane on public roads!
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2.2 Break-in instructions
The crane should break-in after delivery. Please observe the following specifications:
a) Continuously monitor the temperature and oil pressure indicators while driving!
Warning:
Stop immediately if there are any fault indications!
b) Perform the following checks after the first 50 km and 100 km:
1) Make sure that wheel nuts are tight and do not over-tighten them (maximum
permissible torque is 600 N.m);
2) Check engine water and oil levels;
3) Check transmission, transfer case and drive axle oil levels;
4) Visually inspect engine, transmission device and axles for any leakage or loose
components;
5) Check that drive axles are properly seated;
6) Check that the steering mechanism and suspension devices are properly seated;
7) Check that there are no other loose chassis components;
8) Visually inspect tire condition and inflation.
c) Breaking in the brake linings:
To achieve optimum braking performance, all new brake linings must be broken in
by activating the brakes. Activate the brakes by pumping them at low to medium speed.
Hard braking is not permitted. In general, the break - in distance depends on the type of
vehicle, but a minimum of 500 km is recommended. During this phase, the maximum
brake drum or braking lining temperature may not exceed 2000C. The temperature rise
resulting from each individual braking action should not exceed 15% of maximum.
Danger:
The risk of accident increases when new brake linings are subjected to one or more
braking operations over extended period of time or if the vehicle is forced to a stop by
hard braking from high speed several times. Hard braking and continuous braking are
not permitted!
d) During the initial phase, all components of crane are in break-in state. During the
first 100h, the working load should not be too great and working speed should not be
too high, the maximum lifting capacity should not exceed 80% of the rated one and it is
not permitted to work at maximum speed.
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2.3 Planning crane operation
In addition to a perfectly working crane and a well-trained crew, crane operation planning
is an important principle of safe crane operation.
The crane operator must obtain or receive the necessary information in a timely fashion
before driving to the work site. In particular:
a) Type of crane operation;
b) Work site and travel distance;
c) Route;
d) Height and width clearance measurements;
e) Electric transmission lines (including voltages);
f) Space restrictions at the work site;
g) Movement restrictions caused by buildings;
h) Weight and dimensions of the load(s) to be lifted;
i) Required hoisting height and boom projection;
j) Ground bearing capacity at the work site.
Based on the above information, the crane operator must assemble the equipment required
to operate the crane:
a) Hook block / load hook;
b) Separate lifting accessories;
c) Counterweight;
d) Jib;
e) Underlay materials for support pads.
Warning:
Crane operation may not be possible or improvisation can result if a crane operator does not
have all the required data.
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2.4 General safety technical guidelines
2.4.1 Requirements of the crane operator and conductor
The primary responsibility of crane operator and conductor is to control, operate, adjust the
crane and conduct the operation in a manner that is safe for both himself and others. The
main operating errors, which are made again and again while operating or driving a
crane, are as follows:
a) Slewing too quickly;
b) Quick braking of the load;
c) Diagonal pulling when the load is still on the ground;
d) Loose wire rope formations;
e) Overloading;
f) Crashing into bridges, roofs or high voltage wiring due to insufficient vertical clearance;
g) Unsuitable operation when lifting a load with several cranes at the same time.
About 20% of accidents are caused by improper maintenance:
a) Insufficient lubricating oil, lubricating grease or antifreeze;
b) Broken wire ropes, worn parts;
c) Emergency limit switches or load moment limiter not operating properly;
d) Brake or transmission failure;
e) Hydraulic defects (for example: cracked hoses);
f) Loose bolts.
Danger:
In the interest of both yourself and others, make sure you understand how your
crane operates and familiarize yourself with all the risks associated with the work to be done.
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Qualifications for operator and conductor are as follows:
2.4.1.1 Operator
a) The driver with authorized certificate;
b) The person who has been trained at least half a year under qualified personnel’s
supervision;
c) The maintenance personnel and inspectors who need to operate the crane for a task;
d) Healthy and agile;
e) Eyesight (remedied eyesight included) is above 0.7, no color blindness;
f) Hearing is qualified;
g) Has the ability to estimate and monitor load is enough;
h) The operator must be familiar with the operating instructions for the crane, and know the
working principle, structural performance, functions and adjusting methods for the safety
devices, as well as master the operation essentials and maintenance skills;
i) Crane operator and conductor should be familiar with safety rules, safety signals and
symbols;
j) Be qualified with the work in hearing, eyesight and reaction ability; have the requisite
physical to operate the crane safely; and has the ability to estimate distance, height and
clearance correctly;
k) Know how to administer first aid and know how to use a fire extinguisher; know how
to survive in an emergency.
Make sure that only the personnel who are qualified and authorized are allowed to operate
the crane.
Danger:
(1) Operator should check brakes, hook, wire rope and safety devices before operation. If
there is something abnormal, fix it as soon as possible;
(2) The operator must focus his attention on his work during operation and is forbidden
to chat with others. Generally speaking, operator can only follow the signal sent out
by appointed persons. However, for a stop signal, the operator should obey it at all times,
no matter who send it out. He should refuse to follow signal which violates operation
regulations. Stop the crane immediately if somebody is found climbing the crane;
(3) Operator who is in low spirits or poor health is not allowed to operate the crane. Prohibit
drinking and driving.
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2.4.1.2 Rigger
During operation of the machine, the rigger is responsible for ensuring that the load is
slung or released safely and carefully and decides which loading equipment and
lifting accessories are to be used in accordance with work plan. Rigger is also responsible for
conducting safe operation of the crane.
A qualified rigger should meet the following criteria:
a) With crane operation certificate;
b) Be qualified with the work in hearing, eyesight and reactivity;
c) Have the requisite physical strength to carry the loading equipment and
lifting accessories;
d) Be able to estimate the load mass, balance the load and judge the distance, height and
clearance correctly;
e) Have been trained in the skill of handling load;
f) Be able to choose the proper loading equipment and lifting accessories according
to conditions of the load;
g) Have been trained in hand signals for operation and is familiar to use them;
h) Be able to safely use audio equipment (such as interphone) to send out oral order
exactly and clearly;
i) Be capable of conducting the operating of crane to move the load safely;
j) Make sure that only authorized personnel are allowed to carry out work.
2.4.1.3 Signal person
The signal person is to transfer signal from the rigger to operator. He can substitute for the
rigger to do conducting and rigging work, but such work can only be done by one
person at any time.
A qualified signal person should meet the following criteria:
a) Be qualified with the work in hearing, eyesight and reactivity;
b) Be able to estimate the distance, height and clearance correctly;
c) Have been trained in hand signals for operating and is familiar to use them;
d) Be able to safely use audio equipment (such as interphone) to send out oral order
exactly and clearly;
e) Be capable of conducting crane operation to move the load safely;
f) Make sure that only authorized personnel are allowed to carry out work.
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2.4.2 Selecting an operating site
It is very important to choose an appropriate location for crane operation in order to minimize
safety risks. When selecting the placement location of the crane, observe the following:
a) The operation of the crane can be carried out within the necessary radius (working
radius and counterweight slewing radius);
b) Support the crane and other things only on ground with sufficient load bearing capacity.
2.4.2.1 Slopes and ditches
The crane may not be set up too close to slopes or ditches. Maintain adequate safety
clearances in accordance with the type of soil. The formula for calculating the safety
clearance is as following:
For non-cohesive and soft cohesive

ground:
A2=2T
For stiff or semi-solid cohesive ground:
A1=T
T refers to the depth of ditch.
Danger:
If the safety distance can not be maintained, fill and level up the slope and ditch. Otherwise
the crane can topple over!
2.4.2.2 Permissible ground pressure of outrigger
When the crane is supported, the outriggers transmit significant forces to the ground. In
certain cases, a single outrigger has to transmit almost the entire weight of the crane, plus
the load weight, to the ground.
The ground must be able to safely absorb this pressure every time. If the outrigger pad area
is inadequate, then it must be supported from below according to the load bearing capacity of
the ground. The required support area can be calculated as follows:
Support area = crane support force / load bearing capacity of the ground
Warning:
Even though the crane is supported by several outriggers together, the ground
pressure of outrigger should be calculated from the total weight of crane on one outrigger.
The maximum pressure on the front and rear outriggers will not exceed the value referred in
Section 1.3.3.
02 - 7
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Permissible ground pressure is shown in the following table:
Soil type Permissible ground

pressure (kg / cm2)
A Back-filled, not naturally compacted ground 0-1
Natural, clearly undisturbed ground:
1. Mud, peat, marshy soil 0
2. Non-cohesive ground, sufficient compactly layered soil

Fine to medium grained sand 1.5
Coarse-grained sand to gravel 2.0
3. Cohesive ground:
B Sludgy
0
Soft
0.4
Firm
1.0
Semi-compact
2.0
Hard
4.0
4. Rock with few fissures, in healthy, unweathered condition and
in a favorable location:
15
In cohesive layer order
In massive or column-style shape 30
Artificially compacted ground:
1. Asphalt 5 -15
C
2. Concrete 50 - 250
Concrete group B I
350 - 550
Concrete group B II
If there is any doubt about the load bearing capacity of the ground at the placement site, soil
tests should be carried out, for example with a penetrometer.
Caution:
Only strong materials may be used for the outrigger pad bases; for example properly
dimensioned wooden timbers. In order to ensure that pressure is evenly distributed over the
base surface, the outrigger pads must be positioned in the center of the support base.
02 - 8
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2.4.3 Supporting
a) Before operation, all the wheels must be away from the ground;
b) Before extending the vertical outriggers, extend the horizontal outriggers to the specified
positions;
c) All the outriggers must be extended according to the data in the lifting capacity table and
secured by pins;
d) Before operation, the crane must be leveled. Under any working conditions, the
inclination angle of the crane can not be more than 0.6°.
Danger:
If the crane is positioned at an incline, and if the boom is turned towards the slope, then the
radius is increased as a result. It is possible that the crane can topple over in extreme cases.
After the crane is supported, check the following safety measures:
02 - 9
1145-000-02-20Y
a) The placement location has been selected in such a way that the crane can be operated
with the least possible radius;
b) The load bearing capacity of the ground is adequate;
c) There is sufficient distance to ditches and slopes;
d) All outriggers have been extended to their specified positions;
e) The outriggers are secured with pins;
f) The outrigger pads are secured;
g) The crane is aligned horizontally;
h) The axles are relieved, which means the tires do not touch the ground;
i) It has been ensured that there are no live electrical wires within the working range of the
crane;
j) There are no obstacles which will hinder the required crane movements.
2.4.4 Working conditions
a) Pay attention to the ambient temperature in the work site. The suitable temperature
range is -20℃ - + 40℃. Excessive high or low temperature will damage the
components of crane;
b) If wind speed is higher than the maximum permissible wind speed (13.8m/s, grade 6) for
the crane operation, it is prohibited to lift a load;
c) In case of thunderstorms, stop working on the crane immediately and telescope the
boom in and bring it into driving condition.
Danger:
Operate the crane according to the above instructions, otherwise accidents may occur!
02 - 10
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With the following table, the wind force and wind speed can be estimated correctly:
Wind force Wind speed
Effect of the wind on the land
Beaufort Description m/s km/h
0 Calm 0 - 0.2 0 - 0.9 No wind, smoke rises vertically
Wind direction shown by smoke drift but not
1 Light air 0.3 - 1.5 1-5
by wind vanes
Light Wind felt on face, leaves rustle, vanes moved
2 1.6 - 3.3 6 - 11
breeze by wind
Gentle Leaves and small twigs in constant motion,
3 3.4 - 5.4 12 - 19
breeze wind extends light flag
Moderate Raise dust, loose paper, small branches
4 5.5 - 7.9 20 - 28
breeze moved
Fresh Small trees in leaf begin to sway, crested
5 8 - 10.7 29 - 38
breeze wavelets on inland water
Strong Large branches in motion; difficult to use
6 10.8 - 13.8 39 - 49
wind umbrellas, whistling heard in telegraph wires
Whole trees in motion, difficult to walk against
7 Near gale 13.9 - 17 50 - 61
the wind
8 Gale 17.2 - 20.7 62 - 74 Breaks twigs off trees, impedes progress
Slight structural damage (roof tiles and
9 Strong gale 20.8 - 24.5 75 - 88
chimney covers, etc. blown off)
10 Storm 24.6 - 28.3 89 - 102 Trees uprooted, considerable damage occurs
Violent
11 28.4 - 32.6 103 -117 Widespread damage
storm
12 Hurricane 32.7 - 36.9 118 -133 Severe devastation
d) Strong electromagnetic fields are likely to be present if the construction site is close to a
transmitter. Under this condition, consult a high frequency specialist or contact with the
local franchiser or the manufacturer.
Danger:
Electromagnetic fields can pose direct or indirect danger to persons,

equipment and objects, for example, effect on human organs due to radiation and
spark or electric arc formation.
In order to minimize the danger due to high frequency radiation, operator should operate
the crane according to the following instructions:
1) Every crane must be totally grounded. Check visually or with a simple tester
to ensure that ladder, cab and wire rope are grounded;
2) All personnel working on the crane or with large metal objects must protect
themselves from burns by wearing non-conductive synthetic gloves and suitable
clothing while working;
3) There is no need to panic if you feel your hand warm up. Always work under
the assumption that the respective workpiece, structural steel member or support is
hot;
4) The temperature of objects affected by high frequency radiation depends on their

size. Cranes, carriers and coverings, for example, are hotter;
5) Contact with other crane loads is not permitted when operating the crane.
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1145-000-02-20Y
Otherwise, electric arc may occur and the wire rope will be damaged. At this time,
check the wire rope immediately.
6) An insulator is required at all times between the crane load hook and loading
equipment. Do not touch the wire rope above the insulator;
Insulator
Insulator Insulator
7) Loads that are attached to the crane may not be touched by any unprotected
parts of the body after the load has been lifted or set down;
8) Do not work with a bare upper torso or in short pants, this is prohibited;
9) To minimize absorption of high-frequency radiation, larger loads should be

transported horizontally if possible;
10) Loads must be grounded, or additional insulation used (rubber material between
the object and gloves) when manual work is required;
11) Use a suitable measuring instrument to check the temperature of the object. If, for
example 500V can be measured on a tool at a distance of 1cm to 2cm, then the tool
may not be touched with bare hands;
12) To avoid secondary accidents, use a seat belt when working on structures that are
high off the ground;
13) Handling explosive matter (such as refueling) may only be done at least 6m away
from the place where sparks could form due to handling of larger metal parts.
Use only conductive rubber hoses to refuel;
14) Any accidents and unexpected events must immediately be reported to the local
construction supervisor and safety engineer.
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2.4.5 Points for attention
Before beginning any work, the crane operator must make sure that the crane is in
safe operating condition. All safety devices, such as load moment limiter, hoisting limit switch,
lowering limit switch, brakes, etc., are in good working order.
The load moment limiter must be adjusted according to the current crane configuration. The
loads given in the lifting capacity table may not be exceeded. The loading equipment, load
carriers and ropes must be in accordance with specified requirements. The weight of the
hook and loading equipment must be subtracted from the load given in the lifting capacity
table.
The counterweight required depends on the weight of the load to be lifted and the boom
radius required for operation. The deciding factor for the selection of the counterweight is the
data in the corresponding lifting capacity table.
Danger:
The crane may topple over if the counterweight is not installed according to the lifting
capacity table!
Danger:
When lifting a load, reeving of wire rope should be in accordance with the data in lifting
capacity table. Otherwise the wire rope may break off and the winch reducer and motor may
be damaged.
Pay special attention to the following items:
a) No person is allowed to stand under the boom during operation;
b) No person is allowed to stand on slewing table;
c) No standing within slewing radius;
d) Prohibit lifting a load without outriggers;
e) The inclination angle of the crane can not be more than 0.6° during operation;
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f) Never allow people to stand beneath swaying loads;
g) Never carry people on the load or on lifting equipment;
h) Prohibit overloading and do not pull load at an angle. Forbid lifting staggered load;
i) Prohibit lifting load buried in ground or frozen on the ground;
j) It is forbidden to drive with a load;
k) It is forbidden to drive with movable counterweight;
l) It is forbidden to telescope the boom with a load;
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1145-000-02-20Y
m) Under any conditions, wire rope on the winding drum is not allowed to be less than 3
windings;
n) Never adjust the brake of hoist mechanism during lifting a load;
o) The operator is not permitted to leave the operator’s cab when the load is suspended in
the air;
p) When working in the vicinity of power cables, a sufficient safety clearance must be
maintained if the power is not cut off or the hazardous area is not covered or fenced off;
Minimum safe
Rated voltage (kV)
distance (m)
＜1 1
1 - 110 3
110 - 220 4
220 - 380 5
If rated voltage is unknown 5
If, despite all precautions having been taken, a flashover occurs, carry out the following
procedure:
1) Keep calm;
2) Do not leave the cab;
3) Warn those around the crane not to move and not to touch the crane;
4) Move the boom away from the danger area.
q) The operation should be stable and gentle. Do not carry out any jerky movements with
the joysticks; avoid any sudden acceleration or braking or conversion operation;
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r) Checks on the crane should be carried out from time to time during operation. Once
there is any abnormity, find out the reasons and fix them;
s) When the actual lifting load reaches 90% of the rated one, the buzzer will sound
the alarm. At the time, much attention should be paid to the operation;
t) No modification of the crane is allowed. Otherwise the person will take the consequence
himself;
u) Under normal conditions, it is prohibited for a load being lifted by two or above
two cranes at the same time. But if this operation is needed under special conditions, it
should comply with the regulations stipulated in GB6067-85, as follows:
1) Wire ropes must be vertical;
2) Hoisting / lowering operations of each crane must be kept synchronized;
3) The maximum load weight lifted by each crane must not exceed their respective
rated lifting capacities.
If above requirements cannot be fulfilled, decrease the rated lifting capacity to its 80%.
During lifting work, the chief engineer must be on site to command the operation.
Warning:
Stop working if one of the following instances occurs:
(1) The crane is overloaded or the load weight is uncertain;
(2) The load may fall off because it is secured or hanged loosely or unevenly;
(3) There is no lining pad between the edges of load and wire rope;
(4) The lighting in the work site is dim and the load or the signal can not be seen very clear;
(5) There is defect or damage of structure and components which will impair the safety of
the crane, such as failure of brake and safety devices or damage of wire rope.
02 - 16
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2.5 Signs on the crane
There are many safety signs on the crane. The meaning of each of them is as follows:
Warning: Swinging load
Note: Lifting point
Caution: Risk of falling
Prohibited: No access for unauthorized personnel!
Prohibited: No entry
Danger: Crushing / Collision
02 - 17
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Danger: Snagging / Dragging
Danger: Crushing / Shearing
Danger: High temperature / Do not touch
Prohibited: Naked flame
Note: First-aid kit
Note: Fire extinguisher
Note:
There is an emergency hammer in operator’s cab. Use the hammer to break the glass
to survive in an emergency.
02 - 18
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2.6 Hand signals
For all movements, the crane operator must always keep the load, as well as the crane
hook or loading equipment when the crane is not loaded, in his field of vision. If this is not
possible, the crane operator may only operate the crane if he is signed by an assigned
conductor. The operator may be guided by hand signals or an interphone. It is absolutely
essential that there be no misunderstandings.
Warning:
Danger of accident caused by misunderstood hand signals! Hand signals must be

mutually agreed upon and clearly executed!
We recommend using the hand signals described on the following pictures for the sake of
safe operation.
1. Start 2. Use main winch 3. Use auxiliary winch
Hold the right arm Tap fist on head; then Tap elbow with one
stretched vertically use regular signal. hand; then use regular
upwards. The palm signal.
faces forwards.
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1145-000-02-20Y
4. Lift the load 5. Lower the load 6. Lift the load slowly
With forearm vertical, With arm extended With forearm vertical,

extended fingers downward, forefinger palm of the hand facing
pointing up, move hand pointing down, move upwards, wave hand up
in small horizontal hand in small horizontal repeatedly.
circle. circle.
7. Rotate 8. Lower the load slowly
Turn left: With right forearm vertical, the palm of With arm extended
the hand facing outwards, lower the forearm downwards with a 30° angle
sideways horizontally, fingers pointing in the to the body，palm of the
direction of rotation. hand facing downwards,
wave hand down repeatedly.
Turn right: With left forearm vertical, the palm of
the hand facing outwards, lower the forearm
sideways horizontally, fingers pointing in the
direction of rotation.
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1145-000-02-20Y
9. Rotate slowly 10. Indicate load lowering

position
Turn left: With right forearm vertical, the palm of
the hand facing outwards, move forearm Extend the fingers
horizontally and repeatedly, fingers pointing in the to point at the position the
direction of rotation. load should fall on.
Turn right: With left forearm vertical, the palm of

the hand facing outwards, move forearm
horizontally and repeatedly, fingers pointing in the
direction of rotation.
11. Raise boom 12. Lower boom 13. Raise boom slowly
Arm extended, finger Arm extended, Forearm extends in

closed, thumb pointing finger closed, thumb front of body with
upward. pointing downward. palm facing
downwards, another
hand moves up and
down with thumb
pointing upwards.
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1145-000-02-20Y
14. Lower boom slowly 15. Extend boom 16. Retract boom
Forearm extends in Both fists in front of Both fists in front of
front of body with palm body with thumbs body with thumbs
facing pointing outwards. pointing toward
upwards, another hand each other.
moves up and down
with thumb pointing
downwards.
17. Stop 18. Emergency stop 19. End a movement
Arm extended, palm Both arms extended, Cross your hands in

down, and move palms down, front of your forehead.
the arm back and forth move arms back and
horizontally. forth horizontally.
02 - 22
Operation –
Chapter 3
crane chassis
0063152-000-03-20Y
3.1 Vehicle operating and control instruments
1 Steering wheel 13 Fuse box
2 Display unit 14 Glove compartment
3 Foot pedal (R): Engine control 15 Inside door handle
4 Foot pedal (L): Service brake 16 Inside door switch
5 Footboard 2 17 Outlet nozzles
6 Footboard 1 18 Outside mirrors (left and right)
7 Driver's seat 19 Sun visor
8 Keyboard 20 Toolbox
9 Extinguisher 21 LCD
10 Center console 22 Right-hand buttons
11 Passenger's seat 23 Left-hand buttons
12 Co-driver's seat
3-1
0063152-000-03-20Y
3.1.1 Steering wheel
1 Steering wheel
2 Outlet nozzles
There are several outlet nozzles arranged on different positions of the instrument
panel in the driver's cab for ventilation. The rotary switches can regulate the
ventilation direction and speed.
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0063152-000-03-20Y
3 Left-hand steering column switch
a) Turn signal activation (left / right)

Jog steering column forwards: turn signal (right) activation
Jog steering column backwards: turn signal (left) activation
b) Switch from low beam to high beam and operate headlamp flasher
If need to pass over the other vehicles, jog the switch upwards in the high beam
position. The high beam and low beam of the headlamp will light up simultaneously.
Jog the switch upwards and downwards continuously to operate headlamp flasher
No matter what working conditions other lamps are in, once the headlamp flasher is
on, the headlamp will light up.
Jog the steering column switch upwards or downwards to switch from low beam to
high beam.
c) Lighting switch
Rotate the end of the steering column switch towards the driver.
The first stage is to activate the front width lamps, rear width lamps, front corner
marker lights, rear corner marker lights, license plate lamp and operating instrument
lamp.
The second stage is to activate the headlamp.
4 Right-hand steering column switch
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0063152-000-03-20Y
a) Activate windshield wiper

Rotate the end of this steering column switch to activate the windshield wiper. The
windshield wiper has 4 stages:
HI: High speed
LOW: Low speed
OFF: Off
INT: Intermittent
b) Activate windshield wiper washer system
Press the button on the end of this steering column switch. The washer and wiper
begin to work. They will not stop working until the button is released.
Caution:
If the washer continues working for 15 seconds or the tank is empty, the wiper will
stop its work. Use the wiper with washer in sunny days. In cold days, precautions
should be adopted to prevent the wiper from being frozen on the windshield.
c) Activate engine retarder and exhaust brake
When engine RPM exceeds 1100 r/min, jog the switch backwards to activate engine
compression brake and auxiliary exhaust brake. The retarder control light will
illuminate simultaneously.
Jog the switch forwards to switch off engine compression brake and auxiliary
exhaust brake. The retarder control light will extinguish simultaneously.
Caution:
Never apply engine control when retarder is activated. Otherwise, engine
compression brake and auxiliary exhaust brake will be deactivated automatically.
d) Activate parking signal
Jog the switch upwards to activate the left and right turn signals simultaneously, thus
to light up the parking signal.
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5 Steering wheel adjustment switch

The steering wheel angle and height can be adjusted by the driver. Turn the adjustment
switch upwards to adjust the height and angle of the steering wheel.
Caution:
(1) Risk of fatal injury if adjust the steering wheel while driving!
(2) Turn the switch downwards to lock the steering wheel after adjustment.
6 Horn
a) Electric horn
It is in the central area of the steering wheel (See above illustration Pos.6). Press
either of the two buttons on the left or right side of the central area to activate the
electric horn.
b) Air horn
This button is situated on the side of driver's left foot.
Pressed: Air horn alarms.

Released: Air horn stops alarming.
7 Ignition starter switch

LOCK
START
ON ACC
Ignition starter switch has 4 stages: LOCK, ACC, ON, and START.
LOCK: No electricity is supplied to the entire electrical system. The key can be plugged
in and pulled out.
ACC: Turn the key to ACC if cigarette lighter and DVD need to be activated without
engine running. If turn the key to ACC during engine running, the engine will be
shut down.
ON: The entire electrical system is electrified.
START: Turn the key from ON to S to start the engine. Once the engine is started,
release the key to ON.
Caution:
If the key is not in the position LOCK, it cannot be pulled out.
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0063152-000-03-20Y
8 Switch Front cover opened

Pull the switch towards the driver to open the front cover of the driver’s cab from which to
check and repair the electrical elements and air conditioning, and add fluid to the
windshield washing fluid container. Push down the cover to close it.
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0063152-000-03-20Y
3.1.2 General operating instruments
1 Tachograph
2 Odometer
3 Fuel gauge
4 Water thermometer
5 Barometer
6 Right-hand rotary switch
7 Left-hand rotary switch
8 LCD and its diagnosis screens
9 Display unit
10 ZF transmission diagnosis display
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1 Tachograph
Tachograph displays engine speed (RPM) and its actual

running time.
The pointer should be in the green region during vehicle
driving. Do not let the pointer stay in the red region for a long
time during engine running, which would result in engine
damage.
2 Odometer
Odometer displays the vehicle speed whose unit is km/h. It

is used to record the total driving distance which can be used
as a reference for vehicle's maintenance intervals.
3 Fuel gauge
If the ignition key is turned to position ON, the fuel gauge
1 will display the fuel reserves. 1 represents fuel reserve
100% and 0 represents fuel reserve 0%.
1/2
Caution:
Add clean fuel into the fuel reservoir when the pointer is
0
near 0 to ensure normal driving.
4 Water thermometer
120
℃ 100 If the ignition key is in ON, the water thermometer will
display the coolant temperature of the engine. The
80 pointer points to the white region in normal driving
conditions and points to the red region when driving in
60 high-temperature areas at high speed or climbing the
40 ascending gradients.
5 Barometer
The two barometers resp. display the air pressure of
15 main brake air reservoirs for front axles and intermediate
bar / rear axles.
10
Caution:
5
If the air pressure is less than 0.55MPa, the warning light
0 “Air pressure too low” will illuminate and the buzzer will
send out alarm. Risk of danger if start off at this time!
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6 Right-hand rotary switch

Switchover brightness adjustment / instrument display screens
Pressed: set to display screens of instruments
Turned: set to brightness adjustment
7 Left-hand rotary switch
Switchover data setting / diagnosis
For details, refer to the actual screen of LCD.
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8 LCD and its diagnosis screens
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0063152-000-03-20Y
Display screens of instruments:

Press switch 6 to set display screens.
Set sequence: Main screen → Auxiliary screen → Next auxiliary screen → Diagnosis screen
If no button is pressed for 3 to 5 seconds, return to main screen automatically.
a) Main screen
Display of engine oil level, engine oil pressure, battery voltage, trip and total trip.
1) Engine oil level and battery voltage will be displayed if engine is not started;
EPLACS
% 0 5 10
3% V 18 24 32
Trip ODO
APP1: 8% 999.9km 999999km
2) Engine oil pressure and engine voltage in working conditions will be displayed after
engine is started.
EPLACS bar 0 5 10
3% V 18 24 32
8 Trip ODO
APP1: % 999.9km 999999km
Press switch 7 to clear up trip.
b) Auxiliary screen
TCG
80%
Actual Engine - Percent Torque
3Gear Engine Total Hours of Operation 8000h
TSG: 8Gear 12 : 15 6.10.2008
Display of actual engine torque, engine total operating hours, the current gear, time and
date etc.
1) Press switch 7 to set Hour.
Turn switch 7 to set Hour when figure of “Hour” flashes.
2) Press switch 7 again to set Minute.
Turn switch 7 to set Minute when figure of “Minute” flashes.
Set sequence is as follows:
Hour → Minute → Year → Month → Date → Time
Wait 3 seconds to exit this mode.
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c) Next auxiliary screen
Engine Intercoolant Temperature 80℃

3% Engine Intake Manifold Temp
100℃
APP2 Eng Fuel Temp80℃ Eng Oil Temp 110℃
Display of engine intercoolant temperature, intake manifold air temperature, fuel and
engine oil temperature.
Note:
EPLACS: Engine Percent Load at Current Speed
APP1: Accelerator Pedal for Chassis
APP2: Accelerator Pedal for Superstructure
TCG: Transmission Current Gear
TSG: Transmission Selected Gear
d) Diagnosis screen
SPN/FMI：730/0 K：13900
Output relay 2
2 Grid heater：no increasing boost temperature
after activation
Turn left rotary switch for page up / down.

When errors are activated, last error is displayed.
Turn left: page up
Turn right: page down
More than 1 errors. More than 2 errors. Just 3 errors.
1One error
1
Current: the 1st error.
Press arrow to 2
Current: the 2nd error
Press arrows to 3
Current: last error.
Press arrow to
page down. page down or up. page up.
If no error is activated, press the right rotary switch to switch to diagnosis screen.
Diagnosis screen displays "No error".
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9 Display unit
STOP
1 Control light Diesel engine preheating system

2 Control light Longitudinal differential lock
3 Control light Transversal differential lock
4 Control light Parking brake closed
5 Warning light Engine oil level too low
6 Control light Retarding brake active
7 Warning light Engine defects
8 Warning light Engine cooling water level too low
9 Warning light Engine speed too high
10 Control light Set suspension to “Sprung”
11 Control light Charge monitoring
12 Control light High beam
13 Control light Rear fog light
14 Warning light Door not closed well
15 Warning light Engine stop owing to serious engine defects
16 Warning light Filter soiled
17 Warning light Transmission defects
18 Control light Vehicle direction of travel left
19 Control light Vehicle direction of travel right
20 Warning light Brake pressure too low
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0063152-000-03-20Y
1 Control light Diesel engine preheating system

In winter (the engine coolant temperature below -4°C), preheat the
engine before starting.
Turn the key to ON position.
Illuminates:
Preheat the engine.
Extinguishes after about 20 sec.:
Start the engine.
2 Control light Longitudinal differential lock
Illuminates:
The longitudinal differential lock is active and locked.
3 Control light Transversal differential lock
Illuminates:
The transversal differential lock is active and locked.
4 Control light Parking brake closed
Illuminates:
Parking brake is active.
Do not start the vehicle until the parking brake is released and the
control light extinguishes.
Illuminates:
The engine oil level is too low.
6 Control light Retarding brake active
Illuminates:
Engine compression brake and exhaust brake are active.
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0063152-000-03-20Y
Illuminates:
Engine defects. Rectify it.
Illuminates:
Engine cooling water level is too low.
Add cooling water in time.
9 Warning light Engine speed too high

Illuminates:
Engine speed is too high.
Decrease the engine speed to avoid engine damage.
10 Control light Axle suspension set to "sprung"
Illuminates:
Suspension of axles 1 and 2 is set to “Sprung”.

Illuminates:
The ignition key is in position ON.
Extinguishes:
– The engine is started;
– The engine begins to charge the battery.
Caution:
If the warning light does not extinguish during battery charging, it
is generator or charging system fault. Stop to check at once!
12 Control light High beam
Illuminates:
High beam or headlamp flasher is active.
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13 Control light Rear fog light
Illuminates:
Rear fog light is active.
14 Warning light Door not closed well

Illuminates:
The door is not closed well.
Caution:
Do not drive the vehicle when the warning light lights up.
Illuminates:
The engine shuts down owing to serious engine defects.

Never start off until rectify it.
16 Warning light Filter soiled

Illuminates:
The filter in chassis hydraulic system is soiled.
Clean or replace the filter.
17 Warning light Transmission defects
Illuminates:
Transmission defects. Check at once!
18 Control light Vehicle direction of travel left
Illuminates:
Vehicle travels left.
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19 Control light Vehicle direction of travel right
Illuminates:
Vehicle travels right.
20 Warning light Brake pressure too low
Illuminates:
Brake pressure too low. Do not drive the vehicle.
Extinguishes:
Brake pressure increased to the specified value.
Caution:
Do not drive the vehicle if the warning light lights up!
10 ZF diagnosis display
The information and error codes of the transmission will be displayed on ZF diagnosis
display. For detailed information, refer to Chapter 3.3.4.
3.1.3 Foot pedal: Engine control
The engine control is an electron accelerator. Apply it to accelerate or release it to decelerate

of the vehicle.
3.1.4 Foot pedal: Service brake
Apply the service brake to decelerate and stop the vehicle.
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3.1.5 Keyboard
1 Button Outrigger power source

2 Button Sliding beam illumination
3 Button Rear fog light
4 Button Transversal differential lock
5 Button Longitudinal differential lock
6 Button Rotating beacons
7 Button Front fog light
8 Button Tempomat
9 Button Temposet
10 2-handed button Lock the axle suspension
11 Buttons Air conditioning system
12 DVD player
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0063152-000-03-20Y
1 Button Outrigger power source
This button is with a lock.

Before activating this button, move the lock downwards.
2 Button Sliding beam illumination
Pressed:
Sliding beam is switched on.
3 Button Rear fog light
Pressed:
Rear fog light is active.
4 Button Transversal differential lock
Pressed:
Transversal differential lock is activated.
Activate this button in off-road driving to prevent wheels skidding.
Pressed again:
Transversal differential lock is deactivated.
Caution:
Activate this button when vehicle skids. Once it drives on road,
press the button to release the transversal differential lock to avoid
axle damage.
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0063152-000-03-20Y
5 Button Longitudinal differential lock
Pressed:
Longitudinal differential lock is active.
Activate it in off-road driving to prevent front / rear wheels skidding.
Pressed again:
Longitudinal differential lock is deactivated.
Caution:
Activate this button when vehicle skids. Once it drives on road,
press the button again to release the longitudinal differential lock
to avoid axle damage.
6 Button Rotating beacons
Pressed:
The rotating beacons are active.
7 Button Front fog light
Pressed:
Front fog light is active
8 Button Tempomat
Pressed:
Tempomat is active.
Note:
(1) Tempomat refers to drive the vehicle at a constant speed set by
ECU without applying engine control. It is usually used in
long-distance driving to release the driver's fatigue.
(2) A driving speed of more than 48km/h can be stored using SET + or
－ to regulate the driving speed between 50 to 72 km/h.
(3) The driving speed also can be increased by applying engine
control when the Tempomat is activated.
(4) Regulate the engine speed to 1500 RPM with outrigger engine
control after Tempomat is activated. In this operating mode, use
engine control or SET + or － to regulate the engine RPM.
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0063152-000-03-20Y
9 Button Temposet
Pressed:
Temposet is activated.
 Press SET + or – one time.
Result:
– The speed is increased / decreased by 2 km/h.
 Press and hold + or –
Result:
– The speed is continuously increased / decreased by 2 km/h.
If the vehicle is in neutral / parking position, press SET + or – to
regulate the engine speed between 650 to 1500 RPM.
10 2-handed button Lock the axle suspension
Pressed once:
Axle suspension is locked.
Pressed twice:
The axle suspension is unlocked.
Danger:
Press the button when the vehicle stops. Set the axle suspension to
“Sprung” in driving conditions.
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11 Buttons Air conditioning system
1) Temperature
Interior temperature range: -30.0℃ to 80.0℃
25.0℃ displayed (never changed with the temperature): Interior temperature sensor
defects
2) Outer air circulation
3) Defrosting air supply
4) Interior air circulation
5) Footwell air supply
6) Front window supply
7) Fresh air supply
8) Fan speed bar chart:
1 bar – stage 1, 2 bars – stage 2, 3 bars – stage 3,
4 bars – stage 4, 5 bars – stage 5, 6 bars – stage 6
9) Fan speed button
Arrow up – fan speed (blower), faster
Arrow down – fan speed (blower), slower
If the fan speed button is not activated, arrows up / down are invalid.
If the fan speed button is activated, press arrows up / down to increase / decrease
the fan speed.
If the fan speed is increased / decreased to the highest / lowest stage, arrows up /
down will be invalid.
10) Refrigeration
11) Mode button
Changeover front window supply / footwell supply / footwell and defrosting air supply
12) Defrosting air supply button
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0063152-000-03-20Y
13) Circulation button

Changeover interior / outer air circulation
14) A/C button
Control light illuminates: compressor activated
Control light extinguishes: compressor deactivated
15) Press AUTO: auto operating mode is activated
Press AUTO twice, or press A/C, Defrosting air supply: exit auto operating mode
Interior air circulation is the default mode of auto operating which can be adjusted
manually.
16) OFF button
Pressed: Air conditioning system is turned off
Press any button (except OFF) to activate air conditioning system.
17) Temperature adjustment button
Temperature range: 17℃ to 29℃.
Pressed: The temperature is increased or decreased by 1℃ between 17℃ and 29℃
Press this button and hold, the temperature will be continuously increased or
decreased.
The set temperature will flash and the interior temperature will be displayed after 5
seconds.
LO: set temperature below 17℃
HI: set temperature above 29℃
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0063152-000-03-20Y
The air conditioning system is of diagnosis function.

– Press and hold OFF;
– The error codes will appear on the display.
C0: Normal
C3: The interior temperature sensor uninstalled or defects
C5: The evaporator temperature sensor uninstalled or defects
C6: Water valve steering gear uninstalled or defects
C7: Air door for mode adjustment uninstalled or defects
Warning:
Never use heating device during driving if engine coolant temperature is below 70℃.
Caution:
(1) Do not use air conditioning for a long time when the engine is stopped or is running
at idling speed; otherwise, it will cause excessive consumption of battery and thus
affect normal driving;
(2) If the vehicle continuously drives at low speed, please downshift 1 gear to increase
the engine RPM. If start the vehicle suddenly or climb long ascending gradients,
please switch off air conditioning to prevent the engine from overheating;
(3) In winter or other periods without using air conditioning, run the air conditioning for
several minutes once a month to benefit the lubricating circulation and ensure the
system in good state;
(4) Check refrigerant regularly. If there is no or not enough refrigerant, add it timely;
(5) If there are abnormal vibration, noise or smell during operation, stop and examine
the machine immediately. Never run with faults;
(6) Clean the surface of condenser regularly. Do not clean it with steam. Clean it with
compressed air or cold water;
(7) Never dismantle the belt or pipeline of compressor after using the air conditioning;
(8) In summer, close the shutoff gate valve on the hot-water pipe of heater at the bottom
of driver's cab; otherwise refrigeration effect may be affected. In winter, open the
shutoff gate valve to make hot water enter into the heater. For hot water type heater,
engine coolant temperature will affect the interior temperature. If the engine coolant
temperature cannot be heated, the driver's cab will not be warmed.
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0063152-000-03-20Y
12 DVD player
1) Button Power
2) Button Open control panel
3) Button Changeover play \ pause \ band
4) Rotary switch Volume set
5) IR sensor
6) LCD (display)
7) USB port
8) MINISD port
9) Alphanumeric keypad
10) Buttons Band \ Skip previous \ Skip next \ fast-forward \ fast-backward
11) Function key
12) Button Mode select
13) Port Disc tray
14) Button Reset
15) Button Open / Close the disc tray
16) Control light LED
17) Induction switch
18) Control panel
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0063152-000-03-20Y
Switch off button 1 and press button 2 to insert DVD.

Press button 15 to take DVD out.
The control panel can be installed and removed.
How to remove:
– Press 1 and 2;
– Slide the panel leftward and pull it out toward the operator from right side.
How to install:
– Slide the panel from left side;
– Secure it.
Caution:
Do not touch the connector with hand, which will result poor contact. If the connector is
polluted, clean it with soft cloth.
Dismantle the control panel as few as possible to reduce the chance of touching the
connector.
Caution:
Turn the ignition starter switch to "ACC" when using DVD player without engine running.
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3.1.6 Center console
1 ZF range selector
2 Drive range switch
3 Cigarette lighter
4 Parking brake
5 Storage compartment
6 Pressure gauges
7 Buttons
8 Cup holder
9 Ashtray
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1 ZF range selector
Tilt the selector forwards one time and return, the gear will upshift 1 gear. If tilt the selector
forwards and hold, the gear will upshift to the highest gear, and vice versa. If push the
selector leftwards and return, the working conditions will be changed over automatic mode
and manual mode (See above illustration).
2 Drive range switch
D: Drive (forwards). 16-forwards shift. Turn the switch to

D no matter in automatic mode or manual mode when
drive the vehicle forwards.
R: Reverse. 2-reverse shift can be changed over
automatically.
N: Neutral. Shift to N when starting.
DM: Maneuver forwards
RM: Maneuver in reverse
3 Cigarette lighter
Press the cigarette lighter for 3 to 5 sec. Pull it out to light
cigarette. After using it, return it back.
Caution:
If using the cigarette lighter without engine running, turn
the ignition key to ACC.
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4 Parking brake
Forwards Pull the parking brake backwards to lock the vehicle.

Locked Push the handle forwards to release vehicle locking.
Released
Caution:
Do not start the vehicle unless the parking brake is
released and the control light “Parking brake closed”
extinguishes.
5 Storage compartment
6 Pressure gauges
① Pressure gauge 1 for steering oil circuit

② Pressure gauge 2 for steering oil circuit
③ Pressure gauge for suspension oil cylinders of
axles 1 and 2
7 Buttons
They are stand-by buttons.
8 Cup holder
9 Ashtray
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0063152-000-03-20Y
3.1.7 Crane lighting
Take the lights on the left as an example. The right lights are the same as the left ones. For
details, refer to Chapter 3.2.1.
1 Front high beam
2 Front low beam
3 Front turn signal
4 Side turn signal
5 Front width lamp
6 Front fog lamp
3.1.8 DVD reversing system
The display of DVD is installed at the middle top position above the front panel of driver's cab.
As for detailed information, please refer to the operating instructions attached to the crane.
Caution:
Switch the ignition starter switch to "ACC" position if using DVD reversing system without engine
running.
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3.1.9 Door – driver's cab
a) Open the door from outside

Key hole
Door handle
Hold the handle and pull it outwards.
b) Close the door:

The door will be locked automatically when the door is closed.
Caution:
Ensure the door is closed well before driving.
c) Open the door from inside
Pull the inside door switch upwards and hold the handle to push the door outwards.
d) Lock the door from inside
The locking knob is near the door window glass.

Press the locking knob to lock the door from inside. Pull the locking knob upwards before
opening the door.
Caution:
If the door is not closed well, the locking knob cannot be pressed down.
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e) Lock the door from outside
Insert vehicle key into the key hole. Switch it clockwise to lock the door.
Caution:
Ensure the locking knob is pressed down. Switch the key anticlockwise to unlock the
door.
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3.1.10 Seats in driver's cab
3.1.10.1 Driver's seat
The driver’s seat with single armrest has pneumatic suspension and can be adjusted to suit
any driver height or size. Adjust driver's seat before setting off.
1 Switch, adjust headrest setting

2 Handle, adjust backrest setting
3 Handle, adjust seat cushion angle (rear section)
4 Handle, adjust seat cushion angle (front section)
5 Handle, adjust damper
6 Lever, adjust horizontal setting
7 Rotary switch
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0063152-000-03-20Y

Press this switch to move the headrest upwards or downwards. Release the switch to
lock the headrest.
Pull handle 2 forwards. Release it until the backrest stops at a suitable angle.
Pull handle 3 upwards. Release it until the cushion (rear section) stops at a suitable
angle.
Caution:
Shake the seat after seat cushion adjustment to ensure the seat is locked.
Pull handle 4 upwards. Release it until the cushion (front section) stops at a suitable
angle.
Caution:
Shake the seat after seat cushion adjustment to ensure the seat is locked.
5 Handle, adjust damper
Rotate handle 5 anticlockwise to lock the damper for air bag. Rotate it clockwise to unlock
and activate the damper.
Pull lever 6 upwards. Release it until the cushion stops at a suitable position.
7 Rotary switch
Turn the switch clockwise to raise the armrest and anticlockwise to lower the armrest.
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3.1.10.2 Co-driver's seat
The co-driver’s seat is equipped with double armrests, whose stiffness of the suspension is
adjusted mechanically.

5 Rotary switch, adjust stiffness of the suspension
7 Rotary switch
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0063152-000-03-20Y

How to use this switch refers to above instructions of driver's seat.
How to use this handle refers to above instructions of driver's seat.
Caution:
For handles 3 and 4, shake the seat after seat adjustment to ensure the seat is locked.
5 Rotary switch, adjust stiffness of the suspension
Turn the switch clockwise or anticlockwise to adjust the seat cushion depth according to
co-driver’s actual conditions.
Caution:
Do not turn the switch below the range of 40kg or above the range of 130kg.
How to use this lever refers to above instructions of driver's seat.
7 Rotary switch
How to use this switch refers to above instructions of driver's seat.
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3.1.10.3 Passenger's seat
The passenger’s seat is equipped with double armrests and seat belt.

3 Rotary switch
For how to use above switches, refer to above instructions of driver's seat or co-driver’s.
Putting on seat belt:
Risk of fatal injury if seat belt is not worn!
All occupants must be belted in before setting off in the crane and during the drive.
Button
Insert tongue piece into belt lacer to fasten the

belt.
Press the button to unfasten the belt.
Tongue piece Belt lacer

3.1.11 Toolbox
The toolbox is in the operating panel of the driver's

cab, in which there are two tool boxes. One is big
and another is small.
Press the cover downwards to open the toolbox.
Press the cover again to close it.
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3.2 Before starting up the vehicle
3.2.1 General checks before setting off
a) Checking oil level

1) Check oil level in the vehicle engine;
2) Check oil level in transmission, transfer case and axles;
3) Check oil level in chassis hydraulic reservoir.
b) Checking the fuel reserve
Check fuel reserve at fuel gauge in driver cab.
Caution:
Do not run the fuel tank dry!
If the fuel tank has been run dry, always deaerate the entire fuel system.
c) Checking the coolant level
Fill coolant equalizing reservoir up to overflow on filler neck.
Danger:
Risk of injury due to scalding of the skin.
Engine must be cold when performing coolant level check.
d) Checking the tires
1) Check working conditions of the tires;
2) Check air pressure and inflate tires to 1MPa.
Caution:
Do not exceed the maximum air pressure during inflation.
e) Checking the mounting connections
1) Check the following parts, such as bolts in steering and drive systems, retaining bolts
of axial pin in suspension cylinder and wheel bolts, for proper seating;
2) Check the parts in steering and brake systems for flexibility, safety and reliability.
Especially check the following parts, such as the fittings of steering tie rods, ball
heads of steering booster cylinders, retaining bolts of steering wheels, brake air
chambers of axles and pipes, for tightness.
f) Checking the door locks, doors, windows and operating mechanisms for damage and
outside mirrors for proper position;
g) Checking electrical system
1) Check battery terminal post for reliability and check whether electrolyte level
adheres to specified requirements;
2) Switch the ignition starter switch to position ON, and check the instruments, switches,
lighting, signals and wipers for function.
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h) Checking pipes
Check the fittings of oil pipes, air pipes and water pipes for leakage and check whether
water is visible in air reservoir.
Caution:
(1) Prop up or withdraw the handle of
drain valve to drain out the water;
(2) Do not start off the vehicle until the
drain valve is closed after the water is
drained out.
Handle of drain valve
i) Checking the control light of air filter
If the control light is red, clean or replace the filter cartridge.
Caution:
Clean the dust in the dust collector at the bottom of air filter regularly.
j) Checking the crane general transport condition
To be in a suitable condition for transportation, all loose parts on the mobile crane must
be fastened and secured.
1) Set the axle suspension / axle locking system to "sprung" suspension level for road
driving;
2) Point crane superstructure in direction of travel and mechanically lock to prevent
from twisting;
3) The telescopic boom must be fully telescoped in and set down on the boom support;
4) Close windows and doors of crane operator's cab;
5) Individually secure the sliding beams using pins to prevent them from unintentionally
extending;
6) Secure all locks on tool boxes and engine hood.
k) Checking the lighting
Ensure the ignition starter switch is switched on.
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Checking the lighting before setting off (See above Fig.).

1 Corner marker lights
2 Rotating beacons
3 Side turn signals
4 Side marking lights and reflectors
5 Front fog lamps
6 Front low beam
7 Front high beam
High / low beam is used to light up the road and the lighting color is white. Low beam
is anti-dazzle.
8 Front turn signals
9 License plate lamp
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10 Combination signals
 Left rear combination signals (on chassis frame left rear part)
Left rear combination signals are combined in a rectangle plate.

The lighting color of the signals:
Corner marker light: red
Turn signal: amber
Brake light: red
Rear width lamps: red
Rear fog lamp: red
Reversing light: white
Side marking light: amber
License plate lamp (white) is at the lower part of left rear combination signals.
 Right rear combination signals (on chassis frame right rear part)
Right rear combination signals are combined in a rectangle plate.

The lighting color of the signals:
Corner marker light: red
Turn signal: amber
Brake light: red
Rear width lamps: red
Rear fog lamp: red
Reversing light: white
Side marking light: amber
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Check the following illuminations and photoelectric warning devices before

setting off.
1) Interior illumination
It is installed on the roof of the driver's cab to supply interior illumination.
2) Sliding beam illumination
It is installed near the outrigger beam to supply illumination for sliding beam. It is
convenient for the operator to observe working conditions of sliding beam at night.
3) Support control unit illumination
It is installed in the support control unit to supply illumination for support control unit
at night.
4) Buzzer
The reversing light will illuminate and the buzzer will send out slow alarm when
reversing gear is applied.
The warning light “Brake pressure too low” will illuminate and the buzzer will send
out slow alarm when the pressure of the air brake system is too low.
The warning light “Engine cooling water temperature too high” will illuminate and the
buzzer will send out slow alarm when the engine cooling water temperature is too
high.
Danger:
Danger of accident if lighting is defective!
Arrange to have any defective lights repaired by an expert before setting off!
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11 Driver's cab
1) Adjusting driver's seat
The driver's seat has pneumatic suspension and can be adjusted to suit any driver
height or size.
– Adjust backrest setting
– Adjust rear cushion angle
– Adjust front cushion angle
– Adjust horizontal setting
Note:
Functions of driver's seat are not completely the same as the co-driver's seat's. For
detailed information, refer to Chapter 3.1.10.
2) Adjusting the mirror
Clean outside mirrors before setting off and adjust to suit driver's field of view.
Adjust the outside mirrors manually.
Result:
– You can switch between the left and right outside mirrors.
– Mirror is adjusted.
3) Adjusting the steering wheel
The steering wheel is adjusted mechanically.
Operate the control handle of steering wheel (See Chapter 3.1.1).
Result:
– The angle and height of the steering wheel are adjusted to suit the driver.
Danger:
Never adjust the steering wheel, driver’s seat and outside mirrors while driving.
4) Turning heater / ventilation on
The cab can be heated or ventilated to the desired temperature.
For a detailed operation, see chapter 3.1.5.
To adjust the heater or ventilation, use the keypad in air conditioning control panel.
Caution:
The shutoff gate valve on the hot-water pipe of heater at the bottom of driver's cab
must be turned off when using air conditioning in summer and turned on in winter.
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5) Checking main controls

Ensure that the battery master switch is on when carrying out following checks.
Check the following components:
– High beam
– Front fog lamp
– Rear fog lamp
– Fan
– Windshield wiper / washer system / windshield washing fluid container
– Horn
– Rotating beacons
Danger:
Danger of fatal injury due to defective main controls! Arrange to have any defective
functions repaired by an expert before setting off.
12 Fuse
1) Open the cover of the center console and take it out;
2) Open the cover of fuse box;
3) Check the fuse and replace the defective one.
Warning:
Use the fuse of same size and specification; otherwise, the electrical system will be
damaged.
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3.2.2 Axle suspension / axle locking system
3.2.2.1 General
Axles 1 and 2 are hydro-pneumatically sprung, and axles 3, 4 and 5 are leaf-spring sprung.
3.2.2.2 Adjusting axle suspension
Only axles 1 and 2 are hydro-pneumatically sprung.
Illustration – Commissioning box for hydro-pneumatic suspension
Level control for axles 1 and 2:
Warning:
For road driving, perform level control on a level and load-bearing surface.
Never raise or lower the vehicle when driving on an uneven road surface.
Ensure that the following prerequisites are met:
a. The vehicle is on a level surface
b. The engine is running
c. The transmission is in neutral "N"
Warning:
Do not perform level control unless the vehicle is stationary!
Warning:
Level control can only be performed by an expert. Otherwise, all consequences are rest
with yourself.
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Use the selective switch “Deaerate the suspension cylinder” to deaerate the suspension
cylinder when the first commissioning is performed.
1) Automatic level control

The crane is automatically moved to a level position by the selective switch “Level the
suspension cylinder" on the commissioning box (level control can only be performed in
the correct control direction). After the end position is reached, level control will stop
automatically and suspension cylinder will stop at the level position.
2) Manual level control

The crane is manually moved to a level position by operating the selective switch
“Deaerate the suspension cylinder” on commissioning box.
- Adjust the selective switch “Deaerate the suspension cylinder” until one control light
goes off and another lights up.
Warning:
Hydro-pneumatic suspension height can only be adjusted when the vehicle front / rear
heights are different and when the vehicle is stationary.
The axle suspension must be locked before supporting the crane.
● Switch on the 2-handed button “Lock the axle suspension”;
● The control light “Set axle suspension to ‘sprung’” goes off.
Result:
Axle suspension is locked.
Caution:
When axle suspension is locked, manual level control can not be performed.
The vertical cylinders must be extended until all wheels are away from the ground.
Warning:
Risk of danger! The crane may topple over when its stability is lowered.
Warning:
Do not unlock the axle suspension before wheels contact the ground.
Danger:
When the axle locking system is used:
a. Ensure that no persons are presented in the crane danger zone!
b. Perform level control on a level and load-bearing surface.
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3.3 Driving the crane
3.3.1 Crane driving conditions

— Hook, counterweight, jib and auxiliary winch are not attached to the crane.
— Before the crane can be driven on public roads, the telescopic boom must be fully
telescoped in and placed on the receptacle bracket.
— Sliding beams must be fully retracted and secured with pins.
— The axle suspension system has been set to "Sprung".
— The vehicle is at the level setting for road driving.
Warning:
Do not drive the crane on public roads with hook, counterweight, jib and auxiliary winch.
Otherwise the axle will be overloaded.
Warning:
Always observe national and regional regulations for axle loads!
Illustration - Driving condition
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3.3.2 Starting and stopping the engine
a) Starting the engine
Caution:
Before starting the engine, ensure the following prerequisites are met:
– the battery master switch has been turned on
– the parking brake has been applied
– the transmission is in neutral "N"
How to start the engine:
– Turn the ignition starter switch (See Chapter 3.1.1) to position ON for preparation.
– Turn the ignition starter switch to position S.
Caution:
If the engine does not start after a maximum of 10 seconds, wait for 1 minute. The starter
can be operated three times for 10 seconds per attempt with a pause in between of one
minute respectively. If the engine stops within 4 seconds, the sensor controlling the
engine defects. In order to avoid engine stopping, turn the ignition starter switch to
position "0". Preheat for 10 seconds before setting off. The engine will run with defects
and the warning light “Engine defects” will illuminate simultaneously.
With flame starting device at ambient temperature of less than - 20℃
To improve the cold start process and the warm-up phase, the engine is equipped with a
flame starting device.
Checking the instruments after starting the engine
The following control lights must extinguish when the engine is running:
1) Control light ”Charge monitoring”
2) Warning light “Brake pressure too low”
Warning:
Do not perform full-load operation to engine if engine temperature does not achieve
normal level.
Turn off the engine immediately in the event of:
(1) Dropping or sharply fluctuating oil pressure;
(2) Reduced performance and RPM without a change in engine control;
(3) The appearance of large amounts of smoke;
(4) Suddenly occurring abnormal engine noises.
b) Turning off the engine
Caution:
Before turning off the engine, ensure that the following prerequisites are met:
– the parking brake has been applied
– the transmission is in neutral "N"
– the battery master switch is set to "ON"
·Turn the ignition starter switch back to the stop.
·Pull off and store the ignition starter switch.
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3.3.3 Driving
a) Changing the idling speed
Caution:
Apply service brake before shifting from "N" to "D". The engine RPM will be decreased if
the required gear is selected.
Warning:
Run the engine at idling speed before shifting from "N" to "D" or “R” with the vehicle
stationary.
b) Setting axle suspension and level control
Set axle suspension to "sprung" and ensure vehicle level.
c) Releasing parking brake
Pull back the hand lever of parking brake as far as the stop in the hand lever's
longitudinal direction and push forward.
Warning:
Do not release parking brake if the air pressure is lower than 5.5bar. That is to say, do not
release parking brake if the warning light “Brake pressure too low” lights up.
Release the parking brake until the warning light goes off!
Caution:
When the parking brake is released, the crane can immediately start moving.
d) Checking brake system
e) Service brake
Depress engine control pedal to increase engine RPM. The vehicle begins to move.
Depress service brake pedal and check the service brake.
f) Retarder
The retarder consists of engine compression brake and exhaust brake.
Warning:
Utmost care should be taken when operating the retarder!
Caution:
The retarder can only be operated with the engine turned on. If the retarder is being
operated, it is not possible to accelerate by engine control.
Sensible use of the retarder and anticipating driving methods reduces wear on brake and
thereby reduces operating cost.
On long descending gradients
On long descending gradients, select a switching stage that leaves further switching
stages available for any other adjusting braking procedures which may be required.
Correctly use the retarder as possible as you can to relax the service brake.
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Caution:
Apply the same gear as in ascending gradients.
If there is not sufficient braking effect, brake vehicle using the service brake and change
down.
On snow, ice and dirty road surfaces
Careful use of the retarder will ensure safe and sure deceleration even under bad road
surface conditions.
Danger:
In the event that the wheels lock when operating the service brake, select a lower
switching stage!
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3.3.4 Automated shift transmission
Shift module contains transmission control unit (TCU), the valve for "shifting", shift cylinder
and sensor to activate automatic shift operation.
A detailed description can be found in Chapter 3.1.6.
3.3.4.1 Selecting the direction
D: Drive
R: Reverse
N: Neutral
DM: Maneuver forwards
RM: Maneuver in reverse
For detailed information, please refer to Chapter 3.1.6.
M/A
The automated shift transmission has no clutch pedal, so apply engine control before climbing
on an ascending gradient. Release the parking brake hand lever when the clutch is closed.
The engine control can be continuously increased.
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3.3.4.2 Diagnosis display
ZF diagnosis display
ZF displays:
Automatic driving mode display
Manual driving mode display

Here: 5th gear.
Caution:
Only in drive range "D", the gearshift mode can be changed between automatic and manual
mode.
Automatic mode is activated automatically when the ignition is switched on. In the neutral "N"
and reverse "R" drive range, automatic mode is always activated.
Danger:
When parking brake is released, the vehicle starts to roll immediately.
When the parking brake is released, brake crane with service brake or accelerate with engine
control.
The transmission display is set on the instrument panel of driver's cab to display the error
codes. The main information and error codes calling up are as follows (For detailed
information, please refer to AS-Tronic Transmission Repair Manual attached to the crane).
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System self check (with ignition ON)
Transmission in neutral
Manual driving mode display

Here: 5th gear.
System error. Restricted further travel possible.
Serious system error! Stop.
Low air pressure Shift from 10th to 8th gear

(1 bar apply as 1 gear)
Foot away from accelerator
(Accelerator test) Lo reverse gear engaged
Clutch overload Hi reverse gear engaged
Communication error with display
Clutch wear display
Example of error code: 53
Example of error code: 153 (4 bars apply as "100")
Example of error code: 227 (4 bars and 2 arrows apply as "200")
Calling up the error numbers:

a) Switch on ignition.
b) Turn rotary switch to "N".
c) Hold control lever in "+" position.
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Danger:
(1) Do not select reverse "R" if the vehicle does not completely stop. Stop the vehicle at first
and then select reverse "R";
(2) Change reverse "R" to drive "D" or drive “D” to reverse “R” when the vehicle completely
stops. Otherwise, the gear range will keep in neutral "N";
(3) If select neutral "N" in drive, the power transmission will be cut off and the retarder will be
invalid.
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3.3.5 Important control instruments while driving
a) Checking the engine oil pressure

Engine oil pressure display on bar chart in display unit of 1 bar – 5.5bar.
Caution:
In case of low oil pressure (the engine oil pressure is below 0.06 ± 0.015MPa), there is no
engine lubrication. This results in engine damage. Immediately bring the crane to a
standstill and turn off the engine.
b) Checking compressed air supply
The two barometers resp. display the air pressure of air reservoir for front axle and air
reservoir for intermediate / rear axles.
Caution:
If the pressures of the air reservoirs are below 0.55MPa, the warning light “Brake
pressure too low” will light up and the buzzer will send out alarm simultaneously.
Immediately bring the crane to a standstill and rectify the cause of the defect. Otherwise,
it is very dangerous.
c) Checking the fuel reserve
Fuel quantity display on bar chart in 1 or 0.
1 means fuel tank is full. 0 means fuel tank is empty.
Caution:
If the pointer is near “0", refill the fuel reserve. Do not drive when the fuel tank is empty, or
the fuel system will have to be vented.
d) Checking the coolant temperature
Coolant temperature display on the water thermometer. In normal conditions, the pointer
points to the green range. The pointer will point to the red range when driving in high
temperature area or climbing slopes.
Caution:
If the pointer points to the red range for a long time while driving, immediately bring the
crane to a standstill and check the engine coolant system. Otherwise, this will result in
engine damage.
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3.3.6 Off-road driving
This vehicle is equipped with differential locks for driving off-road, on tracks and in winery
conditions.
Caution:
The differential locks may only be added when the crane is stationary.
Warning:
In order to avoid damage to driving axles, ensure that the following prerequisites are met:
(1) Only add differential locks and off when the vehicle is stationary!
(2) Never add differential locks when the driving wheels are turning!
(3) Drive carefully, do not start jerkily, only drive on straight routes and do not attempt to
corner!
(4) Only drive on difficult terrain (e.g. sand, slush, loose or slippery subsoil etc.) with
differential locks.
The vehicle is equipped with following off-road drive devices:
– Longitudinal differential lock in transfer case
– Longitudinal differential lock axle 4
– Transversal differential locks axles 2, 4 and 5
Warning:
If do not need the differential locks anymore, turn the differential locks off as soon as possible.
Considerable damage can be caused by driving on solid subsoil with good grip when a
differential lock is on.
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3.3.7 Maneuvering
For extremely slow-speed driving, a maneuvering option is provided.

For maneuvering purposes, the system can call on gears of maneuver forwards and
maneuver in reverse. If maneuvering function is used, upshift is limited.
Warning:
In maneuvering mode, the force of clutch will be increased. Only select this operating mode
when absolutely necessary. Lower gear is recommended to reduce clutch force.
Do not apply maneuvering mode when the vehicle is struck.
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3.3.8 Towing
Warning:
The following towing regulations must be adhered to:
(1) Release the parking brake when towing, or the brake system will be damaged;
(2) When towing, the speed must always remain below 20 km/h;
(3) Use the towing coupling to tow the vehicle;
(4) Only tow with a tow bar;
(5) Turn on the hazard warning system and the driving light.
a) Towing with a defective drive motor and / or shift transmission
If the driving motor cannot be started, a compressed air supply must be established from
the towing vehicle to the mobile crane. A hose coupling is attached at the front under the
bumper to supply compressed air to the mobile crane to be towed.
Use a hose pipe to connect this attachment for the external supply with the towing
vehicle.
Warning:
The supply pressure of the compressed air brake system of the mobile crane to be towed
must be at least 6 bar.
With the engine turned off, the vehicle can only be steered from a speed of 5 km/h -10
km/h.
b) Towing with an intact drive motor
1) Towing with damage to the transfer case
Disconnect the drive shafts from the transfer case to the driving axles at the driving
axles and tie up.
Using the drive range switch, switch the transmission to neutral "N" to allow the
engine to run at idling speed.
2) Towing with damage to the driving axles
Remove the defective driving axles.
Warning:
Only authorized and specially trained personnel can carry out towing arrangements in
case of damage to the driving axles.
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3.3.9 Finishing driving operations
a) Stopping
● Brake the crane until it comes to a standstill;
● The selected drive range can remain switched on;
● Use the service brake or parking brake to ensure that the crane does not roll away.
Caution:
For longer stop (more than 1 minute), shift the transmission into neutral "N". This will
reduce clutch wear and increase the service life of the clutch.
b) Stopping the vehicle when the engine is running
● Brake the crane until it comes to a standstill;
● Shift the transmission into neutral "N";
● Apply the parking brake and the parking brake control light lights up.
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3.4 Outrigger - operation
The crane is equipped with 4 outriggers. Its outrigger beams are connected with the chassis
frame and the 2 sections of sliding beams can extend and retract synchronously. A support control
unit (switch box) with buttons is attached to both sides of the vehicle (rear sides of the front
outrigger beam) for controlling the 4 sliding beams to extend and retract simultaneously or
independently.
Support control unit
Sliding beam section 1
Illustration – outrigger extended
Warning:
Extend outriggers before crane operation. Select even and hard working sites. If the working site
is soft or uneven, put suitable materials and bases beneath the outrigger pad.
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3.4.1 Installing and removing the outrigger pads

Vertical cylinder
Outrigger pad
Socket pin
a) Installing the outrigger pad

Before the outriggers extending, withdraw socket pin and pull outrigger pad outwards
until the outrigger pad center meets the vertical cylinder. Insert socket pins and secure
them.
b) Removing the outrigger pad
After the outriggers are retracted, withdraw the socket pin and slide outrigger pads
inwards until it reaches the limit position. Insert socket pins and secure them.
3.4.2 Extending and retracting the outriggers
The two support control units with buttons are attached to both sides of the vehicle. Their
functions are the same and the layouts of their buttons are symmetrically arranged. The
extending / retracting of the outriggers and vertical cylinders, engine on / off and engine RPM
regulation can be controlled simultaneously or independently. The inclinometers on the center
of the units display the crane’s deviation (at the slewing ring). The two support control units
are connected by cables. The signals of the right support control unit (auxiliary control unit)
are transmitted to the left support control unit (main control unit) via the cables, and then to
the valves and engine controllers etc.
Extend outriggers before crane operation. Select even and hard working sites. If the working site
is soft or uneven, put suitable materials and bases beneath the outrigger pads.
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Left support control unit

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Right support control unit

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Operation procedures (Take left support control unit as an example):
Caution:
Turn on the outrigger power switch (in driver's cab, for detailed information, refer to Chapter
3.1.5). Only when the left and right outriggers are energized and the power control light
illuminates, the following procedures can be activated. If one of the buttons “Emergency stop”
is activated, no extending and retracting movements of outriggers can be initiated.
1) Put the outrigger pad to working position according to Chapter 3.4.1;
2) Remove the retaining pin;
3) Open the support control unit with the key;

4) Switch engine on. The chassis engine and hydraulic system begin to work;
5) Press corresponding buttons to extend right rear outrigger and right front outrigger.
Release the buttons until the outriggers extend to a desire position;
6) Press corresponding buttons to extend left rear outrigger and left front outrigger. Release
the buttons until the outriggers extend to a desire position. Press corresponding buttons
to extend all outriggers simultaneously. Press corresponding buttons to extend right front,
left front, right rear and left rear vertical cylinders to lift the crane up. Press corresponding
buttons to extend all vertical cylinders simultaneously. After all vertical cylinders are
extended, check whether the crane is level with the inclinometer. Inclination angle should
be no more than 1°. Press buttons to align the crane horizontally. If the vehicle is not
horizontal, retract or extend the outrigger to level the crane;
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Illustration — Inclinometer
7) Secure and lock the outriggers with retaining pins when the outriggers extended to a
desired position.
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Retract the outriggers according to the reverse sequences.

Note:
(1) Press the engine off button. The chassis engine stops;
(2) Set the changeover button “Engine Rpm / idling speed” to engine Rpm position by
pressing this button. Set the changeover button “Engine Rpm / idling speed” to idling
speed position by releasing this button. The outrigger speed can be changed via
operating this button. Press button “Sliding beam illumination” to turn on sliding beam
illumination. Press again to turn off sliding beam illumination;
(3) The button “Changeover outrigger fully / half extending” is not used;
The movements, such as, extending / retracting the vertical cylinders and extending /
retracting the outriggers, are interlocked. Once a certain button is activated, before its
movement stops, the conversed movement cannot be activated.
The movements, such as, one outrigger or vertical cylinder retracting / extending or all
outriggers or vertical cylinders retracting / extending, are interlocked. If one outrigger or
vertical cylinder is extended or retracted, the buttons for extending or retracting all
outriggers or vertical cylinders are invalid. If all outriggers or vertical cylinders are
extended or retracted, the buttons for extending or retracting one outrigger or vertical
cylinder are invalid.
(4) Calibrating vehicle deviation sensor to 0°;
The vehicle deviation sensor must be calibrated to 0° if the sensor or support control unit
is reinstalled or replaced.
How to calibrate:
- Extend the outriggers and vertical cylinders;
- Level the crane (Be sure the crane is level!);
- Press and hold buttons “Emergency stop” and “Extending and retracting the 5th
outrigger” simultaneously for more than 10 seconds;
- Release these buttons until the central LED on the inclinometer lights up.
Caution:
(1) Turn chassis engine off when crane superstructure works;
(2) Remove the socket pins before extending and retracting the outriggers. Before driving,
secure and lock the pins after the outriggers are fully retracted;
(3) The speed for extending or retracting the outriggers can be adjusted by the engine
control;
(4) The clearance between sliding beam and outrigger beam can be regulated by the
adjusting bolts. (For detailed information, refer to Chapter 7.5.8);
(5) The telescopic boom must be set down on the boom support when retracting and
extending the outriggers;
(6) Close covers for the support control units after operation or when cleaning the crane, so
as to prevent water from entering;
(7) If any of the emergency stop buttons is pressed, other buttons will be invalid.
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3.5 The crane at the jobsite
Select crane operating location where the outriggers can be extended to provide the support
specified in the load chars and the crane can be leveled.
3.5.1 Converting from driving mode to crane operation

The crane is on a level and load-bearing surface;
The parking brake is applied;
The transmission is in neutral position "N";
The engine is running.
The axle suspension must be locked before the crane is supported. Then, convert to crane
operation.
3.5.2 Outrigger pad
Move the outrigger pads from transport position to operating position. Place stable materials
such as wood, steel plates or concrete slabs of a suitable size beneath the outrigger pads,
depending on the ground conditions.
3.5.3 Converting from crane operation to driving mode

The crane is supported and level. The wheels are not in contact with the ground;
The axle suspension is locked;
The telescopic boom is fully telescoped in and locked to the boom support at the front;
The hooks are secured and the counterweights are taken away;
The transmission is in neutral position "N".
3.5.4 Switching the axle locking off
Retract outrigger cylinders and the outriggers all the way and turn the axle locking off.
Warning:
If the axle locking is turned off without the wheels being in contact with the ground, then the
axle suspension can be damaged if the axles drop down.
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3.5.5 Converting to driving mode

- The engine is turned off
- The ignition is turned off
Result:
- The crane is switched to driving mode.
3.5.6 Supporting the crane with support control unit
1) Extending the outrigger with support control unit

The operator must monitor the extension and retraction of the outriggers. Make sure that
there are no persons or objects within the danger zone when extending or retracting the
outriggers.
2) Extending vertical cylinders with support control unit
Warning:
Ensure that the crane has been raised until the wheels are no longer touching the ground.
Otherwise, the crane may topple over.
Do not extend the vertical cylinders all the way during crane operation (up to stop position).
3.5.7 Checking outriggers

Make sure that four outriggers have been extended. If only the outriggers on the load side are
extended, the crane could topple over.
3.5.8 Before leaving the work site
Perform the following checks before leaving the work site:

1) Check that the axle suspension is set to “Sprung”;
2) Check whether the vertical and horizontal cylinders are fully retracted;
3) Check whether the outrigger pads are in transport position and have been secured;
4) Check whether the sliding beams have been fully retracted and pinned;
5) Check whether retaining pins have been secured in their holders;
6) Check whether the telescopic boom has been retracted and placed on the boom support;
7) Check whether the slewing table panels are locked;
8) Check whether the doors and windows of the crane cabs are closed;
9) Check whether the spare wheel has been properly secured;
10) Check whether the hook block is lashed using the eye provided on the front towing
coupling and whether towing coupling has been properly secured;
11) Check whether the counterweights, jib and auxiliary winch have been taken away from
the crane.
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Operation – crane
Chapter 4
Superstructure
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4.1 Control instruments and indicators
4.1.1 Operator's cab
1 Front windshield wiper 2 Instrument console 3 Monitor for main winch

4 Roof window wiper 5 Fan 6 Fire extinguisher
7 Emergency hammer 8 A/C 9 Operator’s seat
10 Right control box 11 Left control box 12 Accelerator pedal
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4.1.2 Operator's seat
4.1.3 Right control box
Button, rapid gear for main Operating illustration,

1 2 Joystick, right 3
winch right
4 Control panel, right (Blank) 5 Button (not used)
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4.1.3.1 Operating illustration, right
Note:
The right deadman switch is located on the back of right joystick. All operations controlled by
left / right joystick will be valid once the deadman switch is pressed and held.
Warning:
Do not press the deadman switch for a long time with tools!
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4.1.4 Left control box
Operating illustration,
1 Button (electric horn) 2 Joystick, left 3
left
4 Control panel, left 5 Button (not used)
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4.1.4.1 Operating illustration, left
Note:
The left deadman switch is located on the back of left joystick. All operations controlled by left /
right joystick will be valid once the deadman switch is pressed and held.
Warning:
Do not press the deadman switch with tools for a long time!
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4.1.4.2 Control panel, left
1 Switch Pre-selection of boom pin operation

2 Switch Pre-selection of cylinder pin operation
3 Switch Pre-selection of derrick / telescope
4 Switch Pre-selection of manual / automatic telescoping operation
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1 Switch Pre-selection of boom pin operation
Left position: Closing the boom pin

Right position: Opening the boom pin
2 Switch Pre-selection of cylinder pin operation
Left position: Closing the cylinder pin

Right position: Opening the cylinder pin
3 Switch Pre-selection of derrick / telescope
Left position: Derricking the boom

Right position: Telescoping the boom
4 Switch Pre-selection of manual / automatic telescoping operation
Left position: Automatic telescoping

Right position: Manual telescoping
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4.1.5 Instrument console
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1 Control light Boom pin operational

2 Control light Boom code
3 Control light Cylinder pin beyond its target hole
4 Control light Cylinder pin not reaching its target hole
5 Control light Telescopic cylinder locked
6 Control light Telescopic cylinder unlocked
7 Control light Boom pinned
8 Control light Boom unpinned
9 Warning light Main / auxiliary winch approaching upper limit
10 Warning light Main / auxiliary winch approaching lower limit
11 Control light Power of counterweight remote control box
12 Load moment limiter
15 Warning light Oil pressure too low
16 Warning light Engine stop owing to serious fault
17 Warning light Engine coolant temperature too high
20 Warning light Lubricant level too low
21 Switch Central lubricating system
22 Switch PTO
24 Switch Oil cooler
25 Switch Corner marker lights and working lights on boom head
26 Battery master switch
27 Switch Working lights
28 Switch Emergency off
29 Switch Window wiper front window
30 Switch Window washer system front window
31 Bypass key switch
32 Disable switch Supplying hydraulic oil
33 Switch Slow gear
34 Switch Tilting operator’s cab
35 Cigarette lighter
36 Switch Extend or retract counterweight cylinders
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1 Control light Boom pin operational
Illuminates:
It is permitted to close the boom pin.
Do not close the boom pin until the control light lights up.
2 Control light Boom code
The numbers that the control light flashes every interval indicate the
corresponding telescopic section the telescopic cylinder in.
3 Control light Cylinder pin beyond its target hole
Illuminates:
The cylinder pin is passing its target hole.
Retract the cylinder a little to align the cylinder pin with its target hole.
4 Control light Cylinder pin not reaching its target hole
Illuminates:
The cylinder pin does not reach its target hole.
Extend the cylinder a little to align the cylinder pin with its target hole.
Note:
If the cylinder pin is aligned with its target hole, the control lights 3 and 4
will light up simultaneously.
Do not operate the cylinder pin until control lights 3 and 4 light up.
5 Control light Telescopic cylinder locked
Illuminates:
The telescopic cylinder is locked with the telescopic boom.
6 Control light Telescopic cylinder unlocked
Illuminates:
The telescopic cylinder is unlocked with the telescopic boom.
7 Control light Boom pinned
Illuminates:
The telescopic section is pinned.
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8 Control light Boom unpinned
Illuminates:
The telescopic section is unpinned.
Illuminates:
Main / auxiliary winch approaches upper limit.
Illuminates:
Main / auxiliary winch approaches lower limit.
Illuminates:
The remote control box is activated.
12 Load moment limiter

Load moment limiter is a computer system for controlling and monitoring mobile crane. It
can precisely check whether the crane is in safe working conditions and display some
basic parameters, such as boom length, boom angle, working radius, rated lifting capacity
etc., on the LCD.
Illuminates:
Crane superstructure engine detects engine defects.

Illuminates:
Ignition starter switch is turned to the 1st position.
Extinguishes after enging starting:
The battery is charged.
Illuminates after enging starting:
Charge defects. Rectify at once.
15 Warning light Oil pressure too low
Illuminates:
Oil pressure of crane superstructure engine is too low, lower than 0.5
bar (idle speed) or 2.5 bar (rated RPM).
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16 Warning light Engine stop owing to serious fault
Illuminates:
Crane superstructure engine detects engine that stops.
Illuminates:
Engine coolant temperature is too high, greater than 98℃.
Illuminates:
Engine oil level in superstructure engine is too low.
Illuminates:
Illuminates:
The lithium base grease level in central lubricating system is too low.
Check it at once and fill lubricating grease if necessary.
21 Switch Central lubricating system
Pressed on bottom:
The central lubricating system begins to work to lubricate every
lubricating point automatically.
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22 Switch PTO
Pressed on bottom:
PTO is activated. Superstructure engine RPM is increased from 600
r/min (idle speed) to 850 r/min (Pressed on top to deactivate the PTO till
850 RPM reached);
Pressed on bottom after 3 seconds:
PTO is activated. Superstructure engine RPM is increased from
850r/min to 1250r/min (Pressed on top to deactivate the PTO till 1250
RPM reached);
Pressed on bottom after 3 seconds:
PTO is activated. Superstructure engine RPM is increased from
1250r/min to 1850r/min (Pressed on top to deactivate the PTO till 1850
RPM reached);
Pressed on top:
PTO is turned off. Superstructure engine RPM is changed to idle speed.
Caution:
Turn on the PTO during lifting loads.
With two switch positions, in clockwise direction
Position 1:
Electrical system for engine is energized.
Position 2:
Engine starts.
Caution:
After the engine has been started, release the key to let it return to the
position 1 automatically. Return key to P0 first if you want to restart the
engine.
24 Switch Oil cooler
Pressed on bottom:
The fan of oil cooler begins to work.
In following situations, the fan will work automatically:

a) The left joystick is deflected to the right or left;
b) The temperature of hydraulic oil is greater than 60℃. The fan will
not stop working until the oil temperature is less than 60℃ or the
battery master switch is switched off.
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25 Switch Corner marker lights and working lights on boom head
Pressed on bottom:
The corner marker lights and working lights on boom head are on.
26 Battery master switch
Right position:
– The battery master switch near the battery on slewing table is
switched on;
– The switch background is lighting on.
– The superstructure is energized.
27 Switch Working lights
Position 1:
Switches background lighting on;
Position 2:
Switches background lighting, working lights on cab front and boom on.
28 Switch Emergency off
Pressed:
Cut off the output of oil line and PLC to ensure safe operation of the
crane in the event of a clear emergency.
29 Switch Window wiper front window
2 stages:
1 Intermittent
2 Wipe
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30 Switch Window washer system front window
Pressed:
Switch on the windshield washer system on the front window.
31 Bypass key switch

If the hook block contacts the hoisting limit switches during its upward
movement, the buzzer sends out fast acoustic warning and the crane
movements, such as “Spool up winches”, “Telescope boom out”, and
“Derrick boom down” are cut off;
If the hook block contacts the lowering limit switch during its downward
movement, the buzzer sends out fast acoustic warning and the crane
movement “Reel off winches” is cut off;
If the maximum permissible load moment is exceeded, the buzzer
sends out fast acoustic warning and crane movements, such as “Spool
up winches”, “Telescope boom out” (automatic telescoping), “Telescope
boom in” (automatic telescoping), and “Derrick boom down” are cut off;
The switch-off of dangerous movements can be bypassed by activating
the bypass key switch on the instrument console.
Danger:
Increased accident risk when bypassing the dangerous movements!
Carry bypassing movements with maximum care and minimum speed.
Never telescope with load!
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32 Disable switch Supplying hydraulic oil

This switch should always be used in conjunction with the joysticks to
supply hydraulic oil to winches. Detailed operating method is as follows:
a) Supply hydraulic oil to main winch
1) Rotate the switch to right position and deflect the right joystick
forwards until the buzzer sends out slow acoustic warning;
2) Rotate the switch to left position and deflect the joystick to
neutral position.
b) Supply hydraulic oil to auxiliary winch
1) Rotate the switch to right position and deflect the left joystick
forwards until the buzzer sends out slow acoustic warning;
2) Rotate the switch to left position and deflect the joystick to
neutral position.
Do not stop supplying hydraulic oil to main / auxiliary winch until the
buzzer sends out slow acoustic warning (Frequency: 0.5HZ). One
supplying circle is about 3 minutes.
Caution:
It is prohibited to press the deadman switches when deflecting the
joysticks forwards.
If the load is suspended in the air for a period of time due to crane
shutdown, supply hydraulic oil to the winches before operating the
winches. The times of supplying hydraulic oil should be according to
crane downtime (T):
(Preheat the machine for 15 to 30 minutes in winter)
a) If 0.5 hours ≤ T ≤ 6 hours, supply oil 1 circle at 1000 RPM, 1 circle
for 3 mins;
b) If 6 hours ≤ T ≤ 12 hours, supply oil 2 circles at 1000 RPM, each
circle for 3 mins;
c) If T ≥ 12 hours, supply oil 3 circles at 1000 RPM, each circle for 3
mins.
33 Switch Slow gear
Right position:
Apply all crane movements with slow gear.
a) Crane movements “Slewing”, “Spool main winch up” and “Reef
main winch off" have 1 stage.
b) Crane movements “Telescope” have 2 stages:
1) 1 (extremely slow): intermediately deflect the right joystick to
the right / left
2) 2 (slow): fully deflect the right joystick to the right / left
c) Crane movements “Derrick” have 2 stages:
1) 1 (slow): boom length is less than 40m
2) 2 (extremely slow): boom length is greater than 40m
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34 Switch Tilting operator’s cab

The operator’s cab can be tilted upwards for 20°.
Right position:
Tilt cab upwards;
Left position:
Tilt cab downwards.
35 Cigarette lighter
With 24V power source.

It can be used as the power source for other electrical appliances.
36 Switch – Extend or retract counterweight cylinders
Right position:
Activate the counterweight remote control box.
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(Following instructions are for crane equipped with Hirschmann computer system)
4.2 Computer system
4.2.1 General
Notice!
Note:
The monitor illustrations in this chapter are only examples. The numerical values in the
individual icons and tables do not necessarily match exactly to the crane.
The load moment limiter is a computer system for controlling and monitoring mobile cranes. In
addition to controlling the boom telescoping via computer programs, it is also of self-diagnosis
function.
The load moment limiter calculates data from the pressure sensor, length sensors, angle
sensors and other monitoring devices to judge whether the crane is in safe working conditions,
and displays the basic parameters, such as boom length, boom angle, working radius, rated
lifting capacity etc., on the LCD.
If the actual load is greater than 90% of the rated one, the warning light lights up and buzzer
sends out slow acoustic warning.
sends out fast acoustic warning and all dangerous crane movements are switched off.
The crane can only work towards safe directions till the dangerous operation is deactivated.
The load moment limiter can prevent crane from toppling or being destructed, thus ensures
crane’s safe operation. However, do not rely entirely on the load moment limiter. If the rated
lifting load displayed on the load moment limiter is different to the one shown in lifting capacity
table, refer to the lifting capacity table.
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The load moment limiter includes the following icons:

a) Auxiliary icons
Wind speed on boom head (m/s), engine working hours, current time and date;
b) Displays
Fuel gauge, water thermometer, engine oil pressure gauge, tachometer and main pump
pressure gauge;
c) Warning light icons:
Hoisting limit switch activated, lowering limit switch activated and engine defects;
d) Buttons
Bypass the buzzer and function keys.
Warning icons
Boom
Crane extension
status status
Load
information
Function
keys Displays
Function icons
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4.2.2 Programs
4.2.2.1 Switching on the computer system and performing self-test
After the computer system is switched on, the load moment limiter performs a self-test
automatically to check whether the three PLC controllers are connected. If no errors are found
during the system test, the monitor displays the following screen (See Fig. 1). Shortly after that,
the screen as shown in Fig.2 appears on the monitor.
Fig. 1 Self-test passed
Fig. 2 OM selection
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If the connection error is found during the test, the corresponding controller cannot pass the
test and the monitor shows the following screen (See Fig. 3).
Fig. 3 Self-test failed

Troubleshooting:
If an error message appears on the monitor?
– Turn off the engine and ignition and rectify the errors (especially checking the connectors)
– Start again to perform self-test again.
Caution:
If an error is found during communication, the buzzer will not stop sending alarm after
computer turned on. It is a normal phenomenon. Please rectify the communication fault.
After OM is selected, it switches automatically to the main screen – configuration program
(See Fig. 4). Many parameters can be monitored from this screen in real time.
Fig. 4 Main screen – configuration program
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The functions of the individual monitor operating elements are program-dependent, and can
be different in any running program. Therefore the individual programs will be described in
detail.
a) Function keys
F1 OM selection
F2 Telescopic boom length
F3 Telescoping
F4 Parameter set
F5 Diagnosis
F6 Not used
F7 Not used
F8 Buzzer bypassed
Note:
If the lowering limit switch, overload protection or pipe overpressure protection is activated,
press function key F8 to switch off the alarm. But the current error cannot be eliminated.
The error can only be rectified manually according to actual working conditions or the hints
given by the system.
b) Boom status
Display of main boom length, angle, radius, height etc. If the jib is selected, it will also
show the configuration of jib.
c) Display of OM code, counterweight, reeving, outrigger, winch speed, etc.
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d) Displays
Engine RPM Oil reserve

Engine oil pressure Coolant temperature
Engine working hours Pressure of main oil line
e) Load information
Display of load capacity bar (in percent), load weight, maximum load and wind speed.
f) Boom extension status
Display of individual telescopic section current extension status and target extension
status.
Order: Telescope 1 to telescope 5 from left to right.
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g) Warning icons
Can bus error
Engine defects
Lowering limit switch active
Hoisting limit switch active
Error code for load moment limiter
Warning
Stop
Current time
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4.2.2.2 Setting up operating mode
Set main operating mode and boom status before telescoping.

Press function key F1 (Shown in Fig. 4 Main screen) to switch to Fig. 5.
Current OM Target OM
图（五）主工况选择界面
Fig.5 Main OM selection
F1: select OM
F2: select reeving number
F3: arrow left (Move to the left. The selected data is highlighted in red.)
F4: arrow right (Move to the right. The selected data is highlighted in red.)
F5: arrow up (Increase the value. Range: 0 – 9)
F6: arrow down (Decrease the value. Range: 0 – 9)
F8: exit Fig. 5 after confirmation
For example
If the monitor shows , it indicates

– outriggers extended completely
– 92t counterweight
– main boom working condition
– 6 reevings
Note:
The numerical values are just for illustration and do not necessarily match exactly to the crane.
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Press function key F2 (Shown in Fig. 4 Main screen) to switch to Fig. 6.
Fig.6 Individual telescopic section extension status
F1 / F2: select data (The selected data is highlighted in red.)

F3: arrow up (Increase the value. Range: 0 – 9)
F4: arrow down (Decrease the value. Range: 0 – 9)
F5: match current telescopic combination with the select one
F8: exit Fig. 6 after confirmation
Caution:
(1) Only when the set OM is valid, can the telescoping operation be carried out;
(2) The operating mode highlighted in red is not suitable for lifting load, so automatic
telescoping operation is unavailable. Only manual telescoping operation is available.
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4.2.2.3 Telescoping operation
Two telescoping operations: manual / automatic

Automatic telescoping is strongly recommended.
The manual telescoping can only be activated when automatic telescoping is invalid or
during maintenance.
Boom combination illustration
Current state: 1－ 2― 3－ 4－ 1 (42.2 m)
Target boom length

Telescopic section V, numbers 1 - 4
Telescopic section IV, numbers 1 - 4
Telescopic section III, numbers 1 - 4
Telescopic section II, numbers 1 - 4
Telescopic section I, numbers 1 - 4
Numbers “I – V”: the corresponding telescopic section (highest number = furthest telescopic
section)
Numbers “1 – 4”: Telescopic section extension status (in percent %)
1: 0% 2: 45% 3: 90% 4: 100%
a) Automatic telescoping (3 steps in total)
1) Ensure that the following prerequisites are met:
– The valid operating mode has been set;
– The boom angle shouldn’t be less than 75°;
– Switch A has been set to “telescope”;
– Switch B is in neutral position;
– Switch C is in neutral position;
– Switch D is in neutral position;
– Icon does not appear.
If a telescoping error is detected (the above red icon illuminates), telescope the
boom manually until the error is removed. For detailed information, please refer to
manual telescoping operation.
As for how to check the current errors and how to clear up the stored errors,
please refer to the following contents.
A B C D
Caution:
All prerequisites mentioned above must be met. Otherwise, the automatic
telescoping operation can’t be activated.
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2) Ensure the current boom status is correct.

– Press function key F3 (shown in Fig. 4) to switch to Fig. 7;
– Confirm current boom status.
 If the current boom status matches with the actual one, press function key
F8 for confirmation;
 If the current boom status doesn’t match with the actual one, press function
key F6 for modification. As for how to modify the boom status, please refer
to following instructions.
Fig.7 Boom status confirmation
Danger:
It is very import to confirm the current boom status!
Improper setting will result in incorrect telescoping movement and cause fatal
accidents!
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After current boom status is confirmed, the system will switch to Fig.8.
Fig. 8 Telescoping
Top display area displays the following parameters:

– Boom length
– Boom angle
– Working radius
– Wind speed
Main display area displays:
– Control light icons
– Boom current status
– Boom target status
– Information about boom pin, cylinder pin and other related information.
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Control light icons:
Caution:
The instrument console is also arranged with such control lights as “Cylinder pin
beyond its target hole”, “Cylinder pin not reaching its hole”, “Telescopic cylinder
locked / unlocked”, “Boom pinned / unpinned”. These control lights will illuminate and
extinguish together with the corresponding icons on the touch screen.
Control light “Telescopic cylinder locked/unlocked” will illuminate only when icons
“Left cylinder pin opened/closed" and “Right cylinder pin opened/closed " are
illuminate simultaneously.
3) Telescope the boom sections automatically
– Ensure that the following prerequisites are met:
 Keys and are highlighted in green;
 Key is highlighted in green.

– Press function key F7;
Result
Switch D
 Keys , and are highlighted in grey.
– Set switch D (shown on the right) on left control box to left position. The
telescopic boom begins to initiate automatic telescoping movement.
Note:
The keys and will be highlighted in green if the telescopic sections

achieve their target status.
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Error calling up:

If an error is detected during telescoping, the telescoping movements will stop
automatically and this icon “ “ will be highlighted in red.
Press F2 to switch to Fig 9.
The contents highlighted in red are the detailed error information.
Rectify the errors manually according to the instructions.
Fig. 9 Boom telescope errors
Stored error cleared up:

If the icon “ “ is highlighted in red, but no contents in Fig. 9 are highlighted in red, it
indicates stored error exits.
Set switch D (in front page) from neutral position to right or left position and quickly
return to neutral.
Modify the current boom status:
Before switching to Fig. 8, confirm the current boom status (See Fig. 7) first.
If the displayed boom status differs from the actual one, press function key F6 “N” to
switch to Fig.10 for modification.
How to rectify the current boom status (See Fig. 10):
– Press function keys F1, F2 and F3 to select the corresponding telescopic section
which needs to be modified;
– Press function keys F5 / F6 to increase / decrease the numerical values;
– Press function key F7 “Y” to switch to Fig. 11;
– Enter correct password;
– Enter correct values;
– Press function key F7 “Y” for confirmation.
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Fig. 10 Current boom status modification
Fig. 11 Enter password
Danger:
It is very important to confirm the current boom status. If the current boom status is set
incorrectly, risk of fatal danger! If you need the password, please contact our
technician.
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b) Manual telescoping (7 steps in total)
Caution:
Because the manual telescoping is complex, it is recommended to initiate manual
telescoping only when the automatic telescoping is invalid or during maintenance.
1) The valid operating mode has been set. For details, please refer to the instructions in
“Automatic telescoping”;
2) Switch A is set to right position;
3) Switch B is in neutral position;
4) Switch C is in neutral position;
5) Switch D is in neutral position;
A B C D
Caution:
The boom angle is permitted to be lower than 75°. However, the operator should
select a safe angle according to actual boom length to ensure the safety of
telescoping.
6) Press function key F2 in Fig. 8 to switch to Fig. 12;
7) Telescope boom sections manually.
In Fig.12, if the above prerequisites are met, key will be highlighted in green.
In that case:
– Press function key F7;
Keys and are highlighted in grey.

– Set switch D to right position;
– Move the right joystick;
– Set switches B and C to required position to telescope boom sections manually.
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10 Control light
icons
1 Boom code
7 Target status
2 Telescope speed
9 Current status
3 Current cylinder
length
8 Target
telescoping 4 Current boom
section length for boom
pin opened
6 Pressure and
engine RPM 5 Target boom
length for boom
pin closed
Fig.12 Boom status during manual telescoping
Note:
The icon numbers mentioned in the following contents are the ones marked in Fig.12.
Observe the following instructions before carrying out manual telescoping

operation:
1) Lock and unlock telescopic cylinder
Danger:
Do not unlock the cylinder until the icons “Left cylinder pin opened” and “Right
cylinder pin opened” light up. Otherwise, risk of serious damage!
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2) Pin the telescopic section
Caution:
The movement “Telescope boom out / in” must be initiated slowly if
boom pin is released.
It is recommended to set right switch to right position and slowly
telescope the boom in / out to prevent the boom pin beyond its target
pin hole.
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3) Unpin the telescopic section
Caution:
Ensure the cylinder is locked (the 2 control lights on the right all
light up) before unpinning the telescopic sections.
If icon “Boom pinned” goes out, but icon “Boom unpinned” does not light up and the
value shown on pressure gauge keeps about 130 bar
– Stop closing the boom pin;
– Release boom pin till control light “Boom pinned” lights up;
– Close the boom pin again.
Caution:
The boom must be telescoped in slowly with a large boom angle (slow gear is
recommended) if the boom section is unpinned.
Icon "Boom operational” must be lighting up during boom telescoped-in process.
Accelerate telescoping operation after the telescopic cylinder retracts for a certain
length.
Caution:
In automatic telescoping operation, check the icon "Boom operational” for illuminating.
If not, grease the boom sections.
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4) Limitations for manual telescoping operation

The movement “Extend the telescopic cylinder” will be switched off automatically to
prevent the telescopic cylinder from being damaged if following prerequisites are met:
– All telescopic sections are telescoped in completely;
– Telescopic cylinder is unlocked;
– Telescopic cylinder is in the tail of telescopic section V;
– Icons “Cylinder pin beyond its target hole” and “Boom pin operational” light up.
In this case, only the telescopic section IV can be telescoped in.
Activate the bypass key switch to release this limitation.
Caution:
Do not press and hold the bypass key switch for a long time with other tools.
Otherwise, risk of inestimable loss.
5) Methods for identifying which boom section is carrying out movement

– Method 1
The lighted boom codes show that the corresponding telescopic sections will
carry out movements.
Control light “Boom code" lights up: 1
Control light “Boom code" goes out: 0
Number of telescopic section = “Code 1” * 1 + “Code 2” *2 + “Code 3” *4
For example:
If control light on Code 1 and Code 2 light up, the telescopic section III will carry
out movements.
– Method 2
Observe the boom code from the following area of Fig.12.
The icon of telescopic section I is highlighted in green which indicates the

telescopic section I is to carry out relevant movements.
– Method 3
The times the control light flashes every interval show that the
corresponding telescopic section will carry out movements.
6) If the boom section is unpinned, icon 4 displays the current boom length for boom pin
opened and icon 5 displays the target boom length for boom pin closed.
The length of telescopic cylinder will vary with the moving of joystick.
7) Icon 8 (Target telescoping section) indicates that the corresponding boom section
highlighted in green will carry out relevant movements. For example, in Fig. 12, the
highlighted section is telescopic section I. So, the telescopic section I is to carry out
telescoping movements.
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Points for attention during telescoping

(1) In automatic telescoping operation, the telescopic cylinder will drive the boom to
retract automatically if the telescopic section is unpinned (the control light "Boom
unpinned” lights up);
If the boom does not retract for a long time:
– Change automatic telescoping to manual telescoping;
– Extend the boom for 5 – 10 mm with slow gear (the second stage);
– Retract it again with slow gear (the second stage).
In this case, the operator must observe the above procedures; otherwise, risk of great
impact on the boom during retracting.
(2) If the boom pin cannot be closed during the process of telescoping in the boom
automatically:
– Open the boom pin manually until the control light “Boom pinned” lights up;
– Change to automatic telescoping again.
If the boom pin still cannot be closed, repeat above steps.
(3) If the icon “Boom telescoping fault” lights up during automatic telescoping operation
under the condition that the crane has worked for a long time:
– Extend the telescopic cylinder with slow gear (the second stage) until the length
of the telescopic cylinder varies.
If the icon 5 lights up during extending the cylinder:
Retract the telescopic cylinder till both the control light 3 (Cylinder pin beyond its
hole) and control light 4 (Cylinder pin not reaching its hole) all light up;
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(Following instructions are for crane equipped with Hong’ an computer system)
4.2 Computer system
4.2.1 General
Notice!
Note:
The monitor illustrations in this chapter are only examples. The numerical values in the
individual icons and tables do not necessarily match exactly to the crane.
The load moment limiter is a computer system for controlling and monitoring mobile cranes. In
addition to controlling the boom telescoping via computer programs, it is also of self-diagnosis
function.
The load moment limiter calculates data from the pressure sensor, length sensors, angle
sensors and other monitoring devices to judge whether the crane is in safe working conditions,
and displays the basic parameters, such as boom length, boom angle, working radius, rated
lifting capacity etc., on the LCD.
The load moment limiter can prevent crane from toppling or being destructed, thus ensures
crane’s safe operation. However, do not rely entirely on the load moment limiter. If the rated
lifting load displayed on the load moment limiter is different to the one shown in lifting capacity
table, refer to the lifting capacity table.
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The load moment limiter includes the following icons:

a) Auxiliary icons:
Wind speed on boom head (m/s), engine working hours, current time and date;
b) Instrument icons:
Fuel gauge, water thermometer, engine oil pressure gauge, tachometer and main pump
pressure gauge;
c) Warning light icons:
Hoisting limit switch activated, lowering limit switch activated and engine defects;
d) Button
Bypass the buzzer
Instrument
Auxiliary icons Warning Buzzer
icons light icons bypassed
button
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4.2.2 Programs
4.2.2.1 Switching on the computer system and performing self-test
After the computer system is switched on, the load moment limiter performs a self-test to check
whether the three PLC controllers are connected. If no errors are found during the test, the
monitor displays the following screen (See Fig. 1):
Fig. 1 Self-test passed

If the connection error of controller 0 (PLC) is found during the test, the monitor displays the
following screen (See Fig. 2).
Fig. 2 Self-test failed
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Troubleshooting:
a) Turn off the engine and ignition and rectify the errors (especially checking the connectors)
b) Start again to perform self-test again.
If self-test has run successfully, it switches to the “Main screen – Configuration program” (See
Fig. 3) automatically.
Fig. 3 Main screen - Configuration program

Icon line on bottom:
a) Auxiliary icons (from upward to downward)
1) Wind speed 3) Time
2) Engine working hours 4) Date
b) Instrument icons (from left to right)
1) Oil reserve 4) Engine RPM
2) Oil pressure 5) Pressure of main oil line
3) Coolant temperature
c) Warning light icons
1) Hoisting limit switch activated 4) Buzzer bypassed button
activated
2) Lowering limit switch activated
3) Engine defects
Icon line on top:
a) Boom length d) Boom’s working condition
b) Boom angle e) Tricolor light
c) Working radius
Caution:
The starting time of load moment limiter is longer than starting the PLC’s, so it is a normal
phenomenon to hear the buzzer alarm. The alarm will stop automatically after Fig.1 appears.
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Troubleshooting:
If the alarm does not stop after Fig. 1 appears, it may be
a) Connection error
b) Hoisting limit switch activated
c) Lowering limit switch activated
d) Overload protection activated
e) Pipe overpressure protection activated
Pressing “Buzzer bypassed button” can switch off the alarm, but the current error cannot be
eliminated. The error can only be rectified manually according to actual working conditions or
the hints given by the system. The error can be found in Fig. 20: PLC status check – Control
lights status.
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4.2.2.2 Setting up operating mode
Set operating mode before telescoping.

Press the key “Operating mode setting” on the top left-hand corner of “Main screen” to switch
to “Operating mode set” screen (See Fig.4).
Caution:
Only when the operating mode is valid, can the system carry out telescoping operations.
Definition of “Operating mode code” (5-digit short code):
A B C D E
The 1st digit The 2nd digit The 3rd digit The 4th digit The 5th digit
Boom \ jib Telescoping
Outrigger Counterweight Jib combination
selection combination
Three kinds of OM setting methods:
a) Manual matching; c) Looking up lifting capacity table
b) Entering 5-digit short code;
The manual matching is recommended.
Method 2:
Enter 5-digit
short code
Method 3:
Look up lifting
capacity table
Method 1:
Manual
matching
Fig. 4 Operating mode set
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a) Manual matching
1) Select corresponding parameters in such items as counterweight, main boom, rope
reeving, jib and offset according to actual conditions. The operating mode code is
generated automatically and displayed on the screen;
2) Press key “Save” to confirm the settings and return to the main screen.
For the detailed information, please refer to Fig.5, Fig.6, Fig.7 and Fig.8.
If the selected parameters can form a valid OM code, it will be displayed on the screen
automatically; if the selected parameters cannot form a valid OM code, there will be no
valid OM code displayed.
Caution:
(1) When modify the value of a parameter, its input frame must be selected. If the input
frame is highlighted in yellow or blue, it means that the input frame is selected;
(2) Click “▼” to display vertical axis of value field. If there are too many parameters for
selection, click “▲” or “▼” to scroll upward or downward.
Fig. 5 Fig. 6
Fig. 7 Fig. 8
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b) Enter 5-digit short code

1) Enter OM code according to OM Code Manual. Press the key “Input” to switch to Fig.
9;
2) Press the key “Save” to confirm the settings and return to Fig.4.
Caution:
If the input OM code is invalid, a dialog box will appear to require operator to enter the OM
code again according to OM Code Manual.
c) Look up lifting capacity table
1) Press “Table” to switch to Fig.10;
2) Enter load weight and radius range to check the OM code;
3) Enter OM code.
Fig. 9 OM code input Fig. 10 OM check
Caution:
(1) Press "Find" to check whether the valid OM can be generated after entering the load
weight and radius range. If the OM is invalid, check whether the load weight or the
radius range is too large. Decrease the values according to actual working conditions
and check again;
(2) Select a suitable OM and press key “Save” to switch to Fig.4. Press key “Save” again
to return to Fig.3;
(3) The “counterweight and outrigger” dialogue box is displayed;
(4) Do not carry out lifting operation until the current counterweight matches with the
selected one.
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4.2.2.3 Telescoping operation
Two telescoping operations: manual / automatic

Automatic telescoping is strongly recommended.
The manual telescoping can only be activated when automatic telescoping is invalid or
during maintenance.
Boom combination illustration
Current state: 1－ 2― 3－ 4－ 1 (42.2m)
Target boom length

Telescopic section V, numbers 1 - 4
Telescopic section IV, numbers 1 - 4
Chaptersection
Telescopic 4 III, numbers 1-4
Telescopic section II, numbers 1 - 4
Telescopic section I, numbers 1 - 4
Numbers “I – V”: the corresponding telescopic section (highest number = furthest telescopic
section)
Numbers “1 – 4”: Telescopic section extension status (in percent %)
1: 0% 2: 45% 3: 90% 4: 100%
a) Automatic telescoping (3 steps in total)
1) Ensure that the following prerequisites are met:
– The valid operating mode has been set;
– The boom angle shouldn’t be less than 75°;
– Switch A has been set to “telescope”;
– Switch B is in neutral position;
– Switch C is in neutral position;
– Switch D is in neutral position;
– Icon “ ” does not appear.
If a telescoping error is detected (the above red icon illuminates), telescope the
boom manually until the error is removed. For detailed information, please refer to
manual telescoping operation.
As for how to check the current errors and how to clear up the stored errors,
please refer to the following contents.
A B C D
Caution:
All prerequisites mentioned above must be met. Otherwise, the automatic
telescoping operation can’t be activated.
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2) Ensure the current boom status is correct;

– Press the key “Telescope” to switch to Fig. 11;
– Confirm current boom status.
If the displayed boom status matches with the actual one, press key “Yes” to confirm.
If the displayed boom status does not match with the current one, press key “No”.
As for how to reset the boom status, please refer to the following instructions.
Fig. 11 Boom status confirmation
Fig.12 Boom status modification
Danger:
accidents!
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After current boom status is confirmed, the system will switch to Fig.13.
Button -
telescope Information
line
Fig.13 Boom status during telescoping

Top display area displays the following parameters:
– Boom length
– Boom angle
– Working radius
The information line displays the OM code and other related information.
Main display area (right-hand corner) displays:
– Boom current status
– Boom target status
3) Telescope the boom sections automatically.
– Ensure that the following prerequisites are met:
 Key “Telescope” is highlighted in grey;
 Key “Start” is highlighted in blue.
– Press the key “Start”;
Switch D
Result
 Keys “Start”, “Back” and “Manual” are highlighted in grey.
– Set switch D (shown on the right) on the left control box to left position. The
telescopic boom begins to initiate automatic telescoping movement.
Note:
The keys “Back” and “Manual” will be highlighted in blue if the telescopic sections
reach their target status.`
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Error calling up:

If an error is detected during automatic telescoping, this icon “ “ will be highlighted
in red.
Press icon “ “ to call up the errors. The contents highlighted in yellow are shown
the information about the errors (See Fig.14).
Rectify the errors manually according to the instructions.
Fig. 14 Boom telescope errors

If the icon“ ” is still highlighted in red after the errors are rectified, set switch D (in
front page) from neutral position to right or left position and quickly return to neutral.
Modify the current boom status:
If the current boom status differs from the displayed one, press “No” in Fig.11 to
switch to Fig.12.
How to rectify the current boom status (See Fig. 15):
– Select the telescopic section which needs to be modified (The selected one will
be highlighted in yellow);
– Press “+1” or “-1” to change the boom status;
– Press “OK” to confirm.
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Fig. 15 Current boom status modification
Danger:
accidents!
If user needs authorization code, please contact our technical personnel!
b) Manual telescoping (7 steps in total)
Caution:
Because the manual telescoping operation is complex, it is only recommended to initiate
manual telescoping only when the automatic telescoping is invalid or during maintenance.
1) The valid operating mode has been set. For details, please refer to the instructions in
“Automatic telescoping”;
2) Switch A has been set to right position;
3) Switch B is in neutral position;
4) Switch C is in neutral position;
5) Switch D is in neutral position;
A B C D
Caution:
The boom angle is permitted to be lower than 75°. However, the operator should
select a safe angle according to actual boom length to ensure the safety of
telescoping.
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6) Press key “Manual” in Fig.13 to switch to Fig. 16;

7) Telescope boom sections manually.
In Fig.16, the current boom status can’t be modified, but the target boom status can
be modified if the OM code is valid.
– Press key “Start” after the target boom status is set;
– Set switch D to right position after the key “Start" is highlighted in grey;
– Deflect the right joystick;
– Set switches B and C to required position to telescope boom sections manually.
14 Boom target 1 Telescope out 2 Telescope in

status
13 Boom code
3 Boom code
12 Current
telescopic 4 Boom
cylinder length unpinned
11 Target boom
length for boom 5 Boom pin
pin opened operational
10 Current boom
length for boom 6 Right cylinder
pin closed pin opened
9 Boom pinned 8 Right cylinder pin 7 Main oil line

closed pressure
Fig.16 Monitor screen – Boom status during manual telescoping

Note:
The icon numbers mentioned in following contents are the ones marked in Fig.16.
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Observe the following instructions before carrying out manual telescoping

operation:
1) Lock and unlock telescopic cylinder
Danger:
Do not unlock the cylinder until the icon 9 lights up. Otherwise, risk of serious
damage!
The instrument console is also arranged with such control lights as “Cylinder pin
beyond its target hole”, “Cylinder pin not reaching its target hole”, “Telescopic cylinder
locked / unlocked”, “Boom pinned / unpinned”. These control lights will illuminate and
extinguish with the icons on the touch screen.
2) Pin the telescopic section
Caution:
The movements “Telescope boom out / in” must be initiated slowly if
boom pin is released.
It is recommended to set right switch to right position and slowly
telescope the boom in / out to prevent the boom pin beyond the target
pin hole.
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3) Unpin the telescopic section
Caution:
Ensure the cylinder is locked (the 2 control lights on the right all light
up) before unpinning the telescopic sections.
Troubleshooting
If icon “Boom pinned” extinguished, but icon “Boom unpinned” does not illuminate
and the value shown on pressure gauge keeps about 130 bar
– Stop closing the boom pin;
– Release boom pin till control light “Boom pinned” lights up;
– Close the boom pin again.
Caution:
The boom must be telescoped in slowly with a large boom angle (slow gear is
recommended) if the boom section is unpinned.
Icon 5 should be lighting up during boom telescoped-in process.
Accelerate telescoping operation after the telescopic cylinder retracts for a certain
length.
4) Limitations for manual telescoping operation
The movement “Extend the telescopic cylinder” will be switched off automatically to
prevent the telescopic cylinder from being damaged if following prerequisites are met:
– All telescopic sections are telescoped in completely;
– Telescopic cylinder is unlocked;
– Telescopic cylinder is in the tail of telescopic section V;
– Icons 2 and 5 light up.
In this case, only the telescopic section V can be telescoped in.
Activate the bypass key switch to release this limitation.
5) Methods for identifying which boom section is carrying out movement
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– Method 1:
The lighted boom code/codes shows/show that the corresponding telescopic
section will carry out movements.
Control light “Boom code" lights up: 1
Control light “Boom code" goes out: 0
Number of telescopic section = “Code 1” * 1 + “Code 2” *2 + “Code 3” *3
For example:
If control lights on Code 1 and Code 3 light up, the telescopic section IV will carry
out movements.
– Method 2:
Observe the boom code from Fig.16 Monitor screen – Boom status during
manual telescoping.
– Method 3:
The times the control light flashes every interval show that the
corresponding telescopic section will carry out movements.
6) If the boom section is unpinned, icon 10 displays the current boom length for boom
pin closed and icon 11 displays the target boom length for boom pin opened.
7) The length of telescopic cylinder will vary with the moving of right joystick.
8) Modify the boom target status
– Press the number frame till it is highlighted in yellow;
– Press “+1” and “-1” (The input data should be valid combination).
The boom current status can’t be modified in Fig.16. It can only be modified in Fig.15.
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Points for attention during telescoping

(1) In automatic telescoping operation, the telescopic cylinder will drive the boom to
retract automatically if the telescopic section is unpinned (the control light "Boom
unpinned” lights up);
If the boom does not retract for a long time:
– Extend the boom for 5 – 10 mm with slow gear (the second stage);
– Retract it again with the slow gear (the second stage).
In this case, the operator must observe the above procedures; otherwise, risk of great
impact on the boom during retracting.
(2) If the boom pin cannot be closed during the process of telescoping in the boom
automatically:
– Open the boom pin manually until the control light “Boom pinned” lights up;
If the boom pin still cannot be closed, repeat above steps.
(3) If the icon “Boom telescoping fault” lights up during automatic telescoping operation
under the condition that the crane has worked for a long time:
– Extend the telescopic cylinder with slow gear (the second stage) until the length
of the telescopic cylinder varies.
If the icon 5 lights up during extending the cylinder:
 Retract the telescopic cylinder till both the control light 3 (Cylinder pin
beyond its hole) and control light 4 (Cylinder pin not reaching its hole) all
light up;
 Change to automatic telescoping again.
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4.2.2.4 System checks and diagnosis
Switch to Fig.3 “Main screen - Configuration program”;

Press button “Check and diagnose” in “Routine operation” menu to switch to Fig.17.
The “Communication test” is default.
Press the other 4 buttons to check and diagnose the system according to the requirements.
Fig.17 System checks and diagnosis Fig.18 Sensor check

a) Control system test
Carry out simulant test of load moment limiter to check the percentage between actual
load and rated load. As for detailed information, please refer to Operating Manual for Load
Moment Limiter.
b) Sensor check
Observe the real-time output values of sensors (See Fig.18).
c) PLC status check
Test the actual input and output values of PLC in different crane movements.
The frame highlighted in white displays analog quantities, and the grey frame displays
Boolean quantities.
In the following flow charts, the grey frame will be highlighted in red and the white
frame will display the corresponding data (See Fig.19 & Fig.20).
From the flow charts, the operator can check actual parameters, do diagnosis and judge
whether the operation is mis-operated.
For example, if the remote controller needs to be operated, switch “Counterweight
cylinders active” (in remote controller) must be turned to right position. If switch
“Counterweight cylinders active” is turned to left position, the remote controller will be
invalid. In this case, the frame color of “Counterweight cylinders active” (shown in Fig. 20)
will not be highlighted in red.
The crane movements "Derrick " and "Spool up / reef off main winch” can also monitor the
input and output values of PLC. The operator can monitor the parameters according to
working requirements.
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Fig.19 PLC status check - Slewing monitoring
Fig.20 PLC status check – Control lights status

4) PLC parameters set
Enter password before setting parameters.
If password is confirmed, Fig.21 will appear.
Caution:
The PLC parameters should only be set by technical personnel.
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Fig.21 PLC parameter set
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4.3 Starting up the crane
4.3.1 Checks before starting up
Ensure that the following prerequisites are met before starting up:
a) Checking the engine oil level
1) The machine has been leveled;
2) Pull out the dipstick and clean it;
3) Re-insert it into oil and pull out again;
4) Check whether the oil level is between MIN. and MAX. markings.
Warning:
If the oil level is lower than the Min. marking, fill oil. Otherwise, the engine will be damaged
seriously!
b) Checking oil level in hydraulic fluid reservoir
The oil level in hydraulic fluid reservoir must be between MIN. and MAX markings.
c) Checking the fuel reserve
The fuel reserve is displayed on the bottom part of load moment limiter screen. “1’
represents fuel reserve of 100% and “0” represents fuel reserve of 0%.
Caution:
Deaerate the fuel system before adding fuel.
If the fuel tank has been run dry, always deaerate the whole fuel system.
Do not run the fuel tank dry!
d) Checking the coolant level
Fill coolant expansion tank up to overflow on filler neck. If the coolant level is too low, the
warning light “ “on the instrument console in operator’s cab will light up.
The coolant used in engine is antifreeze and antirust fluid. Add antifreeze fluid in different
grades of freezing point according to different ambient temperature (Generally speaking,
the antifreeze fluid grade is -5℃ in the condition of new product leaving the factory. In
winter, the antifreeze fluid grade is -25℃ to -35℃). Never use water to substitute for
antifreeze and antirust fluid.
Danger:
Engine must be cooled to be lower than 50℃ when performing coolant level check.
Otherwise, danger of injury due to scalding of the skin!
e) Checking central lubricating system
The grease container must be kept filled with grease.
f) Checking general conditions of crane
1) Check that the crane is properly supported on a level load-bearing surface, and has
been set up horizontally;
2) Check that the toothed ring of the slewing ring connection is clean and greased;
3) Check that the front and rear parts of oil cooler and A/C radiator have been cleaned
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and are free of blockage;

4) Ensure that there are no people or objects in the crane danger zone;
5) Make sure that the cable / rope drums and sensors are free of snow and ice;
6) Make sure that there are no loose parts on the superstructure or the telescopic boom.
Danger:
Before raising the boom, check that there are no loose parts on the boom. Otherwise, rise
of accident from falling parts!
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4.3.2 Starting the engine
a) Switching on battery master switch
Right position:
1) The battery master switch near the battery on slewing table is
switched on;
2) The switch background lights up;
3) The superstructure is energized.
b) Switching on the engine

With two switch positions, in clockwise direction
Position 1:
Electrical system for engine is energized.
Position 2:
Engine starts.
Caution:
(1) After the engine has been started, release the key to let it return to the position 1
automatically. This key has the function to prevent the engine from being started
repeatedly (i.e., if the engine has been started, the next engine starting will be invalid until
the key is returned to the original zero position);
(2) Never run the motor for 15 seconds continuously. The motor can be operated two times
per attempt with a pause in between of several minutes each time to avoid battery
discharging electricity and starting motor being damaged. If the engine cannot be started
after 3 attempts, have the engine defects rectified.
4.3.3 Computer system after engine start
The Main screen - Configuration program will appear on the monitor after the computer system
is switched on and has passed its self-test. After the engine starts, the relevant data, such as
engine working hours, date, time, oil reserve, oil pressure, coolant temperature and engine
RPM etc., can be monitored via the load moment limiter screen. Check the relevant data. Once
an error is detected, turn off the engine and find out the cause.
OM (operating mode) set can be performed on the Main screen - Configuration program. For
detailed information, please refer to Chapter 4.2.2.
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4.4 Safety devices
4.4.1 General
Every time the crane is operated, the crane operator is required to satisfy himself about the
functionality of the safety systems.
Danger:
Danger of accident from defective warning and safety systems!
Operating the crane with defective warning and safety systems can lead to life-threatening
accidents!
4.4.2 Support control unit
To ensure the working safety of the crane, the crane must be properly supported on a level
load-bearing surface, and be set up horizontally.
A support control unit with buttons is attached to each side of the vehicle for operating the
outrigger, together with an electronic inclinometer from which the operator can observe
horizontal alignment of the crane.
Caution:
The maximum permitted deviation from the horizontal position of the crane is ± 0.6°. Otherwise
fatal accidents may be increased.
If deviation ＞2.0°, the

LED flashes.
If 1.6° ≤ deviation ≤ 2.0°,

the LED lights up.
If 1.2° ≤ deviation ≤1.6°,

the LED lights up.

the LED lights up.
the LED lights up.
If deviation ≤0.4°, the

LED lights up.
4.4.3 Load moment limiter
The load moment limiter is a device for controlling and monitoring the crane's movements.
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4.4.4 Hoisting / lowering limit switch

a) Lowering limit switch
In order to prevent the wire rope from being reeled reversely after being reeled off
completely, the lowering limit switches installed beside the winches will switch off the
movements ”Reel off winches” if there are only 3 rope windings remaining on the winches.
In this case, the acoustic sound will be heard and only the upward movement of the hook
is permitted. During commissioning and maintenance, activate the bypass key switch on
the control console to release the limitation.
b) Hoisting limit switch

If the hook block contacts the hoisting limit switch weight during its upward movement, the
hoisting limit switch is triggered and buzzer sounds. The crane movements “Spool up
winches”, “Derrick main boom down” and “Telescope boom out” are switched off. At this
time, only the crane movements “Reel off winches”, “Derrick main boom up” and
“Telescope boom in” can be switched on. This switch-off can be bypassed when the
hoisting limit switch is released.
Hoisting limit switch on Hoisting limit switch Hoisting limit switch
boom on jib on rooster sheave
weight
Hoisting limit switch
switch ring
Hoisting limit
Dangerous operation (Be switched off) Bypassed (Return to safe operation)
Press the bypass key switch on the control console to switch on the crane movements “Spool
up winches”, “Derrick main boom down” and “Telescope boom out” during commissioning and
maintenance.
Warning:
Never use the bypass key switch in normal operation!
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4.4.5 Hydraulic safety valves
a) Relief valves in hydraulic system

The relief valves in hydraulic system can prevent the pressure in the circuit from rising too
high, thus avoid hydraulic pump and hydraulic motor from being damaged and hydraulic
system from being overloaded.
b) Outrigger locking device
If the high-pressure oil pipe which is connected to vertical cylinder is damaged, the
two-way hydraulic lock in the outrigger hydraulic circuit can block the pressure oil in the
two chambers of outrigger cylinder to prevent the outrigger from retracting or extending,
and thus ensure the safe operation of the crane.
c) Locking device for crane movement “Derrick main boom up”
If the high-pressure oil pipe in the hydraulic circuit of derricking cylinder is damaged, the
balance valve in the hydraulic circuit can lock the hydraulic oil in the lower chamber of
derricking cylinder immediately to prevent the boom upward movement from being down,
and thus ensure the safe operation of the crane.
d) Locking device for crane movement “Telescope boom out”
If the high-pressure oil pipe in the hydraulic circuit of telescopic cylinder is damaged, the
balance valve in the hydraulic circuit can lock the hydraulic oil in the upper chamber of
telescopic cylinder immediately to prevent the telescopic boom sections from retracting
naturally, and thus ensure the safe operation of the crane.
4.4.6 Bypass operation
If the hook block contacts the hoisting limit switch during its upward movement or lowering limit
switch during its downward movement, the hoisting limit switch or lowering limit switch is
triggered. The dangerous movements will be switched off.
If the maximum load moment is exceeded, the overload protection control system will switch
off all crane movements to increase load moment. The buzzer begins to send out alarm. If
necessary, this switch-off can be bypassed by the bypass key switch in operator’s cab. For
details, please refer to the relevant information of “Bypass key switch” in Chapter 4.1.5.
Illustration – Control system switches off the dangerous movements
Auxiliary
Main winch Derrick Slew Telescope
winch
up down up down up down left right out in
Overloading × √ × √ √ × √ √ × ×
Overwinding × √ × √ √ × √ √ × ×
Overlowering √ × √ × √ × √ √ × ×
Danger:
If there is a need to lift or lower the hook a little under special conditions, the operator can
activate the “Bypass key switch” on the instrument console to bypass the crane’s switch-off
movements. Such operation should be performed with utmost caution to avoid accident. And
all consequences resulted from such operation should be taken by the operator!
Never telescope telescopic boom with a load. Otherwise, all consequences are rest with the
operator!
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4.4.7 Wind warning system
The wind gauge is fitted on the boom head of the crane to detect the wind speed. The wind
speed appears in the screen of load moment limiter. If the actual wind speed exceeds the
maximum value, stop the crane operation and lower the boom.
Danger:
Risk of accident from crane toppling if operating in the condition of exceeding the permitted
wind speed!
Wind gauge
4.4.8 Emergency off switch
The “Emergency off switch” (See the following Fig.) is fitted on the instrument console in
operator’s cab. If it is operated, the electrical crane control is switched off. Every movement
carried out will be immediately stopped.
After emergency is removed, the switch-off can be bypassed by turning it in the arrow direction.
Warning:
Only use the “Emergency off switch” in the event of a clear emergency!
Use of the “Emergency off switch” for normal operation is not permitted!
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4.5 Crane operation
4.5.1 Preparations for crane operation
Ensure that following checks are operated before operation:

a) Assess the load condition prior to lifting it;
b) Check the crane position, ground condition and surface bearing condition;
c) Check wire ropes (including wire rope’s end, winding drum and pulleys);
d) Check the liquid level and power source of the crane;
Note:
(1) Fuel reserve of the fuel tank is more than 1/4 of the tank capacity (Check the fuel
gauge);
(2) The oil level in hydraulic fluid reservoir should be between MIN. and MAX markings in
driving condition.
e) The loading and working area should be visible and without obstacles within it. Check the
communication system of operator and supervisor to ensure that nothing will hinder the
operation;
f) Check safety devices for function;
g) Remain the communication between the operator and the rigger.
Warning:
In order to protect the crane and reduce the danger of accidents, always operate the joysticks
slowly and cautiously.
Danger:
Ensure that there are no obstacles in the crane working area and no persons in danger zone.
Give a short warning signal (horn) before starting a crane movement.
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4.5.2 Derricking
The telescopic boom is derricked via an oil cylinder.

The boom angle varies from -0.5° to 82°.
Operate the right joystick to derrick the telescopic boom up / down.
Before derricking, turn the switch A (Shown on the right) to left position.
Switch A
Speed of crane movement “Derricking” has 2 stages, normal gear and slow gear, which are
activated via switch B (See the following Fig.).
Normal gear:
The more the joystick is deflected to the left or right, the higher the derricking speed will be.
Slow gear:
Switch “Slow gear switch” to right position.
If the boom length ＜ 40 m, the speed of “Derricking” is slow.
If the boom length ≥ 40 m, the speed of “Derricking” is extremely slow.
Switch B
The balance valves fitted in hydraulic system can not only ensure that the load is lifted /
lowered steadily but also keep the load at any required position.
Caution
(1) Operation should be carried out stably. Jerky operation will bring great impact to the crane
during load lifting;
(2) Never increasing the working radius with load. Operator should strictly restrict the
maximum working radius according to lifting capacity tables;
(3) Lower the hook fully before derricking up the boom;
(4) For the sake of safety, never derrick down the boom at high speed.
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4.5.3 Telescoping
The boom consists of 6 oval boom sections made from low-alloy and high-strength steel.
The telescopic boom is telescoped in / out via a telescopic cylinder. The movements
“Telescope telescopic boom in / out” are controlled by the right joystick automatically. Every
telescopic section can be varied in 3 lengths: 45% of its total, 90% of its total and 100% of its
total. The telescopic cylinder cannot bear any load.
Before telescoping, turn switch A (See right Fig.) to right position.
Switch A
For the details of telescoping operation, refer to Chapter 4.2.

The balance valves fitted in hydraulic system can ensure that the boom is telescoped in / out
steadily.
Caution:
(1) When auto telescoping mode is performed, the boom angle should exceed 75°;
(2) The hook will be lifted or lowered with the crane's movements “Telescope telescopic boom
in or out”. Therefore, operate the joystick to adjust the height of hook during telescoping;
(3) Carry out telescoping movements with maximum care and minimum speed. Do not
telescope the telescopic boom with load;
(4) Do not telescope the boom out immediately after the boom is telescoped in. Initiate
telescoping movement after 2 seconds;
(5) It is forbidden to pull the load diagonally.
Before carrying out telescoping movement, check whether the block at the head of telescopic
sections is in contact with its adjacent telescopic sections tail completely. If not, adjust the
shim to make them contact completely and ensure that the boom pin and cylinder pin bear no
load under the condition of “Boom telescoped in completely”.
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4.5.4 Lifting / lowering
The hoist mechanism consists of hydraulic motor, balance valve, reducer, brake, lowering limit
switch, hoisting limit switch, wire rope, main hook, auxiliary hook and so on.
The hoist mechanism consists of two parts: main winch and auxiliary winch. The auxiliary
winch is not fitted on the slewing table during driving. The joysticks for controlling main /
auxiliary winch are fitted on the right / left control boxes in the operator’s cab.
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The crane movement “Spool main winch up” or "Reef main winch off” has 3 stages, high speed,
normal speed and low speed, which are activated via the “Slow gear switch” (See the following
Fig.).
The crane movements “Spool auxiliary winch up” or "Reel auxiliary winch off” have 2 stages,
normal speed and low speed, which are also activated via the “Slow gear switch” (See the
following Fig.).
Auxiliary winch
a) Normal speed
The more the left joystick is deflected upward or downward, the higher
the speed will be.
b) Low speed
Result
Slow gear is applied to crane movements "Spool auxiliary winch up" or “Reel auxiliary
winch off ".
Main winch
a) Normal speed
The more the right joystick is deflected upward or downward, the higher the speed will be.
b) Low speed
Result
Slow gear is applied to crane movements "Spool main winch up" or “Reef main winch off".
c) High speed
1) Switch off “Slow gear switch”;
2) Deflect the right joystick;
3) Press and hold the button “Rapid gear for main winch”.
Result
Rapid gear is applied to crane movements "Spool main winch up" or “Reef main winch
off".
The balance valves fitted in hoist mechanism can not only ensure that the winches are spooled
up / reeled off steadily, but also make the load stay at any required position.
The wire rope may be not long enough with the boom telescoping out and derricking up. Such
problem can be solved by changing the reeving numbers of wire rope. Before changing the
reeving numbers, fit the hoisting limit switch weights. For standard reeving numbers for various
boom lengths, please refer to the lifting capacity tables.
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Caution:
(1) Choose proper reevings in accordance with boom lengths;
(2) Under any conditions, there must be at least three windings of wire rope left on the
winding drum;
(3) When a load is lifted away from the ground, it should first be suspended in the air for a
moment. Do not lift the load until the operator confirms that there is no safety hazard. Do
not derrick up and telescope out the boom to lift the load if the load does not leave away
from the ground;
(4) Do not change the joystick between “Spool up” and “Reel off” jerkily. The operator should
return the joystick to neutral position and ensure that the winding drum has stopped
rotating before changing between “Spool up” and “Reel off”. Otherwise, the machine will
be damaged;
(5) The slings must be of enough strength;
(6) The lifting capacity includes the mass of the hook and slings.
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4.5.5 Slewing
The slewing system consists of slewing ring and slewing mechanism which includes hydraulic
motor, planet-gear reducer, slewing brake valve, brake, drive gear and so on.
a) Slewing speed
The speed of the crane movements “Slewing”, varying within 0 – 1.5r/min, is controlled by
the deflection of left joystick. The slewing speed has 2 stage, normal speed and low speed,
which can be activated by switching on the “Slow gear switch”. The low speed offers good
micro-positioning performance.
b) Slewing operation
Slewing movements can be activated by the deflection of the left joystick fitted in the
operator’s cab.
Caution:
(1) Ensure that the superstructure is unpinned before initiating the slewing movement. Insert
and secure the pin after finishing this operation;
(2) Ensure that there are no obstacles in the crane slewing area and no persons in the danger
zone. Give a short warning signal (horn) before starting a crane movement;
(3) Initiate the slewing movements smoothly. It is prohibited to stop slewing movements or
change slewing direction jerkily;
(4) Longer boom length – lower slewing speed;
(5) Heavier load - lower slewing speed;
(6) In order to ensure safe operation of a new crane, the user must check bolts of slewing ring
and tighten the bolts with 1850N.m tightening torque after initiating for 100 operating
hours. Then check and tighten the bolts after 100 and 300 operating hours. After that, do
the checks every 500 hours;
(7) The switch “Extend or retract counterweight cylinders” (See
the Fig. on the right) must be turned to left position before
slewing. Otherwise, switches on the instrument panel are
inactivated and the left joystick cannot initiate slewing
movements. The slewing movements are controlled by the
remote control box.
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4.5.6 Rope reeving
Ensure that the following preconditions are fulfilled:

– The outriggers have already been extended;
– The main boom has been fully telescoped in and turned to the side or rear working area.
a) Derrick boom down and place hook on the ground;
b) Remove the rope securing tubes;
c) Remove hoisting limit switch weight from wire rope;
d) Remove the pouch socket;
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e) Change rope reevings;
Reeve the rope through boom head pulley and hook pulley, and choose correct reevings
according to the lifting capacity table. Secure rope in the boom head (even reeving
number) and rope in the hook (odd reeving number).
Caution:
(1) The hoisting limit switch weight should be fitted on the rope end to ensure the hoisting
limit switch in function;
(2) Spool the rope smoothly and orderly onto the drum.
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4.5.7 Simultaneous crane movements
The simultaneous crane movements, which can greatly improve the working efficiency, refer to
that the crane can carry out 2 movements simultaneously. However, because the simultaneous
crane movements are towards two different directions, the operator should take maximum care
to avoid accident.
Ensure that the following preconditions are met when initiating simultaneous crane
movements:
– Activate the PTO switch to make the engine speed achieve 1850 r/min;
– Do not deflect the joysticks to limit position.
There are 9 simultaneous crane movements available:

a) Auxiliary winch + main winch
– Deflect the left joystick and right joystick at the same time according to the above Fig.
to make auxiliary winch and main winch work simultaneously;
– The more the joysticks are deflected upward or downward, the faster the relevant
movements will be;
– Press and hold button “Rapid gear for main winch” without activating the “Slow gear
switch” to achieve rapid movements of main winch without load;
– Switch on “Slow gear switch” to make relevant movements get slower.
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b) Auxiliary winch + derricking
– Turn switch “Pre-selection of derrick / telescope” (on left control box) to left;
– Operate left joystick and right joystick at the same time according to above Fig. to
make auxiliary winch and derricking mechanism work simultaneously;
– The more the left joystick is deflected upward or downward and right joystick is
deflected leftward or rightward, the faster the relevant movements will be;
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c) Auxiliary winch + telescoping
– Turn switch “Pre-selection of derrick / telescope” (on left control box) to right;
make auxiliary winch and telescopic boom (in manual telescoping operation) work
simultaneously;
– The more the left joystick is deflected upward or downward and right joystick is
deflected leftward or rightward, the faster the relevant movements will be;
– Switch on “Slow gear switch” to make relevant movements get slower;
– For automatic telescoping operation, the right joystick and “Slow gear switch” are
invalid.
Caution:
The “Automatic telescoping operation” is recommended when telescoping the boom.
d) Slewing + main winch
– Operate left joystick and right joystick at the same time according to the above Fig. to
make slewing mechanism and main winch work simultaneously;
– The more the left joystick is deflected leftward or rightward and right joystick is
deflected upward or downward, the faster the relevant movements will be;
switch” to achieve rapid movements of main winch without load.
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e) Slewing + telescoping
– Turn switch “Pre-selection of derrick / telescope” (on left control box) to right;
make crane movements “Slewing” and “telescoping” work simultaneously;
– The more the joysticks are deflected leftward or rightward, the faster the relevant
movements will be;
– Switch on “Slow gear switch” make relevant movements get slower;
– For automatic telescoping operation, the right joystick and “Slow gear switch” are
invalid.
Caution:
The “Automatic telescoping operation” is recommended when telescoping the boom.
f) Slewing + derricking
– Turn switch “Pre-selection of derrick / telescope” (on left control box) to left;
make crane movements “Slewing” and “Derricking” work simultaneously;
– The more the joysticks are deflected leftward or rightward, the faster the relevant
movements will be;
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g) Auxiliary winch + slewing
– Deflect the left joystick between any two adjacent arrows with an angle of 45° to make
auxiliary winch and slewing mechanism initiate relevant movements (See above Fig.)
simultaneously;
– The more the joystick is deflected leftwards or rightwards, the faster the slewing
movements become; and the slower the winch movements;
– The more the joystick is deflected upwards or downwards, the faster the winch
movements become; and the slower the slewing movements;
h) Main winch + derricking
– Deflect the right joystick between any two adjacent arrows with an angle of 45° to
make main winch and derricking mechanism initiate relevant movements (See above
Fig.) simultaneously;
– The more the joystick is deflected leftwards or rightwards, the faster derricking
movements becomes; and the slower the winch movements;
movements become; and the slower the derricking movements;
switch” to achieve rapid movements of main winch without load.
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i) Main winch + telescoping
– In manual telescoping mode, deflect the right joystick between any two adjacent
arrows with an angle of 45° to make main winch and telescoping mechanism initiate
relevant movements (See above Fig.) simultaneously;
– The more the joystick is deflected leftwards or rightwards, the faster telescoping
movements becomes; and the slower the winch movements;
movements become; and the slower the telescoping movements;
– Switch on “Slow gear switch” to make relevant movements get slower;
switch” to achieve rapid movements of main winch without load;
– For automatic telescoping operation, the leftwards and rightwards movements
initiated via the right joystick and “Slow gear switch” are invalid.
– The main winch movements are valid.
Warning:
Carry out simultaneous crane movements without taking a load or with the load being
lifted away from ground. It is prohibited to telescope the boom with load.
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5.1 Safety technical guidelines for assembly
a) The hoist rope must be reeved between the rope pulley on the boom head and hook
pulley in accordance with the corresponding reevings specified in lifting capacity table;
b) Counterweight plates must be fitted according to lifting capacity tables;
c) Lattice components which are not in contact with ground during assembly / disassembly
must be supported by appropriate and stable materials;
Danger:
(1) All assembly work must be carried out using suitable aids (scaffolding or lifting
platforms, etc.)! If this is not observed, personnel could fall and suffer life-threatening
injures;
(2) Do not stand beneath the lattice jib especially when the lattice jib is being pinned or
unpinned.
d) If the lattice components are pushed inside each other for transportation purposes, they
much each be secured with 2 chains;
Danger:
If lattice components are not secured, the inside lattice components will slide out and fall
down. This can result in life-threatening injuries to personnel.
e) Perform the following checks before supporting the crane:
1) Check whether the axle suspension is locked;
2) Check whether the ground provides adequate load-bearing capacity;
3) Check whether the support pads are secured in their operating positions;
4) Check whether the crane is horizontally aligned;
5) Check whether there is sufficient safety clearance to slopes and ditches;
6) Check that the tires are not in contact with the ground;
7) Check whether there are any live cables within the operating range of the crane;
8) Ensure that the work can be carried out with minimum boom projection;
9) Check that there are no obstacles which might hinder required crane movement;
10) The ropes must be checked by an expert before assembly and checks must be
performed at regular intervals in order to detect possible damage or wear and tear at
an early age;
Danger:
The ropes must be removed immediately if any of the following damage is detected.
(1) Breakage of a strand;
(2) Wire breaks;
(3) Broken wire nests;
(4) Reduction in the rope diameter by more than 10% of the nominal size;
(5) Rope deformation.
In order to guarantee safety and operating characteristics, only use original
Zoomlion replacement parts.
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Danger:
After replacing the hoist rope, the lowering limit switch must be readjusted to switch
off when only 3 hoist rope windings remain on the winch; otherwise, the rope end
attachment may be torn out causing the load to topple.
11) Depressurize hydraulic system before connecting and disconnecting the hydraulic
lines with quick-release couplings (Turn off the engine and wait for about 5 minutes).
The hydraulic couplings should be tightened or unscrewed by hand rather than by
tools, otherwise, couplings will be damaged;;
Danger:
Please ensure that the quick-release couplings are connected correctly. Incorrectly
coupled quick-release couplings can result in accident from pressure loss or sudden
leakage.
12) Before setting-up and taking-down the boom (assembling the jib and jib extension),
ensure that the following prerequisites are met:
– The crane is properly supported and level;
– The telescopic boom is fully telescoped in;
– The jib and jib extension have been fitted and the counterweight has been
attached to the slewing table in accordance with the lifting capacity table;
– All pinned connections have been secured;
– All limit switches have been correctly fitted and are fully operational;
– The hoist rope has been correctly placed in the rope pulleys with the rope
guards to prevent it from jumping out;
– There are no loose parts on the boom.
Danger:
In winter, the telescopic boom, jib, jib extension and associated components (limit
switches, cable drums, flashing beacon, wind gauge etc.) must be kept free of snow
and ice.
Incorrectly fitted or faulty limit switches and falling parts (pins, spring-loaded safety
pins, ice etc.) can cause injury!
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5.2 Jib
1 Adapter I 2 Adapter II
3 Jib section 1 4 Jib section 2
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5.2.1 General
Jib is one of the important components of truck crane. It is auxiliary equipment used to
increase the crane lifting height. With the jib assembled, the load can be lifted to a higher
height and the working radius can be enlarged via offset changed.
This crane is equipped with 2 jib sections (See above illustration). The jib is articulated on the
telescopic boom with pins.
Length of jib section 1: 11 m
Length of jib section 1 + jib section 2: 18.6 m
Weight of adaptor I: 130kg
Weight of adaptor II: 100kg
Weight of jib: 885kg
Weight of connecting parts: 155kg
Total weight: 1260kg
5.2.2. Assembly
The jib can be assembled below an angle of 0 or 30 to the telescopic boom according to
5.2.2.1 Assembly of the jib below an angle of 0
a) Extend the outriggers and level the crane with support control units;
b) Fully telescope the telescopic boom in and derrick it down to the rear or the side in the
-1.5 position. Ensure there is 30m slewing range to the slewing center;
c) Connect adaptor I and adaptor II via pins;
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d) Connect the adaptor with jib section 1;
e) Lift the jib section 1, adaptor I and adaptor II which have been assembled together with an
auxiliary crane. Align the boom head pin bores with the pin bores of adaptor I and secure
with pins;
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f) If the 18.6 m jib is required, the jib section 2 must be assembled. Lift the jib section 2 with
an auxiliary crane. Align the pin bores in the head of jib section 1 to the pin bores in the
rear of jib section 2 and secure with pins;
Jib section 1
Jib section 2
g) Reeve the auxiliary hoist rope; install the auxiliary hook and the hoisting limit switch.
Check the jib for proper assembling.
Warning:
Do not drive the crane with jib. Otherwise, the deadweight of the crane will exceed the limit.
Danger:
Standing under the jib during the swing operation is prohibited!
The jib and other components – due to an assembly error – can fall down and cause fatal
injuries.
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5.2.3 Angle settings
This jib can be operated in angles of 0 and 30. The relevant angle is set using pins.
See the following illustration:
● For angle setting 0°
Pin and secure pins in bore A and

bore B.
A B
Release pins in bore A.

● For angle setting 30° Pin C
A
B
The way of changing the jib angle:

a) Deflect the left joystick to reel off the auxiliary hoist rope for 2m to 3m at low speed;
b) Derrick the main boom down to its minimum angle until the jib head lightly touches the
ground. If the jib head cannot touch the ground, support it with plates;
c) Release pins in bore A (see above illustration);
d) Derrick up the telescopic boom slowly until pin in bore A touches pin C and the offset is
set to 30.
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5.2.4 Removing
After jib operation, use an auxiliary crane to lift the jib to release pins. Put the jib at a suitable
position for storage and transportation.
5.2.5 Electrical connections (See the following illustration)
Caution:
The electrical connecting plugs and sockets should be protected against contamination and
dust. For operation with jib, the wind speed sensor on boom head should be assembled on jib
head.
5.2.5.1 Electrical connections on 11m jib
a) Single hook operation
Caution:
In single hook operation, the wind gauge and the hoisting limit switch on jib should be
connected.
1) Insert the cable plug at point A into corresponding socket.
2) Insert the cable plug at point E into corresponding socket.
3) Insert the cable plug at point H into corresponding socket.
b) Two hook operation
Caution:
In two hook operation, the wind gauge, the hoisting limit switch on telescopic boom and
the hoisting limit switch on the jib should be connected.
1) Insert the cable plug at point A into corresponding socket.
2) Insert the cable plug at point E into corresponding socket
3) Insert the cable plug at point F into socket G.
4) Insert the cable plug at point I into socket H, and insert the cable plug at point H into
socket I.
Caution:
the hoisting limit switch on the jib are active.
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5.2.5.2 Electrical connections on 18.6m jib
Caution:
connected.
1) Insert the cable plug at point A into corresponding socket;
2) Insert the cable plug at point E into socket B;
3) Insert the cable plug at point C into socket D;
4) Insert the cable plug at point G into corresponding socket.
Caution:
4) Insert the cable plug at point G into corresponding socket;
socket I.
Caution:
In two hook operation, the wind speed gauge, the hoisting limit switch on telescopic boom
and the hoisting limit switch on the jib are active.
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5.2.5.3 Electrical connections on 11m jib with 8m extension installed
Lattice jib length: 19m

Caution:
connected.
2) Insert the cable plug at point E into socket C;
3) Insert the cable plug at point D into corresponding socket;
4) Insert the cable plug at point G into corresponding socket.
Caution:
socket I.
Caution:
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5.2.5.4 Electrical connections on 18.6m jib with 8m extension installed
Lattice jib length: 26.6 m

Caution:
In single hook operation, the wind gauge and the hoisting limit switch on 26.6m lattice jib
should be connected.
3) Insert the cable plug at point C into corresponding socket;
6) Insert the cable plug at point H into corresponding socket
Caution:
3) Insert the cable plug at point C into corresponding socket;
socket I.
Caution:
5 - 13
0063152-000-05-20Y
5.2.6 Reeving in the auxiliary hoist rope
● Place hoist rope from the main or auxiliary winch over rope guide pulley 1 and over rope
guide pulley 2 at jib head.
Note:
When placing hoist rope over rope guide pulley 2, remove the nuts, screws and rope guard first.
● Tie the load hook with hoist rope.
Rope guide pulley 2
Rope guide pulley 1
5 - 14
0063152-000-05-20Y
5 - 15
0063152-000-05-20Y
5.3 Assembly of the extension
The extension can be only used after pinned and secured with the jib.
5.3.1 Assembly of the extension below an angle of 0
a) Remove the jib from the adaptor;
Adapter
Jib
Note:
The jib and extension can both be attached to telescopic boom via the adaptor.
5 - 16
0063152-000-05-20Y
b) Pin and secure the extension with the adaptor;
Extension
Adaptor
c) Lift the extension and adaptor with the auxiliary crane and attach the extension to the
telescopic boom and secure with pins and spring-loaded pins;
Adaptor
Extension
Telescopic boom
d) The extension can be put into use.
5 - 17
0063152-000-05-20Y
5.3.2 Assembly of the extension and jib
1) Pin and secure the extension to the telescopic boom;

2) Lift the jib with the auxiliary crane and secure it into pin points on the extension with pins
and spring-loaded pins;
Extension
Jib
3) The extension and jib are attached to the telescopic boom and can be used to do lifting
work.
5 - 18
0063152-000-05-20Y
5.3.3 Dismantling the extension
Dismantle the extension in reverse sequence of assembly process with the help of hoist rope.
If the extension cannot be removed, derrick up the boom a little.
The extension cannot be attached with the crane during driving and should be transported
separately by other vehicle.
Caution:
Ensure that the following requirements are met before dismantling the extension:
(1) Ensure that no obstacle is within the slewing range of jib extension and jib;
(2) The outriggers have been extended and the telescopic boom is fully telescoped in;
The rear and side

working area
(3) Do not operate the crane or drive the crane after releasing the pins on the jib support,
otherwise, there is a danger of accidents if the jib falling off;
5 - 19
0063152-000-05-20Y
(4) The telescopic boom has been derricked down to the rear or to the side in -1.5° position.
All assembly and disassembly work from a high position must generally be carried out
using suitable aids (ladders, stairs, etc.) to ensure safety;
(5) When dismantling the jib, do not spool up the auxiliary hoist rope too much;
(6) Remove and store the auxiliary hook according to the conductor’s hand signal.
5 - 20
0063152-000-05-20Y
5.4 Rooster sheave
Rooster sheave consists of bracket, rope pulley shaft, pulley and pins. It should be dismantled
while driving.
Retaining pin
Telescopic boom
Rooster sheave
Rope pulley shaft Bracket Connecting pin
Rooster sheave is set up for rapid hoists over the boom nose to improve the working
efficiency when the loads are light.
5.4.1 Assembly
1) Derrick down the telescopic boom to the rear or the side to its minimum angle;
2) Release the retaining pin and turn the boom nose until connecting pin can be bolted at
point A;
Rooster sheave
Connecting pin
Point A
3) Run auxiliary hoist rope over rooster sheave; reeve in auxiliary hook and attach hoisting
limit switch. Check the assembly and ensure all connections are reliable.
5.4.2 Dismantling
Dismantle the rooster sheave in reverse sequence of assembly process and store it in a safe
place if not needed.
5 - 21
0063152-000-05-20Y
5.5 Assembly of auxiliary winch
The auxiliary winch is not attached to the crane in driving condition. It is attached to the tail of
slewing table with pins when it is to be used.
1 Pin 2 β pin 3 Slewing table tail

4 Auxiliary winch assy. 5 Pin
Assembly process:
1) Lift the auxiliary winch assy. and put the auxiliary winch onto the pin 5;
2) Adjust auxiliary winch until the holes in auxiliary winch and the slewing table are flush;
3) Bolt in pins 1 on both sides and secure with pins 2;
4) Connect the hydraulic pipe of motor with quick-release coupling.
Disassemble the auxiliary winch in the reverse sequence of above steps.
5 - 22
0063152-000-05-20Y
5.6 Counterweight
5.6.1 Counterweight and its assembly & disassembly mechanism
The counterweight consists of a 10t counterweight plate, a 14t counterweight plate, a 8t

counterweight plate and two 6.5t counterweight plates.
Total weight: 45t
5 variants:
● No counterweight
● 10t counterweight
The assembly/disassembly mechanism of counterweight consists of 2 counterweight
cylinders and auxiliary elements. See the following illustration:
Direction A
A
Counterweight
cylinder
Additional
Counterweight plate 3
ballast 4
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0063152-000-05-20Y
Individual weight
Counterweight (t) Combination
(t)
0 - -
10 Counterweight plate 1 10
Counterweight plate 2 14
Additional ballast 4 6.5×2
Danger:
Attach counterweight in accordance with the above table! Otherwise, the crane may topple!
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0063152-000-05-20Y
5.6.2 Assembly
1) Properly support the crane and level the crane horizontally;

2) Retract the counterweight cylinder fully;
3) Ensure that there is no personnel and equipment within slewing radius to ensure their
safety;
4) The slings should have sufficient strength;
5) Attach counterweight 1 on the centering cones of the storage frame by the crane itself;
6) Deposit the required counterweight plates on the counterweight plate 1;
7) Turn the right switch to right position;
Switch – Extend or retract counterweight cylinders

8) Plug the counterweight remote control box to carry out the following steps;
9) Turn the slewing table until the counterweight cylinder is even with the openings in the
upper position of the counterweight plates,
The counterweight cylinders are now located next to the openings of the counterweight
plates;
10) Fully extend the counterweight cylinder;
11) Turn the slewing table until the counterweight cylinder is inserted into the mountings of
counterweight plate 1;
The counterweight cylinders are now located in the mountings of counterweight plate 1;
12) Retract counterweight cylinders until the counterweight plates lift to proper position.
Disassemble the counterweight in the reverse sequence of above steps.
Danger:
The counterweight can only be transported with special dolly; otherwise the axles may be
damaged by excessive axle load.
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0063152-000-05-20Y
Switches and control light on the counterweight remote control box:
Switch 1
● Turn on switch 1 in an emergency

- Result
- The power source of remote control box cut off and the whole system protected
● Turn off switch 1 when the emergency is eliminated
- Result
- The power source of remote control box activated
Control light 2
● Turn Switch – extend or retract counterweight cylinders (See illustration in the above
page) to right position
● Switch off switch 1
- Result
- Control light 2 lights up
Switch 3
● Turn switch 3 to upper position
- Result
- Slewing to the left
● Turn switch 3 to lower position
- Result
- Slewing to the right
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0063152-000-05-20Y
Switch 4
● Turn switch 4 to upper position:
- Result
● Left counterweight cylinder activated
● Turn switch 4 to center position:
- Result
● All counterweight cylinders activated
● Turn switch 4 to lower position:
- Result
● Right counterweight cylinder activated
Switch 5
● Turn to upper position:
- Result
● Counterweight cylinder(s) extended
● Turn to lower position:
- Result
● Counterweight cylinder(s) retracted
5 - 27
Chapter 6 Additional
equipment
1145-000-06-20Y
6.1 Air conditioning in driver's cab
In order to provide a comfortable driving environment, driver's cab of our crane is equipped
with an air conditioning and heater.
a) Temperature
1) Interior temperature range: -30.0℃ to 80.0℃
2) If the interior temperature sensor is defective, 25.0℃ will be displayed and never
changed.
b) Outer air circulation
c) Defrosting air supply
d) Interior air circulation
e) Footwell air supply
f) Front window air supply
g) Fresh air supply
h) Fan speed bar chart:
1 bar – stage 1, 2 bars – stage 2, 3 bars – stage 3,
4 bars – stage 4, 5 bars – stage 5, 6 bars – stage 6
i) Fan speed button
Arrow up – fan speed (blower), faster
Arrow down – fan speed (blower), slower
Note:
If the fan speed button is not activated, arrows up / down are invalid.
If the fan speed button is activated, press arrows up / down to increase / decrease the fan
speed.
If increase / decrease the fan speed to the highest / lowest stage, arrows up / down will
be invalid.
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1145-000-06-20Y
j) Refrigeration
k) Mode button
Changeover front window air supply / footwell air supply/ footwell and defrosting air
supply
l) Defrosting air supply button
Activate this button: enter into defrosting mode
m) Circulation button
Changeover interior / outer air circulation
n) A/C button
Control light illuminates: compressor activated
Control light extinguishes: compressor deactivated
o) AUTO button
Press AUTO once: auto running mode is activated.
Press AUTO twice, or press A/C, Defrosting air supply: exit auto running mode.
Interior air circulation is the default auto running mode which can be adjusted manually.
p) OFF button
Press this button to turn off air conditioning system.
Press any button (except OFF) to activate air conditioning system.
q) Temperature adjustment button
Temperature range: 17℃ to 29℃.
Press this button and the temperature is increased or decreased by 1℃ between 17℃
and 29℃.
Press this button and hold, the temperature will be continuously increased or decreased.
The set temperature will flash and the interior temperature will appear on the display after
5 seconds.
LO: set temperature below 17℃
HI: set temperature above 29℃
The air conditioning system is of diagnosis function.
a) Press and hold OFF.
b) The error codes will appear on the display after 10 seconds.
C0: Normal
C3: The interior temperature sensor uninstalled or defects
C5: The evaporator temperature sensor uninstalled or defects
C6: Water valve steering gear uninstalled or defects
C7: Air door for mode adjustment uninstalled or defects
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1145-000-06-20Y
Warning:
Never use the heater during driving if engine coolant temperature is below 70℃.
Caution:
(1) Do not use air conditioning when the engine is stopped or is running at idle speed;
otherwise, it will cause excessive battery consumption and thus affect normal driving;
(2) If the vehicle continuously drives at low speed, please downshift 1 gear to increase the
engine RPM. If start the vehicle suddenly or climb long ascending gradients, please
switch off the air conditioning to prevent the engine from overheating;
(3) In winter or other periods without using air conditioning, run the air conditioning for
several minutes once a month to benefit the lubricating circulation and ensure the system
in good state;
(4) Check refrigerant regularly. If there is no or not enough refrigerant, add it timely;
(5) If there are abnormal vibration, noise or smell during operation, stop and examine the
machine immediately. Never run with faults;
(6) Clean the surface of condenser regularly. Do not clean it with steam. Clean it with
compressed air or cold water;
(7) Never dismantle the belt or pipeline of compressor after using the air conditioning;
(8) In summer, close the shutoff gate valve on the hot-water pipe of heater at the bottom of
driver's cab; otherwise refrigeration effect may be affected. In winter, open the shutoff
gate valve to make hot water enter into the heater. For hot water type heater, engine
coolant temperature will affect the interior temperature. If the engine coolant temperature
cannot be heated, the driver's cab will not be warmed.
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1145-000-06-20Y
6.2 Air conditioning in operator's cab
In order to provide a comfortable operating environment for the operator, operator’s cab of our
crane is also equipped with an air conditioning and heater, which refrigerates in summer and
supplies heat in winter. The working medium of refrigeration is HFC134a, and working
medium of heat supply is circulating cooling water of engine.
6.2.1 System technical data
1 Refrigerating output 4000 W
2 Heating output 5000 W
3 Air supply output 600 m3/h
4 Voltage 24 V.DC
5 Gross current consumption power ≤310 W
6 Refrigerant oil Depend on compressor
7 Refrigerant R134a
8 Refrigerant charge 1200 g ± 150 g
6.2.2 Operating methods
a) Functions of rotary switches:

A Rotary switch - fan speed:
Fan speed (4 stages - HI, MID, LOW, OFF) of evaporator motor;
Using this switch to choose appropriate fan speed or switch off the system.
B Rotary switch - refrigeration:
Refrigeration on / off.
C Control lights:
Refrigeration control light lights up: compressor starts and refrigeration system is in
working mode.
Power control light lights up: the system is in ventilation mode.
Illustration 1 - Air conditioning operating panel
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1145-000-06-20Y
b) Operating instructions:
1) Refrigeration
– Set switch B to ON;
– Switch on switch A;
– Control light lights up and air conditioning begins to work.
2) Heating
– Set switch B to OFF;
– Switch on switch A;
– Open the hot-water valve;
– The heater begins to work.
3) Ventilation
– Set switch B to OFF;
– Switch on switch A.
Outlet nozzle direction regulation can change the angle and direction of cold wind.
Regulate switch A to obtain 3-stage fan speed: HI, MID, LOW.
Caution:
(1) Under the idle-speed working condition, the use of air conditioning would cause
excessive consumption of battery, at this time, set the fan speed switch to LOW and
increase the idle speed;
(2) The heating system is connected with water tank via a valve. When the ambient
temperature is below 0℃, add antifreeze fluid into the system to prevent brass pipe of
radiator from freezing within -30℃.
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1145-000-06-20Y
6.2.3 Points for attention:
a) Do not remove any part of the air conditioning to prevent coolant from leaking;
b) Check tightness of the belt regularly to prevent it from over-tightening and
over-loosening;
c) Antifreeze fluid has been added into water pipe lines with proper proportion before the
crane is handed over, and the system circulation has been carried out for no less than 15
min to prevent the heating pipelines from freezing under low temperature;
d) In summer, check whether the hot-water valve is closed before running air
conditioning. Hot-water valve in the heating pipelines can only be switched on in winter;
e) Clean accumulated dirt on the surface of condenser to prevent the refrigeration effect
from being affected;
f) Check and tighten the connections of pipelines in air conditioning system to prevent them
from loosening and leaking after using for a long period;
g) Add refrigerant fluid after replacing the parts.
Name of parts Quantity of refrigerant fluid (CC)
Condenser 40 - 50
Evaporator 40 - 50
Circulating hose for 10 - 20

refrigeration
Fluid reservoir 15 - 25
6-6
1145-000-06-20Y
6.2.4 Remedies for common errors
A: Refrigeration fault
Check fittings of fan motor for tight

Compressor
connection and normal grounding,
is working
and check fan motor for damage.
Condenser
fan motor is Check temperature control switch
not working Compressor for damage, check relay for
Evaporator
is not switching on, and check terminal
fan motor is
working connector of relay for well
working
connection.
Check clutch for damage, check

Condenser Compressor
terminal connector for tight
fan motor is is not
connection and check belt for
working working
tightness and sliding.
Condenser
Refrigeration fan motor Check fan speed switch for malfunction, check fan
fault and motor wire for well connection and grounding wire
compressor of fan motor for normal connection.
are working
Evaporator
fan motor is
Condenser
not working
fan motor
Check whether the fuse is broken, check relay for
and
normal working and check connecting wire of relay
compressor
for tight seating.
are not
working
Evaporator HFC134a is filled too much into the system. Check

fan motor whether it meets the required value with a high /
Compressor and low pressure gauge.
is working condenser
fan motor Check whether HFC134a remains in the system
are working with a high / low pressure gauge.
Evaporator
fan motor,
Inlet / outlet of fluid reservoir are connected in
condenser
reverse.
fan motor,
evaporator Check whether expansion valve is blocked with ice
and or dirt. If it is, replace fluid reservoir.
Insufficient
Compressor condenser
refrigerating Replace HFC134a.
is working are all
output
working
Fan motors
and other Check whether the surface of condenser is
devices are blocked with dirt.
working
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1145-000-06-20Y
B: Heating fault
Evaporator Check solenoid valve for switching on.

fan motor is
Check whether other valves of heating pipelines are closed.
working
Heating
fault Check fan speed switch for malfunction, check fan motor wire and
Evaporator grounding wire for normal connection.
fan motor is
not working Check whether the fuse is broken and check connecting wire for tight
seating.
C: Remedies for other errors

Possible causes of
Error text Possible remedy for error
error
Refrigerating effect of the Often driving in off-road Find out the leaking point
system is good at the condition, fitting loosens with a leak-detecting
beginning, but refrigerating and leakage occurs instrument and tighten the
output is not enough after caused by vibration. loosened parts carefully.
1 using for a period. Bubbles
appear in the inspection hole
of fluid reservoir; and “Values”
shown in the high / low
pressure gauge are low.
Refrigeration does not work, Improper use. Replace expansion valve,

outlet nozzle blows hot air, no Temperature-sensitive and refill HFC134a.
temperature difference capsule wears and leaks
2 between the inlet and outlet of which results in valve
expansion valve and the value hole closed.
shown in the low-pressure
gauge is extremely low.
The air from outlet nozzle is The system is mixed with Open air conditioning
not cold enough, and the impurities, the filtering system intermittently to
temperature of compressor screen of expansion eliminate instantaneous
increases. valve is blocked and thin blocking if blocking is not
3 frost appears at serious;
The value in the low-pressure
expansion valve.
gauge descends rapidly Or dismantle expansion
(approaches to “0”), and the valve to wash it with alcohol,
value in the high-pressure and refill HFC134a after
gauge is high. deaerating the system.
Refrigerating output is not Throttle bore inside the Deaerate the system,
4 enough, and evaporator is expansion valve is not in replace expansion valve
frosted; values in the high / low function. and refill HFC134a.
pressure gauge are all low.
Refrigerating output of the Drying agent in fluid Deaerate the system,

system descends gradually reservoir is saturated, replace fluid reservoir, and
after the system is running for and throttle point in refill HFC134a.
5 a period, the values in the expansion valve is
high-pressure gauge is high blocked with ice.
but the value in the low-
pressure gauge is lower than
0.4Mpa.
6-8
1145-000-06-20Y
After opening the air Temperature control Use universal meter to

conditioning system, only air switch is poorly check temperature control
(not cooling air) blows and the connected; switch for damage;
6
values in high / low pressure
Or electromagnetic Replace electromagnetic
gauge does/do not vary.
clutch coil for clutch for compressor.
compressor is damaged.
Electromagnetic clutch for The compressor stops Check temperature control

compressor is frequently running automatically switch and set it to the Max.
operative but short-time caused by excessively degree (Cold).
engaged. small opening degree of
7
temperature control
The cab cannot be cooled
switch, so refrigerating
down but the values in high /
output is insufficient.
low pressure gauge are
normal.
6-9
1145-000-06-20Y
6.3 Emergency control
6.3.1 Emergency operation – crane superstructure
6.3.1.1 General
a) Emergency operation of the crane superstructure may only be carried out:

1) To remove a dangerous situation.
2) After consultation with our service department.
3) To carry out load reducing movements.
b) The danger zone must be blocked off.
c) No persons or objects may remain in the danger zone!
d) If a load is on the hook, then it must first be set down to relieve the boom.
e) In the event of a defect or failure of load moment limiter, each step must be carried out
and monitored with extreme caution and care, since a visual check on the load moment
limiter is no longer possible. Visual check!
f) All crane movements must be carried out with extreme caution.
1) Telescoping movements must constantly be monitored by a second person.
2) The crane operator must be in visual contact with the second person.
Danger:
There is an increased risk of accident if the above danger notes are not observed!
Observe general risk information!
Warning:
In order to carry out emergency operations, the engine must be running and the hydraulic
system of the superstructure must be functioning. If above requirements cannot be achieved,
equipments of the crane must be taken down using an auxiliary crane. The boom may only be
derricked down if stability of the crane can be ensured.
6.3.1.2 Emergency operation – boom
If the boom cannot be telescoped automatically, telescope the boom manually. For the
manual mode, please refer to Chapter 4.2.2.3.
6 - 10
1145-000-06-20Y
6.3.1.3 Emergency operation – crane movements "Slewing, Derricking, Spool up / reel off
main / auxiliary winch"
In the event that the electrical controls of the solenoid valve for the control system should fail,
these can be manually operated by pressing in the electromagnetic core on the
corresponding solenoid valve.
Caution:
Press down electromagnetic core of directional control valve with pointed objects, e.g. nail
and pen tip. After pressure is stopped, the crane movement will stop immediately.
Danger:
As the opening degree of electro-hydraulic proportional valve cannot be controlled when
electromagnetic core is pressed down manually, the operation must be carried out with
extreme caution to prevent accidents.
Preconditions: the superstructure engine must be running normally;
the hydraulic system of the superstructure must be functioning.
Brake valve
Functions Y6 Y8 Directional
Y5 control valve
(Main (Auxiliary
(Slewing)
winch) winch)
Slewing left 1 0 0 Y11a
Slewing right 1 0 0 Y11b
Derricking up 0 0 0 Y13a
Derricking down 0 0 0 Y13b

Spooling main winch 0 1 0 Y12a
up
Reeling main winch off 0 1 0 Y12b
Spooling auxiliary 0 0 1 Y14a
winch up
Reeling auxiliary winch 0 0 1 Y14b
off
Time-sequential table 1 - Emergency operation of solenoid valves (Superstructure)
6 - 11
1145-000-06-20Y
Illustration 2 - Arrangement of solenoid valves in emergency operation (superstructure)
6 - 12
1145-000-06-20Y
Note:
For emergency operation, please refer to Table 1 and Illustration 2.
As illustrated in the Time-sequential table, if carry out emergency operations of crane
movements “Slewing” and “Spooling up / reeling off winches”, corresponding brake valves
must be actuated except the emergency operation of crane movement “Derricking”.
If the winches cannot start and movement cannot be initiated with load, open the Y12a,
Y12b, Y14a and Y14b for a few minutes to supply hydraulic oil to the winches (open
valve “a” for 8 seconds at first, and then open valve “b” for 8 seconds. Repeat the
process for 10 times), so as to prevent the hook from being down (it is supposed to
lift).
The emergency operations of tilting operator’s cab and lifting counterweight can be operated
by the manual control levers on their corresponding control valve blocks.
6 - 13
1145-000-06-20Y
6.3.2 Emergency operation – crane chassis
6.3.2.1 Emergency operation - outriggers
In the event that the electrical controls of the solenoid valve for the outrigger should fail, these
can be manually retracted and extended by pressing in the electromagnetic core on the
corresponding solenoid valve.
Emergency operation – outriggers
Changeover valve Y1
Directional
Outrigger cylinder Functions and Y2 for oil circuit
control valve
of outriggers
Y2a
Retracting left front
Y6a
Retracting right front
Vertical cylinder 1
Retracting left rear Y4a
Retracting right rear
Y8a
Y1a
Retracting left front
Y5a
Retracting right front
Horizontal cylinder 1
Retracting left rear Y3a
Retracting right rear
Y7a
Y2b
Extending left front
Y6b
Extending right front
Vertical cylinder 1
Extending left rear Y4b
Extending right rear
Y8b
Y1b
Extending left front
Y5b
Extending right front
Horizontal cylinder 1
Extending left rear Y3b
Extending right rear
Y7b
Time-sequential table 2 - Emergency operation of solenoid valves (outrigger)
6 - 14
1145-000-06-20Y
Illustration 3 – Arrangement of solenoid valves in emergency operation (outrigger)
Caution:
The changeover valves Y1 and Y2 must be activated during the operation of outriggers.
6 - 15
1145-000-06-20Y
6.3.2.3 Emergency brake
If there is no compressed air pressure and the air brake system is failed, the brake chamber
springs installed in the 3rd to the 5th axle are actuated to make the vehicle in parking brake
state.
If you want to move the vehicle compulsorily, the parking brake condition must be released.
Detailed steps are as follows:
– Loosen the nuts at the chamber tail with spanner;
– Screw out the threaded rod for about 2.52 in (64mm).
Positions of spring brake chamber and adjusting nuts for spring are illustrated in the following
diagram.
Adjusting nuts at the tail of brake chamber
Warning:
Once air source is supplied or the faults are rectified, screw in the threaded rod timely;
otherwise, parking brake will not be in function.
Caution:
Force of spring under working conditions is about 1764 lb (800 kgf); therefore, dismantling
must be carried out with extreme caution and care, and be done by professionals.
6 - 16
1145-000-06-20Y
6.4 Interphone
In consideration of the requirements for commanding the operation of large-size crane, our
product is equipped with a pair of interphones.
6.4.1 Notices for users:
a) Do not use the radio interphones illegally;

b) Maintenance can only be carried out by professional technicians;
c) Do not modify this interphone under any circumstances;
d) Do not put the interphone directly in the sun for a long time, and do not place it near
heating devices;
e) Do not put the interphone in dusty, moist, water-splattered areas or on uneven surfaces;
f) Once the interphone sends out unpleasant smell or smoke, please cut off the power
immediately and remove its battery group (optional). And then contact the seller.
Warning:
Please turn off the interphone power in potentially explosive atmospheres (such as gas, dust
and smoke), or when the crane is fueling or parking at a gas station.
6 - 17
1145-000-06-20Y
6.4.2 Familiar with the interphone
1 LED control light

Red light lights up: sending signals
Green light lights up: receiving signals
Amber light flashes: receiving dual tone, DTMF or FleetSync signals
Red light flashes: low battery
2 Channel switch
Switch over the switch to select channel 1 to channel 16.
3 Power / volume knob
Turn on the power / volume knob clockwise until it clicks to switch on the interphone.
Rotate it to adjust the volume.
Turn it counterclockwise until it clicks at the OFF position to switch off the interphone.
4 AUX (auxiliary) key
This is PF (programming function) key.
Press this key to start auxiliary function (lower part).
Default setting of this function is null.
5 PTT (push-to-talk) switch
Hold down this switch to call other party through microphone.
6 Side push-key 1
Default setting of this function is null.
6 - 18
1145-000-06-20Y
7 Side push-key 2
Default setting of this function is to cancel noise clipping instantaneously.
Press this key to open noise clipping, so as to tune in week signal and background noise.
Release this key to return to normal mode.
8 Speaker / microphone jack
An optional speaker / microphone can be connected into the jack.
6 - 19
1145-000-06-20Y
6.4.3 Auxiliary programming functions
Auxiliary key, side push-key 1 and side push-key 2 can be programmed into the following
auxiliary functions:
1) Dual tone code
2) Emergency call*
3) Instantaneous sound monitoring
4) Null
5) RF low-power
6) Scanning
7) Canceling scanning temporarily
8) Encryptor
9) Canceling noise clipping instantaneously
10) Canceling noise clipping intermittently
* This function can only be programmed on the AUX (auxiliary) key.
For specified operating methods of this programmable function, please refer to Operating
Manual of Interphone provided by manufacturer.
6 - 20
1145-000-06-20Y
6.4.4 Fundamental operations
a) Switching power on / off

Turn the power / volume knob clockwise until it clicks to switch on the interphone, and
turn the knob counterclockwise to switch off the interphone.
b) Adjusting the volume
Turn the power / volume knob after switching on the interphone to adjust the volume.
Turn the knob clockwise to increase the volume and turn it counterclockwise to decrease
the volume.
Note:
You need to readjust the volume when you are on the phone.
c) Selecting the channel
Turn the channel knob to select channel (channel 1 to 16) as you needed. Turn the knob
clockwise to increase the channel number and counterclockwise to decrease it. If the
channel has not been programmed, it cannot be used. If un-programmed channel is
selected, red and amber LED control lights will flash and alarming sound will be sent out.
d) Making a call
1) Make sure that no one else is talking on the channel that you select.
2) Hold down the PPT switch and speak in normal tone through the speaker. In order to
make the other party receive the best audio frequency, please speak in a distance of
1.5 inches (3 - 4cm) from the speaker.
3) Release PTT switch to receive call.
e) Receiving a call
The seller has probably programmed on your interphone with signals of QT, DQT, dual
tone or FleetSync. If the channel you selected has been programmed with one of the
above signals, you can catch the sound only when there is call of matched signal in your
channel. Other calls will not be heard.
If the channel you selected is not be set with signal type, you can hear calls from any
parties (not limited in the group in which you are participating).
6 - 21
Chapter 7 Maintenance and
service
0063152-000-07-20Y
7.1 General
Products and “After Sales Service” team of ZOOMLION are most reliable for you!
ZOOMLION’s cranes are technically advanced products, which prove their worth daily even
under tough environment and harsh conditions. The high technical standards of these cranes
provide functional security, resistance to failure, convenient and economical operation and
easy maintenance.
We use globally-supported components. The combination of well proven units and modern
manufacturing methods produces cranes that are safe to operate and easy to maintain.
Several hundred cranes are built every year for the international market, supported by
international service.
ZOOMLION's “After Sales Service” plays an important role in ensuring the operational
readiness and high availability of the cranes.
With ZOOMLION, service begins when the crane is handed over. Your crane operators will be
professionally trained in line with their level of knowledge, and we devote much time to this.
We will provide timely “After Sales Service” for you.
The contact by telephone saves time and money. In the event of problems, get in touch as
soon as possible.
Our service technicians are specialists with years of experience, and can be deployed from
local support points. Naturally these product experts have special knowledge and special
tools. They are the backbone of our company’ “After Sales Service” team.
But before you call on these people, it is worth making full use of the facilities for getting
advice mentioned above.
Caution:
Please use original ZOOMLION parts. In the event that replacement parts are used that are
not original ZOOMLION parts, we disclaim all liability, both for system functionality and the
replacement parts.
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7.2 Cleaning and care of the crane
Clean the crane with water.
Caution:
Steam cleaners should be used with extreme caution, always maintain sufficient distance (at
least 800 cm) with the steam jet from the paint surface and thin-film label and use appropriate
water temperature (no more than 60℃) .
Grease all the kinematic pair, e.g., universal propeller shaft and slewing bearing of the crane,
after cleaning, especially cleaning with steam cleaners.
The steering wheel, control panel, floor and dirty upholstery in the driver’s cab should only be
cleaned with warm water mixed with a little washing fluid.
Do not use any scouring agents.
7.3 Maintenance intervals
Please refer to the following chapters when performing maintenance of the crane:
– Chapter 7.3.1 Crane chassis maintenance and inspection plan
– Chapter 7.3.2 Crane superstructure maintenance and inspection plan
Maintenances should be carried out in accordance with maintenance contents and actual
operating conditions for crane.
For individual units, the manufacturer’s specifications must be observed.
The maintenance tasks on the crane chassis are carried out based either on operating hours
or by kilometers traveled.
The maintenance tasks on the crane superstructure are carried out entirely on operating
hours.
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7.3.1 Crane chassis maintenance and inspection plan
Regular maintenance,
Checks
every
First Minimum
maintenance 200 h 400 h 800 h maintenance
after or or or annual Daily Weekly
5000 10000 20000
km km km
★ Diesel engine
Check oil level
For all other
maintenance tasks,
●
follow the instructions
of the engine
manufacturer
Replace engine oil
●
filter
Every
500h or
Replace engine oil 25000 km ●
25000
km
Check coolant level
●
and add coolant
Replace coolant Every 2 years
★ Air filter
Check monitoring
●
device
Clean filter Dirty but not damaged When needed
Replace filter When needed
★ Automatic transmission
Every 6
Check oil level
months
Check for leaks ●
Check or tighten bolts

100 km ●
and nuts
240,000 km,
Oil change but at least
every 2 years
Clean oil drain plug
and replace seals
When dismantle the plug
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0063152-000-07-20Y
Checks
every
First Minimum
5000 10000 20000
km km km
★ Steering
Check oil level of

●
hydraulic system
Observe monitoring
device of pressure ●
filter
Clean pressure filter When needed
Check that steering
linkage, pitman arm,
steering booster
100 km ●
cylinder are firmly
attached, check cotter
pin
Check hydraulic
steering system for ●
leaks
Check position of tie
rods and adjust ●
position of tires
Oil change ● ●
Replace filter of oil

●
tank
Check steering limit
screws of axle, adjust if ●
necessary
Check hydraulic
pressure, readjust if ●
necessary
Check toe-in of axles,
●
adjust if necessary
★ Propeller shaft and bearing seat
Check lubricating 5000

grease km
Check flange bolts,
intermediate bearing 2500
100 km
bolt and tighten if km
necessary
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0063152-000-07-20Y
Checks
every
First Minimum
5000 10000 20000
km km km
★ Transfer case
Check oil level ●
Oil change 5000 km ●
Check for leaks ●
Check or tighten
100 km ●
mounting bolts
Check road / off-road
●
gear transfer function
Check that the radiator
and oil pipe fittings are 100 km ●
firmly attached
Clean deaerating
● ●
nipple
Have tachograph
●
checked
★ Axle, driven
Check for leaks ●

Oil level checks at axle
reducer, differential
●
housing and wheel
hubs
Grease steering 10000
●
knuckle bearings km
Check attachment ●
10000
Oil change 1000 km ●
km
Clean deaerating
● ●
nipple at axle housing
Adjust wheel bearings ● ●

Check transversal /
longitudinal differential ●
lock for function
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0063152-000-07-20Y
Checks
every
First Minimum
after or or annual
or 5000 Daily Weekly
10000 20000
km
km km
★ Axles, non-driven ●
Grease steering 10000

●
knuckle bearings km
Check attachment ●
Replace wheel hub

● ●
grease filling
Adjust wheel
● ●
bearings
★ Tires
Ensure that wheel
nuts are tight,
1000 km ●
re-tighten if
necessary
Check the tire
●
pressure
★ Air pressure system
Check for leaks ●

Check operating
pressure of brake ●
system
Check cut-off
●
pressure
Drain air pressure
●
tank
Replace air drier
●
granular cartridges
Clean air drier
●
preliminary filter
★ Brake system
Check brake lining

●
thickness
Adjust brakes if
necessary, replace ●
linings if required
Check operation of
parking brake and ● ●
service brake
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0063152-000-07-20Y
Checks
every
First Minimum
after or or annual
10000 20000
km
km km
★Hydro-pneumatic suspension
Check hydraulic tank

●
fluid level
Check hydraulic
●
system for leaks
Perform function test ●
Replace filter of
●
hydraulic tank
Check hydraulic
pressure, adjust if ●
necessary
Check pressure
accumulator
● ●
pretension pressure
(nitrogen)
Oil change ● ●
Check mounting and
tightening conditions
●
of suspension
cylinder
Check mounting and
tightening conditions ●
of thrust rod
★ Hydraulic pump
Check for leaks ●
Check screws for

●
proper seating
Lubricate bearings ● ●
★ Electrical system
Check vehicle
lighting for correct ●
operation
Check cable
connections and
●
electrolyte (battery
acid) levels
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Checks
every
First Minimum
after or or annual
10000 20000
km
km km
★ Fuel system
Check for oil leaks ●
Check condition and

● ●
mountings
Drain off water and
● ●
sediments
Clean fuel pump
● ●
preliminary filter
★ Outriggers
Check hydraulic
●
system for leaks
Check hydraulic tank
●
fluid level
Checking ease of
movement of sliding ●
beams
Grease the sliding
block of sliding beam ● ●
and fasten the pins
Adjust telescopic
●
rope and grease
Check support
control unit, readjust ●
if necessary
Oil change ● ●
Replace filter of
●
hydraulic oil
Check operating
pressure of hydraulic ●
system
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0063152-000-07-20Y
Checks
every
First Minimum
after or or annual
10000 20000
km
km km
★ Driver’s cab
Check electric
appliance for ●
function
Check control lights
●
for function
Check engine for
exhaust brake ●
function
Check mounting
bolts in operator’s ●
cab for tightness
★ Suspension system
Check parts for

100 km ●
loosen and damage
Check leaf spring for
●
damage
Check cushion block
of front suspension 100 km ●
for damage
Check rigid limit
block of rear
●
suspension
thickness
Note:
The maintenance intervals on the crane chassis can be calculated either from operating hours
or by kilometers traveled. Perform the maintenance tasks as long as the operating hours or
kilometers traveled (whichever) has reached.
The coolant refers to the engine antifreeze & antirust fluid. Please integrate it in proper
proportion.
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7.3.2 Crane superstructure maintenance and inspection plan
Regular maintenance, Minimum

First Checks
every maintenance
maintenance
100 200 400 1200 annual
after Daily Weekly
h h h h
★ Superstructure engine
Check the oil level
For all other
maintenance tasks,
●
follow the instructions
of the engine
manufacturer
Check the coolant level
in the equalizing ●
reservoir
Replace coolant Every 2 years
★ Air filter
Check monitoring
●
device
Clean or change
(follow the instructions
of the engine
manufacturer)
★ Slewing ring connection
Lubricate slewing ring Every 3

connection months *
Make sure that bolts
200 h ● ●
are tight
Check tilting free play ● ●
★ Rope winches
Check for leaks ●
Check the oil level ●
Check bolts for tight

200 h ● ●
seating
3000
Oil change Every 4 years
h
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0063152-000-07-20Y

First Checks
every maintenance
maintenance
100 200 400 1200 annual
after Daily Weekly
h h h h
★ Pulley
Check, grease if
●
necessary
★ Wire rope
Check, grease if
● ●
necessary
★ Hook
Grease hook ● ●
★ Hydraulic system
Check for leaks ●
Replace pressure oil

200 h ●
filter
Replace return-line
200 h ●
filter
Replace bleeder filter
200 h ●
of hydraulic tank
Check hydraulic oil
(take oil sample and
400 h ● ●
have it checked by oil
supplier)
★ Hydraulic cylinder
Check for leaks ●
★ Electrical system
Check cable
●
connections
★ Operator’s cab
Check instruments for

●
function
Check control lights for
●
function
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0063152-000-07-20Y

First Checks
every maintenance
maintenance
100 200 400 1200 annual
after Daily Weekly
h h h h
★Operator’s cab, extendable or inclinable
Check for correct

●
function
★Load moment limiter
Check working
●
conditions
★Slewing reducer
Check for leaks ●
Check bolts for tight

200 h ● ●
seating
4000
Oil change Every 4 years
h
★Telematik telescopic boom system

Check telescopic
boom for distortions ●
and cracks
Check telescopic
cylinder for proper ● ●
condition
Check the interlocking
device for proper ● ●
condition
Check locking pins
and locking bores for ● ●
proper condition
Check inner and outer
sliding surfaces for ● ●
proper condition
Lubricate the sliding
●*
surfaces
* Carry out a visual inspection before every startup in service.
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7.4 Lubrication
7.4.1 Hydraulic oil
The hydraulic oil tanks for crane superstructure and chassis have been topped up with
hydraulic oil before delivery.
Oil brands for superstructure: NUTO H32 (for frigid zone)
NUTO H46 (for tropical and temperate zone)
Oil brand for chassis: L-HV32 (GB11118.1-94)
Caution:
The quality, viscosity and cleanness of hydraulic oil are the most key factors for normal
operations of the crane.
Ignorance to the changing of hydraulic oil will cause various faults and greatly shorten the
service life of the crane.
Our company will not take any responsibilities for any consequences caused by not complying
with the requests stipulated in this manual during oil changing and filtering.
7.4.1.1 Filtering / changing intervals
Vehicle Filter or Every 6 months Filter or

200 hours later
delivery change change
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7.4.1.2 Changing steps
a) Change hydraulic oil in the hydraulic oil tank

1) Drain out the hydraulic oil;
2) Remove master oil return pipe;
3) Clean the oil tank and filter with chemical cleaning agent (solid particle pollution
grade ≤18/15) carefully;
4) Wash with new hydraulic oil (solid particle pollution grade ≤ 18/15) after drying;
5) Drain out the washing oil;
6) Add new hydraulic oil.
b) Run the engine at low speed to start the pump and drive the mechanisms (to drain out
the original oil in every circuit of the system with new hydraulic oil)
Note:
The original oil is not permitted to return to the oil tank.
Do not stop the oil pump until new oil flows out from the master oil return pipe.
Add new oil continuously into the hydraulic tank to prevent the oil pump from inhaling air.
c) Connect master oil return pipe and oil tank
d) Set each component to initial working state
e) Add hydraulic oil to the required level
Note:
Add oil and deaerate from oil outlet after oil changing to avoid crane abnormal working
and damage.
Caution:
(1) Filter or change the hydraulic oil immediately once it is polluted seriously;
(2) Choose proper hydraulic oil according to the ambient temperature;
(3) The hydraulic oil of different brands cannot be mixed;
(4) Service time of hydraulic oil must be within 24 months, and it cannot be used any more
after 24 months even if it has been filtered.
Liquid level gauge
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7.4.1.3 Checking the oil temperature
A liquid level gauge is installed at the front or rear end surface of hydraulic tank.
Observe the temperature of hydraulic oil from the marks on the liquid level gauge.
The highest working temperature: 80°C.
7.4.1.4 Checking the oil level
Check the oil level in crane’s driving condition (with all the oil cylinders retracted).
The oil temperature and level can be checked from the marks on the liquid level gauge.
Ensure that the oil level is between the minimum and maximum marks in the condition of all
the oil cylinders retracted when filling oil.
The mark 0°C is the minimum mark.
If the oil level has dropped below the minimum mark, top up with hydraulic oil until the oil level
is between the minimum and maximum marks.
Oil reserve of superstructure hydraulic tank: 920 L
Oil reserve of chassis hydraulic tank (for outriggers, suspension and steering system): 130 L
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7.4.1.5 Table – oil feature and brand
Features and brands of hydraulic oil required in different ambient temperatures (regions and
seasons) are listed the following table. Read it carefully before choosing hydraulic oil.
Ambient Ambient Ambient Ambient
temperature temperature temperature temperature
Item
above between above below
40°C -20°C - 40°C -30°C -30°C
Reference standard SH 0358-95
ESSO Nuto ESSO Nuto Mobil DTE Aviation
Type
H68 H32 13M hydraulic oil
Viscosity grade 68 32 32 10
Min. Flash point (split) ℃ 234 212 172 92

More than
Kinematic viscosity at 40℃ mm²/s 61.2-74.8 28.8-35.2 28.8-35.2
10 at 50℃
Max. temperature when kinematic
-50
viscosity at 1500 mm²/s ℃
Min. viscosity index 107 104 144
Max. pour point ℃ -18 -24 -40
7.4.2 Gear oil
Use the gear oil recommended by this manual.

Slewing reducer of our product has been topped up with 90# industrial gear oil (Type:
SY1172-80) before delivery.
Its characteristics are as follows:
Kinematic viscosity (100℃) Flash point (split),
Ingredients
mm²/s ℃
Organic acid fat, phosphoric acid fat,
13.5 - <24.0 ≥165 silicic acid fat, fluorin oil, silicon oil,
polyphenylene oxide + addictive
7.4.2.1 Changing intervals
Vehicle 200 hours later Every 12 months Change

delivery Change oil
oil
Caution:
(1) Change gear oil even if it has not reached the oil change intervals if it is polluted
seriously;
(2) Often check oil level and add oil in time if it is lower than the minimum mark;
(3) Hydraulic oil of different brands cannot be mixed;
(4) Use the recommended gear oil according to ambient temperature. The reducer
mechanism will be damaged due to unqualified gear oil or gear oil with improper
viscosity.
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7.4.2.2 Oil change
a) Winch reducer
Add oil after removing this

plug.
Remove the plug when adding

oil to check whether the oil Drain out the oil after
level has reached the fringe of removing the oil drain plug.
the plug.
Note:
The gear oil quantity for one reducer is about 4 liters.
b) Slewing reducer
Add oil after removing the plug of oil filler aperture.
Check oil level.
Drain oil after removing the

oil drain plug.
Note:
The gear oil quantity for one slewing reducer is about 2.25 liters.
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c) Axles
The gear oil quantity for axle 2: 25 L
d) Transfer case
The gear oil quantity for transfer case: 12.5 L
Gear oil type for heavy-duty vehicle: GL-5 85W/90 (Ambient temperature: -15° - 49°)
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7.4.3 Lubricating grease
Lithium base grease (ZL-2)

Molybdenum disulfide grease (ZFG-4E)
Note:
Use the recommended lubricants.
Filling method: grease or fill with grease pump
Some parts can be lubricated via the central lubricating system (See Chapter 3.2.5.10).
Work wimble
Drop point Moisture
Parameter Appearance degree
(ºC) (%) ≤
Type （1/10mm）
Smooth inunctum with the
ZL-2 lubricating grease color from light yellow to 175 265 - 295 ——
brown
Equal inunctum with the color
ZG-3 lubricating grease from light yellow to dark 90 220 - 250 2.5
brown
ZFG-4E lubricating Equal inunctum with dust
—— 300 - 350 Trace
grease color
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7.4.4 Engine oil
For details about engine oil, see Operating Instructions for Engine.
Caution:
To improve the cold start ability of the diesel engine at a low temperature, use the
recommended engine oil;
The fuel tank must be topped up; otherwise solidification of air moisture inside the fuel tank
will get frozen to rust the oil tank and affect the cold start ability of the engine.
7.4.4.1 Fuel
Ensure that the following prerequisites are met when choosing fuel:
Only the light diesel oil listed in appendix C of GB17691-2005 can be used;
– The light diesel must be filtered for 24 hours and its sulfur content must be lower than
0.5%;
– Choose the proper fuel according to its lowest ambient temperature.
Use the proper diesel oil according to the ambient temperature:
Temperature ≥ 5℃: 0# (GB252-94)
-5℃ ≤ Temperature ≤0℃: -10# (GB252)
-14℃ ≤ Temperature ≤ -5℃: -20# (GB252)
-29℃ ≤ Temperature ≤ -14℃: -35# (GB252)
-44℃ ≤ Temperature ≤ -29℃: -50# (GB252)
Diesel oil quantity (superstructure): 220 L
Diesel oil quantity (chassis): 400 L
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7.4.4.2 Lubricant
Lubricant grade: CF-4 or CH-4

Viscosity grade: according to ambient temperature (See illustration 1)
Illustration 1 Lubrication chart

We recommend the 15W/40 engine oil (Grade: CF-4) at an ambient temperature above -15℃
and 5W/20 engine oil at an ambient temperature below -15℃ to lower the fuel consumption
during oil changing in winter.
The oil level must be between the minimum and maximum marks on the oil dipstick in the
condition of engine turned off and leveled on the ground.
Caution:
(1) Do not check the oil level in the condition of engine running;
(2) Hydraulic oil of different brands cannot be mixed;
(3) Do not use the lubricating oil at grade CE, CC, CB and CA.
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7.4.5 Cooling medium
The cooling water added in the diesel engine must be softened water mixed with 5-in-1
environmental-friendly antifreeze or anti-rusting and long-acting antifreeze fluid.
This crane has been added with 50% softened water mixed with 50% 5-in-1
environmental-friendly antifreeze fluid, specification -25℃ and suitable for ambient
temperature above -5℃.
As for detailed instructions, please refer to Antifreeze Operating Manual.
If you want to change the 5-in-1 environmental antifreeze fluid into long-acting antifreeze fluid,
the long-acting antifreeze fluid must observe the requirements as follows:
a) The long-acting antifreeze fluid is of the ability of anti-rusting and antifreezing. As for the
dosage of long-acting antifreeze fluid, see its manual.
b) As for the long-acting antifreeze fluid produced in China, its dosage can be checked in the
following table:
Type
Dosage JFL-318 JFL-336 JFL-345
Ethanediol % 33 50 56
Specific gravity at 15.6℃ 1.05 1.074 1.082
Boiling point ℃ 104.5±1 108.5±1 110.0±1
Freezing point ℃ -18±1 -36±1 -45±1
Lowest ambient temperature ℃ -10 -26 -35
Add corrosion preventive agent fluid (NL rust preventive emulsion and LQS comprehensive
preventive agent) to the cooling water at an ambient temperature above 5℃.
As for its dosage in softened water, see its manual.
The cooling water quantity: 60 L
Its dosage is as follows:
Cooling water dosage and grade
Dosage and grade Min. Max.
PH 6.5 8.5
Ion in chloride mg/dm 3 - 100
Carbonate mg/dm 3 - 100 Only the water met these

requirements can be mixed
Anion mg/dm 3 - 150 with 5-in-1
Hardness (using long-acting antifreeze environmental-friendly
3 12 antifreeze fluid or anti-rust
fluid) mg/dm 3
and long-acting antifreeze
Hardness of carbonate mg/dm 3 3 - fluid.
Hardness (using anti-corrosion fluid) (Pay
attention to the instructions of
0 10
manufacturer
mg/dm3
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Caution:
(1) Check the viscosity of antifreeze fluid at an ambient temperature below 0℃ every 1000h
and at least every season; to avoid corrosion, replace the antifreeze fluid every 2 years;
(2) For the crane running at an ambient temperature above 0℃ all over the year, you can
use the anti-rusting and antifreeze fluid as the cooling medium.
It is forbidden to substitute coolant with ordinary water!
(3) The performance of 5-in-1 environmental-friendly antifreeze fluid is superior to the
long-acting one. We recommend “basf" special anti-rusting and antifreeze fluid for Benz
engine. Mix it with water in a proportion of 1 to 1;
(4) If you use long-acting antifreeze fluid, the one suitable for all-season and all-purpose is
recommended.
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7.4.6 Lubricating points
Working oil and lubricating grease used in this vehicle can not only ensure normal working of
each mechanism, but also prolong their service life and bring their function into full play.
Therefore, lubricate regularly in accordance with specified grease and lubricating points.
7.4.6.1 Lubrication – superstructure
● Lubricating table
Lubricating Lubricating grease
Pos. Description Lubricating method
intervals type
All sliding surfaces on the ZFG-4E
Grease or inject with
1 telescopic boom Every 10 days molybdenum
grease pump
disulfide grease
2 Upper pulley block (shaft) Inject with grease ZL-2 lithium base
Every 10 days
3 Lower pulley block (shaft) pump grease
Pulley block (shaft) on Inject with grease ZL-2 lithium base
4 Every 10 days
main / auxiliary hook pump grease
Upper articulated-point
Inject with grease
5 shaft and knuckle bearing
pump or using ZL-2 lithium base
of derricking cylinder Every month
central lubricating grease
Lower articulated-point
6 system
shaft of derricking cylinder
Every 6
7 Slewing reducer Pour directly 90# industrial gear oil
months
Inject with grease ZL-2 lithium base
8 Engine control shaft seat Every month
pump grease
Grease, inject with
grease pump or use ZL-2 lithium base
9 Slewing ring and gear Every 10 days
central lubricating grease
system
Inject with grease
Operator’s cab, ZL-2 lithium base
10 Every month pump or use central
extendable or inclinable grease
lubricating system
Hydraulic tank for Every 6 Hydraulic oil (See
11 Pour directly
superstructure months chapter 7.4.1)
ZFG-4E
Sliding surface of sliding
12 Every 10 days Grease molybdenum
beam
disulfide grease
Grease or inject with ZL-2 lithium base
13 Pulley in outrigger Every 10 days
grease pump grease
Counterweight assembly / Every 6 Inject with grease ZL-2 lithium base
14
dismantling mechanism months pump grease
Main / auxiliary winch Every 6
15 Pour directly 90# industrial gear oil
reducer months
ZL-2 lithium base
16 Wire rope Every 10 days Grease
grease
Inject with grease ZL-2 lithium base
17 Pulley block (shaft) on jib Every 10 days
pump grease
Telescopic boom main Grease, inject with ZL-2 lithium base
18 Daily
shaft grease pump grease
Propeller shaft for oil Inject with grease ZL-2 lithium base
19 Daily
pump pump grease
Every 6 ZL-2 lithium base
20 Interlocking device Grease
months grease
7-24
1 ● Lubricating graph - superstructure
2 1 20 19 18 17 16 15
3
4
5
14
2
13
7-25
12
11
6
5 6 7 8 9 10
1145-000-07-20Y
Caution:
(1) Before adding oil, clean the oil cup and the surfaces to be greased;
(2) Lubricate the sliding surfaces not listed in the above table regularly;
(3) The lubricating grease of different brands cannot be mixed;
(4) When injecting grease into the bush, shaft and bearing, inject grease until the original
grease flows out;
(5) If the piston rod of boom derricking cylinder is partly exposed when the boom is secured
on the boom bracket, grease the exposed section every month.
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7.4.6.2 Lubrication –chassis
 Lubricating table
Number of
Lubricating Lubricating Lubricating grease
Pos. Description lubricating
intervals method type
point
Inject with ZL-2 lithium base
1 Water pump shaft 1 1500km
grease pump grease
Suspension oil Inject with ZL-2 lithium base
2 8 1000km
cylinder pin grease pump grease
Suspension thrust Inject with ZL-2 lithium base
3 16 5000km
rod assy. grease pump grease
5000 km Add oil MTU engine oil,
Sinopec 15W/40
Engine oil CH-4 diesel oil or
4 1
container * Mobil Delvac MX
20000 km Change oil
15W/40 CH-4 diesel
oil
Half a year Add oil ZF-Ecofluid M (02E)
engine oil (Parts No.
5 Transmission* 1 300000 km,
for special oil is
not exceed 3 Change oil
0671072160 )
years
Sliding fork for Inject with ZL-2lithium base
6 6 5000 km
propeller shaft grease pump grease
Intermediate
7 bearing for 1 1500 km
grease pump grease
propeller shaft
GL-5 85W/90 gear
8 Transfer case* 1 10000 km Change oil oil for heavy-duty
vehicle
Universal-joint
9 bearing for 26 1500km
grease pump grease
propeller shaft
1500 km Add oil GL-5 85W/90 gear
Hub reducer for
10 8 oil for heavy-duty
drive axle
10000 km Change oil vehicle
1500 km Add oil GL-5 85W/90 gear

Central reducer for
11 4 oil for heavy-duty
drive axle
10000 km Change oil vehicle
Main pin for Inject with ZL-2 lithium base
12 10 5000 km
steering axles grease pump grease
Connecting shaft
13 for steering rocker 5 5000 km
grease pump grease
arm
Battery electrode Industrial Vaseline
14 4 Every season Brush with oil
post LF40
Universal joint for
15 oil pump propeller 2 5000 km
grease pump grease
shaft
Steering drag link Inject with ZL-2 lithium base
16 20 5000 km
union grease pump grease
Steering hydraulic
17 1 10000 km Change oil L-HV32 hydraulic oil
oil tank
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Number of
Lubricating Lubricating Lubricating grease
Pos. Description lubricating
intervals method type
point
Universal joint for HJ-20 mechanical
18 1 5000 km Drip in
steering gear shaft oil
Angular drive Inject with ZL-2 lithium base
19 1 5000 km
device grease pump grease
ZG-S graphite
20 Rear leaf spring 3 10000 km Brush with oil
calcium base grease
10000 km Change oil
Rear leaf spring ZL-2 lithium base
21 3
pin Inject with grease
2000 km
grease pump
Balance beam and
22 thrust rod of rear 24 5000 km
grease pump grease
suspension
23 Ball pin of tie rod 6 5000 km
grease pump grease
Note:
For details of the component marked with *, please refer to the operating instructions provided
by manufacturer.
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 Lubricating graph - chassis

The parts 20 – 23 have no position number.
Caution:
(1) Determine the engine actual working time according to the tachometer and carry out
maintenances in accordance with “Diesel engine maintenance specifications” in
Operating Instructions for Engine;
(2) After adding or replacing lubricating grease, wipe off the grease around the threaded plug
and check for leaks;
(3) For the first replacement of the gear oil for the rear axle after the break-in period of a new
crane:
– Add diluted engine oil into rear axle after draining out the original oil;
– Support the crane rear wheels, start the engine and engage the gear;
– After running for about 5 minutes, wash the rear axle, drain out the washing engine
oil and then add new gear oil.
(4) The oil change intervals for transmission and engine should be reduced in half under
conditions of long parking time and short driving time.
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7.5 Adjusting, cleaning and replacing parts
7.5.1 Replacing the wire rope
Regular checking of the rope is required, especially before using after installing. Moreover,
check the wire rope strictly if special tightening force is acting on the rope, or invisible
damages and new damages occur on the rope.
Suspended wire ropes, rope end connections and drive elements of some wire ropes must be
checked at regular intervals. Check to ensure that the drum and the pulley can rotate
smoothly on their mounting positions, and no obvious indentation of wire rope occurs in the
path of motion for the wire rope.
Caution:
After the rope is used for a period, its strength will be reduced to such an extent that continued
use thereof may be dangerous.
7.5.1.1 Take-down criteria
a) There is 10% broken rope in one strand (excluding the break caused by damage to the
rope core);
b) The diameter is reduced by more than 7% of its nominal diameter;
c) The wire rope is reverse bent or knot;
d) The wire rope is seriously deformed; wire core is revealed, birdcage deformed and is in
corrosion.
Danger:
The wire ropes must be taken down before they reach the above 4 stages.
e) Tension caused by rope coming out from the pulley;
f) Damage caused by heavy objects;
g) Damage caused by electric welding or gas welding;
h) Damage caused by short circuit;
i) Damage caused by the effect of heat;
Caution:
The wire ropes can be taken down according to the wearing conditions before they reach the
above 5 stages.
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Illustration - Damaged wire ropes (For reference only)
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Danger:
The ropes must be taken down immediately if following stages occur.
(1) One strand is broken.
(2) Rope is broken in a small range.
(3) Corkscrew-like deformation: deformation (See picture 1), at the worst point is 1/3 the
nominal diameter of the rope.
(4) Birdcage deformation (See picture 2).
(5) Loop formation (See picture 3).
(6) Loosening of single wires or wire braids (See picture 4).
(7) Knots (See picture 5).
(8) Flattening (See picture 6).
(9) Curling and kinks (See picture 7).
(10) Bends (See picture 8).
If exceptional damages occurred on the rope, the operator must find out the reason and repair
it before replacing the rope.
Damages and friction trace on the crane can provide important clues.
Warning:
If there are any dangerous safety operations, please stop using the wire rope and consult
experts.
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7.5.1.2 Maintenance
Regular maintenance of the rope is required in order to ensure safe operation of the crane
and to greatly increase the service life of the rope.
Within certain intervals, the rope should be lubricated with grease or oil in accordance with the
operating conditions of the rope, particularly in areas in which the rope is subjected to bending
when it runs over the drum and pulleys.
Under the same testing conditions, curvature for well-lubricated rope is 4 times larger than the
rope without lubrication. The lubricant that is used must be compatible with the original one.
Caution:
The lubricant that is used on the rope must be standard commercial lubricant which is
recommended by the manufacturer. Please refer to lubricating tables.
Dirty ropes should be regularly cleaned with brush.
In the event that the lower layers on the drum are used infrequently or not at all, they would be
re-loosened and re-tensioned by pre-tightening force. A rope is most cost-effective when the
entire length is used. An appropriate rope length should therefore be used when operating the
crane over longer periods.
If one certain rope section is more frequently used than the other sections, turnover the rope
at regular intervals. Connect the original rope free end to the drum, so that the working
frequency can be balanced. In this way, service life of the rope can be greatly increased. The
modification of quick-connected rope end should be performed by the wire rope manufacturer.
7.5.1.3 Twisting caused by stretching in non-twisting ropes
The twisting of new wire rope, which has been placed or used for a period, caused by
stretching in non-twisting ropes should be remedied.
When the hook pulley block is operated with multi-reevings, and when the load is lowered and
/ or the rope outer strand seems loose and even arch type appears on the rope, warn in time
and adjust the twisted parts.
Generally speaking, a twisting-proof device is fitted on the fixing point of hoist rope. As for the
ropes without the twisting-proof device, please refer to instructions in 7.5.1.4 ”Remedying the
twisting”.
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7.5.1.4 Remedying the twisting
a) Lowering the hook block

Lower the hook block as low as possible to adjust the rope between the pulley on boom
head and the hook pulley in the maximum length.
b) Judging the rotating direction
Judge that in which direction the hook pulley block is twisted.
The rotating direction is indicated by an actual-line arrowhead on the picture.
As the judgment is hard to make, especially when the hoist rope is extremely long, rotate
the rope in the dotted-line arrowhead direction and check. As a result, the twisted ropes
can certainly be loosened.
c) Loosening the rope at a fixing point
After making sure the rotating direction, loosen the rope at a fixing point on the hook
pulley.
Caution:
As for the adjusting twisted force, the rope reeved on the hook pulley block in odd
number is favorable. Under this circumstance, the fixing end of rope is on the hook, so
the rope can be easily loosened.
d) Rotate the rope end from the 180° position to 360° position carefully, and adjust the
rotation of hook pulley block.
As for the adjustment of rotation, the rotating direction is indicated (by actual-line
arrowhead) on the rope end.
Caution:
It is important for the operator to hold the rope in his front and select correct reference
point.
The rightward rotated rope (Z) as indicated in Picture 1 and the leftward rotated rope (S)
as indicated in Picture 4 must be adjusted by being rotated in. The rightward rotated rope
(Z) as indicated in Picture 2 and the leftward rotated rope (S) as indicated in Picture 3
must be adjusted by being rotated out.
Rules for adjusting twisted rope: the rope end must be rotated in reverse rotating
direction, so that the twisted ropes can be loosened.
Warning:
The rope to be rotated must be as long as possible, so that the rope can be rotated in the
whole length through hoisting motions without load. It is not allowed to rotate the rope on a
short rope section by outside force, as the structure of wire rope can be damaged
permanently.
e) Connecting the rope to the fixing point
After rotating the rope, connect the rope end to the fixing point and tighten.
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f) Raise the hook without load. Repeat this procedure if necessary.

It is relatively safe for the rope structure which is not stretched. This kind of rope only
stretches a little (the twisting will not exceed the head pulley block actually); therefore,
carry out hoisting motions without load for several times.
After the twisting of the rope end being adjusted, re-connect the rope end to the fixing
point, and repeat hoisting motions without load once or for several times. In this way, the
adjusting function for twisting can be spread all over the whole length of the rope across
the head pulley block.
Caution:
When the stretching phenomenon of wire rope is serious (multi-twisting on lower pulley
block and / or the outer strand of a long rope section loosens on several points), repeat
this procedure if necessary in accordance with the length of hoist rope.
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7.5.1.5 Methods for replacing and reeving the wire rope
Danger:
The rope must be replaced with a rope that is of the same type, same diameter and same
reliability as the original.
If the wire rope is of another type, permission from the crane manufacturer should be obtained
at first.
Wire ropes can be easily damaged by external force, so special attentions should be paid
during transportation or when there is no load on them.
Wire ropes should be kept in clean, low temperature and dry places, and should not be laid on
the earthen ground.
Wire ropes can only work normally without twisting or other external damages.
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Correct reeving method:
Wire ropes can be reeved directly on the drum or ring-type objects (See picture 1).
Do not reeve the rope laterally. Because the ropes will be twisted and be damaged by pulling
force.
The best method is to reeve the rope from a higher drum to the lower one (See picture 2).
The rope reeving direction should be the same as its bending direction to prevent additional
stress, so that ropes can be reeved on the drum in good state.
Warning:
Do not drag the rope on the ground to prevent the rope being dirtied.
The rope must be connected with the rotating union to prevent non-twisting ropes from being
twisted caused by outer force.
If the ropes are reeved on the drum in multi-layer, the downmost layer should be tensioned
with a pre-tightening force of 1% to 2% of the minimum breaking force of the rope. This
pre-tightening force can be obtained from the drum brake.
For the pulley block, the hoist rope should be reeved in the same direction as in the drum. If
the ropes are limited by their length, the ropes must be laid on the ground when the ropes are
being reeved onto the hook to ensure that the ropes are not twisted.
After replacing the ropes, test them with part of the load, and then shrink the rope by several
hoisting motions to changeover between the hook with load and the hook without hook. In this
way, the rope can adapt to the bending direction and diameter of the pulley and the drum.
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Replacing the hoist rope

a) Changing crane operating conditions
1) Level the crane on firm and load-bearing ground;
2) Telescope in the boom completely.
b) How to replace the hoist rope
1) Lower the main hook and set it on the ground;
Caution:
Operate carefully to avoid the rope from disordering on the drum.
2) Take down the rope lock and take out the pouch socket;
Keep the parts orderly and do not lose them.
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3) Lower the hook, reeve out the rope from the drum and pull out the rope manually;
Caution:
The lowering limit switch will be activated when only 3 hoist rope windings are left on
the main winch. Press the bypass key switch to release the limitation until the wire
rope is reeled off completely.
4) Take down the rope from the drum;
5) Reeve the new rope (in reverse sequence of above steps);
6) Derrick the boom up and telescope it out. Lower the hook until only 3 hoist rope
windings are left on the winch;
Caution:
Do not lower the hook excessively to avoid rope damage and accident.
7) Reeve the wire rope on the drum with a load whose weight is 30% of the max.
permitted lifting capacity per strand;
Weight of the load: W=0.3NP
Rope reeving: N
Max. permitted lifting capacity

per strand: P
Caution:
Do not exceed the rated lifting capacity.
8) Unload the load from the main hook.
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7.5.2 Replacing the hook
The hook must be taken down by being assessed in accordance with the following
circumstances: (welding up of hook’s disfigurement is not allowed):
a) There’s crack and crevasse on the surface of the hook;
b) The hook’s split degree should not exceed 10% of the original dimension;
c) The abrasion of the dangerous sectional plane reaches 10% of the original dimension;
d) The wear extent of the sectional plane in the point where wire rope suspended exceeds
10% of the original height;
e) The torsion and deformation of hook exceeds 10°;
f) There is plastic deformation in dangerous sectional plane such as the tail of hook, the
screw threaded part and hook web.
7.5.3 Checking and replacing return-line filter
The return-line filter is installed on the hydraulic oil tank to filter the impurities, thus to maintain
the extreme cleanliness when topping up the oil.
WY-type filter has a perpetual alnico which can filter the iron grain bigger than 1um in the oil
and also filter partly the magnetism and none-magnetism mixture. Thus it can greatly improve
the working reliability and prolong the service life of the hydraulic system.
The texture of the filter is non-woven chemical fabric with the advantage of the high filtering
precision, big oil-through capacity, low original pressure loss, great pollution tolerance
capacity and so on. And its filter precision can be calibrated by the absolute filter precision. Its
filter ratio and efficiency meet the requirements of ISO.
Unscrew and remove the filter cover to replace the return-line filter.
The filtered impurities will not flow into the hydraulic oil tank if the filtered is replaced because
the hydraulic oil flows into the hydraulic oil tank via the inner layer of the filter.
a) Replacing intervals:
Every 6 months
From the delivery date Replace the filter
Caution:
Shut off the hydraulic pump when replacing the filter.
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b) Replacing procedures:
1) Remove the cover by wrench;
Hydraulic oil tank

液压油箱
2) Take out the spring and the perpetual alnico units;
Spring
3) Take out and replace the filter;
4) Mount the spring and the perpetual alnico units;
Spring
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5) Put on the cover and screw tight with wench.
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7.5.4 Replacing the hydraulic oil filter for closed slewing pump
a) After the first 100 hours of lifting operation, replace the hydraulic oil filter for the first time
(screw rightward to remove it);
Replace it every 500 hours.
b) Hydraulic oil filter type is 0009830623V (attached 1 piece).
c) Position of hydraulic oil filter:
Hydraulic oil filter
Oil pump (behind superstructure engine)
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7.5.5 Cleaning and replacing the fuel filter
Clean the fuel filter every 250 hours (engine working time); and replace the filter every 1000
hours.
Steps for cleaning or replacing diesel oil filter are as follows:
a) Place a container below the oil drain plug of fuel filter;
b) Unscrew the aeration plug and oil drain plug to drain diesel oil and impurities;
c) Screw off the long central threaded rod and remove the oil filtering bottle, filter, spring
seat and spring;
d) Clean the parts except filter with diesel oil.
Caution:
Do not wash the filter!
e) Check whether the filter is blocked or polluted. If it has been blocked or polluted seriously
or used for 1000 hours, change it with a new one. Replace the O-ring and washer if the
filter is replaced;
f) Set a new washer into the long central threaded rod and put it into the oil filtering bottle.
Install the spring, spring seat, filter and washer or O-ring. Screw the long central threaded
rod into the filter cover until it is tightened;
g) Exhaust air with manual oil pump;
h) Check the filter for leaks.
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7.5.6 Cleaning and replacing the air filter
The air filter is equipped with a maintenance indicator. If the red bar indicator is visible when
the air filter is soiled, the filters must be cleaned or replaced.
After cleaning or replacing the air filters, press the button on the top of indicator.
a) Dismantle and assemble air filter in the following steps:
1) Screw off butterfly nut and pull out the cover;
2) Pull out filters;
3) Clean air filtering bottle and cover;
4) Insert the filter and tighten it with locking nut;
5) Screw the cover into the air filtering bottle with butterfly nut.
Caution:
(1) Ensure the filters and cover are properly installed to prevent dust from entering and
the air filtering effect being affected;
(2) Filters 1 and 2 must be replaced and the filter 1 cannot be washed.
b) Clean the air filter:
 Dry dust
Supply compressed air along the filter flange to blow off the dust.
Do not knock and bump against the filters, and the speed of compressed air supplied
should not be higher than 7kg/cm3.
 If the filter is polluted with oil fume, coal soot and oily filth, wash the filter with
washing fluid in the following steps:
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1) Dissolve the washing fluid into 40℃ warm water.

2) Put the filters into washing liquid for 30 minutes, and wash it with washing fluid
for 4 - 5 mins;
3) Take out the filter and wash dirt and washing fluid with tap water. The water
pressure should not be too high;
4) Dry the filter in the air. It can be dried with fan if needed. But do not dry it with
flame or compressed air;
5) After air-drying the filter cartridge, check the filter paper for proper condition
with bulb. If the paper is in poor condition or the shim is damaged, replace it
with a new one.
Caution:
(1) The filter must be air-dried. Do not use moist filter;
(2) Washing and drying will cost you several hours; therefore, you’d better prepare
another one for option;
Notes: Replace it with a new one after washing for three times.
(3) The filter 1 cannot be washed.
7.5.7 Replacing the pressure filter
This crane is equipped with 2 hydraulic pressure filters installed on the slewing table.
Replace the filter cartridge after the pressure filter has worked for 250 hours.
Installation methods are as follows:
 Screw off the cover of oil filter counterclockwise
 Take out the filter cartridge
 Replace with a new one
Filter cartridge type: HX-63X20
Cover
Filter cartridge
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7.5.8 Adjusting the telescopic wire rope of sliding beam
Adjusting nut 1
Locking nut 1
Locking nut 2 Adjusting nut 2
7.5.8.1 Rectifying the wire rope – extending outriggers
Troubleshooting:
The outriggers still cannot be fully extended after the horizontal cylinders are fully extended.
– The wire rope to extend the outriggers is not properly rectified.
Rectify the wire rope according to the following steps:
a) Make the crane in driving-state (with the outriggers retracted);
b) Unscrew the locking nut 1 and then screw down the adjusting nut 1 until the extending
wire rope is tightened.
Caution:
Do not over tighten the adjusting nut 1; otherwise the wire rope will be in over-tight state.
Re-tighten the locking nut 1 after adjustment.
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7.5.8.2 Rectifying the wire rope – retracting outriggers
Troubleshooting:
The sliding beam section 2 cannot be fully retracted after the horizontal cylinders are fully
retracted.
– The wire rope to retract the sliding beams is not properly rectified.
Rectify the wire rope according to the following steps:
a) Support the crane on firm and flat ground with outriggers fully extended;
b) Unscrew the locking nut 2 and then tighten the adjusting nut 2 until the retracting wire
rope is tightened.
Caution:
Do not over tighten the adjusting nut 2; otherwise the wire rope will be in over-tight state.
Re-tighten the locking nut 2 after adjustment.
Caution:
(1) The wire rope cannot be rotated during tightening nuts;
(2) The wire rope will wear gradually and it will be very dangerous if neglect its wearing
condition and continue using it. According to safety rules for vehicles, such as crane, etc.,
the following items are stipulated:
– There is 10% broken rope in one strand (excluding the break caused by damage to
the rope core);
– The diameter is reduced by more than 7% of its nominal diameter;
– The wire rope is reverse bent or knot;
– The wire rope is seriously deformed; wire core is revealed, birdcage deformed and is
in corrosion;
The wire ropes must be taken down before they reach the above 4 stages.
– Tension caused by rope coming out from the pulley;
– Damage caused by heavy objects;
– Damage caused by electric welding or gas welding;
– Damage caused by short circuit;
– Damage caused by the effect of heat.
The wire ropes can be taken down before they reach the above 5 stages according to the
wearing conditions.
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7.5.9 Tires / wheels
7.5.9.1 Inflating the tires
Before inflating the tires, ensure that following prerequisites are met:
a) the tires are correctly fitted to the rim
b) the clamp collar is correctly seated
c) the maximum permitted tire pressure must not be exceeded
d) check pressure of tires only when they are in cold state
Danger:
(1) Damaged tires, insufficient air inflation or the same tire with different pressure may cause
increased accidents!
(2) When checking the tire inflation pressure on the vehicle or when replacing tires, please
ensure beforehand that the clamp collar is correctly assembled. Otherwise, risk of
accident may occur. If the clamp collar is not correctly seated, please obtain the
assistance of a specialist. Check that disk wheels are safe before starting off.
7.5.9.2 Changing the wheel
The wheel is one of the most important safety components on the vehicle. For this reason,
please check the wheels at the rim and the disk wheel for the following conditions when
changing the tires:
a) Excessive rust or corrosion
b) Bent disk wheel flanges
c) Cracks in the disk wheel
d) Cracks in the wheel spoke
e) Damage to wheel clamp collar
f) Damage to bolt, nut and tapping hole
g) Matching parts for disk wheel
If damaged rims are discovered during checking:
– Remove them and replace them with new parts;
If paint damage or minor rust formation is found:
– Make good the wheels by removing the rust using commercially available paint. Pay
special attention to having a perfect surface in the tire seating area.
Danger:
No welding work is permitted on rims and wheel disks, particularly repairs to worn pin holes
and changing disk wheel. Disk wheel with worn pin holes must be scrapped immediately.
Repairing these highly-stressed disk wheel components causes structural transformations in
the material that can lead to premature overload breakage.
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7.5.9.3 Checking the axle alignment
The axle alignment must be checked at regular intervals. Failure to perform this check can
result in increased tire wear. If extremely high stress has occurred such as driving against
curbs, it is extremely important to check the axle alignment.
Depending on the tire function, different wear patterns occur based on where it is located. We
recommend intervals in the range of 6 months or 5,000km. This process has a positive impact
on driving comfort and tire life.
Illustration – Tire rotation on axles 1, 2 and 5
Illustration – Tire rotation on axles 3 and 4
Caution:
Always have the axle alignment adjusted by a trained expert with special equipment.
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7.5.9.4 Limit of vehicle speed
As the highest vehicle speed of tires is limited (The maximum vehicle speed of Michelin tires
used in our crane is 80 km/h), never overdrive. Otherwise, the tires will be overheated and
their service life will be shortened. Override is also harmful for maintenance and service of the
vehicle.
Do fix your attention on driving. Get out of the way from obstacles (e.g. holes in the ground) in
the front. Slow down to drive over if they cannot be avoided.
7.5.9.5 Storage of tires / wheels
Tires / wheels must be placed vertically. They should be stored in cool and dry places instead
of exposing in the air to prevent them from ageing.
Tires are made of rubber. Do not contact them with chemical substances such as oil, acid and
hydrocarbon during driving, parking or storing to avoid corrosion, deformation and softening.
Tire projecting rims or tire bead toes should be protected during storage, transportation and
installation, so as to keep its tightness.
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7.6 Transportation and storage
7.6.1 Transportation and its points for attention
The crane can be driven by its power or be transported by train or any other carriers for a long
distance. During transportation, the wheels should be blocked with wooden wedges, and the
complete vehicle should be secured with wire ropes. Lock the doors and the windows, and
adopt preventive measures against rain. The lifting positions are shown in the following
illustration:
Warning:
Slings must be of enough strength!
Intermediately extend the 4 outriggers. Secure the 4 outriggers with the lifting rope lock and
take them as the lifting points.
Note:
Wire ropes should not contact the crane directly; otherwise the crane would be scraped.
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7.6.2 The storage conditions and the points for attention in storage
If the crane is not put into use for a long time (over 3 months), the following protective
measures should be taken:
a) Wipe off dust and oily filth to keep the crane clean;
b) Retract all the piston rods of the cylinders to their Min. length;
c) Inflate the tires to specified pressure and put wooden blocks beneath the tires to keep
them away from the ground;
d) Demount the battery and keep it in a dry and ventilating place. Charge it periodically;
e) The surfaces of all exposed components should be greased to prevent them against
corrosion with rust;
f) Clean out dust and sand from wire ropes and grease them with lubricating oil;
g) The crane should be stored in a garage. If not, it must be covered with water-proof cloth
to prevent it against corrosion. In the rainy season, check the crane frequently to prevent
it against rain leakage and corrosion with rust. In winter, antifreeze measures should be
taken;
h) Start the machine once a month and operate all the mechanisms at idle speed to check
whether they work normally;
i) Assign a person to keep the crane in the perfect condition to make it ready for operation
at any time;
j) For the crane which has been stored for more than three months, run it at idle speed for
at least an hour every three months and carry out cleaning and maintenance periodically.
As for the crane which has been stored for more than one and half years, besides routine
cleaning and maintenance, replace the aged sealing elements.
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Chapter 8 Crane inspections
1145-000-08Y
8.1 Re-inspections
8.1.1 General
This crane was tested and commissioned at the manufacturer’s facilities prior to shipment in
accordance with the latest national standards.
The safety level achieved during initial commissioning may not be attainable during operation.
Examples of the root cause of such deviation include; e.g., wear and tear, corrosion, effects of
forced operations, changes in the environment and changes to the mode of operation.
The operator is responsible for taking the necessary steps to ensure that the maximum level
of safety is maintained. After it has been licensed, the crane operator must have the crane
inspected by a competent inspector, as necessary. The inspection frequency varies with the
application situations and the operating conditions, but the minimum interval is one year. See:
GB3811, GB/T6068.
If the crane is sold to other countries or regions, local standards can also apply. The crane
must be inspected by an authorized inspector every four years after it has been licensed. After
the 12th year of operation, the crane must be inspected annually by an authorized inspector.
Warning:
There is a risk of weakening the supporting components when major changes or repairs are
made to the crane!
In such cases, the operator must have the crane inspected by a competent inspector before
putting it back into service.
A competent inspector is someone who has a thorough understanding of cranes based on
technical training and experience and is knowledgeable about the relevant national
occupational safety regulations, accident prevention regulations and generally accepted
engineering principles and is able to assess that the crane is safe to operate.
A professional engineer is someone who has rich experience in designing, manufacturing and
maintaining lifting equipment (e.g., crane) and is knowledgeable about the relevant
regulations and standards and is able to use necessary equipment to inspect, so as to access
whether lifting equipment are safe and to determine what measures to be taken.
Re-inspection of crane is principally a visual inspection, wherein the inspector and engineer
appraise the condition of the crane and its components. The purpose of the inspections is to
prevent accidents by detecting deficiencies in a timely fashion. Any deficiencies determined
by the inspector and engineer must be documented, corrected, and subsequently solved.
A number of important examples of items that are particularly important during the periodic
crane inspections are listed in the following: We wish to advise that only competent inspector
and professional engineer take sole responsibility for the inspections that they carry out. This
chapter does not necessary cover the entire scope of the inspections.
A checklist for periodic inspections recommended for ZOOMLION truck cranes and all-terrain
cranes is included in the appendix to assist the inspectors.
If the inspector has any questions, they should be directed to ZOOMLION’s service
department or other relevant departments.
Danger:
Risk of accident!
Adhere to the following inspection guidelines and intervals.
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8.1.2 Steel bearing structures inspection
Steel bearing components such as telescopic booms, slewing tables, chassis frame,
outriggers and rims must be carefully inspected, at the very least during the annual
recommended crane inspections. Even though weld joints are not normally situated at
maximum load locations, it is nevertheless important that they be inspected with particular
care during the periodic inspections.
If the crane was subjected to excessive operating loads; e.g.; due to an unusual impact, the
load-bearing components must be inspected immediately. If damages (e.g., cracks) are
apparent in any part of the steel structure, the total extent of the damage must be determined
by qualified specialists using appropriate material test methods: e.g., ultrasound or X-rays.
The specialists should then advise whether or not the damaged area can be repaired by
welding or other means.
The following diagrams are samples of the load-bearing weld designs. The welds or steel
structural zones that require inspection may be present more than once and in various forms.
The joints or zones must be inspected all around at the locations identified by arrows.
Warning:
The scope and extend of all inspections remain the sole responsibility of the inspectors. The
following diagrams are provided to assist the inspector. The diagrams are only examples and
are not necessarily 100% complete!
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8.2 Periodic crane inspections
8.2.1 Inspection during break-in period
Perform the following inspections and maintenances after 200 hours of lifting operation.
a) Check the engagement of gears inside hoisting and slewing boxes. Change lubricating
oil and clean these boxes.
b) Drain out hydraulic oil, clean hydraulic oil tank, and change filter cartridge, filter or change
hydraulic oil.
c) Clean dust and oil on each part of the complete vehicle, and check each assembly for
leakage of oil, water, gas and electricity. Adjust and repair them.
d) Check that connecting bolts for each part are properly seated.
e) Check and rectify all safety devices.
Sliding blocks of the crane should be inspected for wear per half year. Adjust or change them
when necessary.
According to the changing of season and temperature, change lubricating oil inside the
engine, transmission, transfer gearbox, steering gear and reducer for hoisting mechanism
and reducer for slewing mechanism. Dismantle, inspect and clean cooling system and inspect
proportion of battery electrolyte.
8.2.2 Inspecting the rims
The wheels, and therefore the rims, are important vehicle safety related components. They
must be tested in accordance with Chapter 8.1.2 “Steel bearing structures inspection” in this
chapter. Furthermore, compliance is required with “Maintenance manual for crane chassis”.
In addition, rims must be checked for crack at the very least during the annually specified
crane inspection. Immediately replace any rims that show evidence of cracks or crack
formation.
After driving a maximum of 40,000 km, the operator shall routinely inspect the rims,
regardless of the actual duty cycle they were exposed to.
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8.2.3 Inspecting the brake systems
The brake system on cranes must be inspected annually.
8.2.3.1 Structural inspection
Check that the following requirements are met:

a) Pipe and hose lines are not damaged, not corroded and are properly routed;
b) Devices are properly installed and fastened;
c) The air pressure tank is not damaged and no external corrosion is visible;
Warning:
No welding nor heat treatments be conducted on the tank walls.
d) Water has been removed from the air pressure tank;
e) Each connection in the pipe lines are proper connected, moving parts are flexible and are
not damaged;
f) The brakes are properly adjusted.
8.2.3.2 Function and performance test
a) Function test
1) Air pressure regulation;
2) Check for leaks of system and pressure of air pressure tank;
3) Check safety valve, switch for air pressure signal lamp and warning device;
b) Performance test
1) Check the function of the brake:
Press down the brake pedal: Friction linings contact the brake drum.
Release the brake pedal: Friction linings immediately return to their starting position.
2) Check effectiveness of brake:
– Measure brake path
At an applied pressure of 8bar and initial speed of 30km/h, the brake path
should be smaller than 10m.
– Determine brake performance on brake test bench
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8.2.3.3 Inspection intervals for brake
Check the following items in regular intervals besides function test and performance test:
 Check the condition of the friction lining every 3 month;
 Dismantle brake drum and check the condition of each component inside the brake every
12 months.
Warning:
Do not brake after dismantling the brake drum.
a) If the remaining lining thickness is less than 1mm (thickness of the new friction lining is
18mm) from rivet, it is imperative that the friction linings (friction pad) are replaced;
Replace worn or oily friction lining.
Danger:
Always replace all the friction linings on each axle simultaneously.
b) The operation of changing the position of brake drum:
Caution:
The diameter should not be over 0.75% of specified diameter during the operation of
changing the position of brake drum.
Specified diameter: 410mm
Allowable position-changing dimension: 3.075mm
Allowable inner diameter: 413.075mm
Danger:
Replace the brake drum no later than when its inner diameter over 413.075mm. If this is
not done, the brake drum can fail, which can cause fatal accidents.
c) Replace the springs, sealing elements and dust cover inside the brake at least every 2
years.
Danger:
All the brake maintenance and repair work may only be carried out by authorized and
trained expert personnel! Danger of fatal accidents due to erroneous maintenance or
repair on the brake!
d) Carry out a brake structure, function and performance test again on all wheels after
completion of assembly work.
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8.2.4 Inspecting the hoist and slewing mechanisms
The hoisting and slewing mechanisms are designed using integrated planetary reducers. The
gearboxes are sized for long life and the propeller shafts and gear wheels are rated for
endurance.
Even through the hoist and slewing mechanisms are designed for long life, an external visual
inspection is not adequate, since their life can be significantly affected by bad maintenance,
defective seals, improper operation or overuse.
The inspection must therefore be carried out by a competent inspector in accordance with the
following requirements:
a) 1000 hours of operation, minimum once per year;
b) Inspecting oil level
For hoisting winch reducer, we recommend that the oil be drained and the amount
compared to the specified oil quality;
c) Evaluating oil color
Assume that the oil has been overheated if it is black and /or a burnt oil smell is detected.
Change the oil;
d) Evaluation of foreign substances found in the oil
If gear oil is polluted seriously, change it even if it has not reached the oil change
intervals.
This inspection should be carried out by a qualified laboratory. The used oil shall be
dribbled onto the specified woven filter medium. Visual inspection using a magnifying
glass may reveal coarse particles. If particles are detected, all the oil’s properties must be
examined by a qualified laboratory.
The maximum permissible quantity of foreign material measured by weight is 0.15% of
total oil weight and the quantity of all mechanical pollutants is not over 0.05% of total oil
weight.
If above values are exceeded, check to determine the root cause of the excessive
abrasion. Damaged components shall be replaced and fresh oil be refilled.
Warning:
Repairs may only be carried out by specialists with appropriate equipment knowledge.
e) Visual inspection
The reducer shall be checked for leakage, since loss of oil, in addition to polluting the
environment, can lead to gear failure.
f) Inspecting the brakes
Check the brakes each time the drive devices are inspected.
If the brakes are invalid, they shall be dismantled to determine the cause. Do not use the
crane until the failures are removed. Whenever a planetary drive device is dismantled
because of accumulated pollutants in the oil, the brakes shall also be inspected.
Warning:
Only qualified personnel with specialized knowledge shall be used to do the repair work.
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g) Documenting the completed inspection and tests

The results of each inspections and maintenance work, including the contents, tasks and
data, shall be documented by the competent or authorized inspector.
The “design life” is not equal to the real life of the mechanism. The actual life is affected
by many additional outside factors, for example:
1) Overload;
2) Inadequate maintenance:
- Oil is not changed in a timely manner
- Using the wrong type of oil
- Too much or too little oil
- Contamination during oil changes
3) Improper operation: extreme acceleration or braking of the load;
4) Assembly errors during repair and maintenance;
5) Undetected leakage;
6) Incorrectly set safety devices or safety devices defects;
7) Extreme environmental conditions:
- Extreme temperatures
- Corrosive atmosphere
- Dust and dirt
Caution:
The reducers must be repaired after using for 10 years.
8.2.5 Inspecting the hooks
The hooks must be often inspected by a competent inspector.

The purpose of the inspections is to avoid accidents by detecting deficiencies in a timely
fashion.
Any deficiencies determined by the inspector must be documented, corrected, and
subsequently reinspected. Inspecting items are as follows:
a) The hook should be inspected for distortion as required, but at least once a year; e.g., at
the hook jaw. Hook jaw distortion may not exceed 10% of the original dimensions. Do not
use a hook that exhibits greater distortion.
b) The hook should be inspected for thread corrosion/wear and tear. Stop using the hook
after finding it.
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8.2.6 Inspecting the wire rope pulleys
Inspect the entire wire rope pulley assemblies for damage and crack at least once a year.
If wire rope pulleys are subjected to any impacts (e.g., with buildings) or are subjected to other
outside forces other than load forces, they must be immediately visually inspected for damage
or cracks.
Danger:
Risk of accident when damaged or cracked!
Replace wire rope pulley as soon as possible.
Also check for wear on the rope groove, replace the pulley if the bottom of the rope groove
has been worn down more than 1/4 of the rope diameter.
8.2.7 Inspecting the crane wire ropes
Wire ropes shall be checked regularly. Strict inspection must be made to the ropes which are
to be newly used after installation. Furthermore, if wire ropes are subjected to special
tightening force or damages to ropes are invisible or damages just appear, particular attention
must be paid to checking safety of wire ropes in the following aspects:
a) Type and number of wire breaks;
b) Position and time of wire breaks;
c) Rope diameter reduction during working;
d) External and internal wear, corrosion and deformation;
e) Damage caused by the effects of heat
f) Total time for being placed.
The take-down criteria refers to the Chapter “Maintenance and service”.
Furthermore, the rope end connections must be checked regularly for their reliability. Visible
impression shall not be appeared at the contacting position between wire rope and drum and
between wire rope and pulley.
Special attention must be paid after any events that may lead to changes to the rope and
whenever the rope starts to be used again after being take down and then re-installed.
8.2.8 Inspecting the tightness of load carrying components
Check that the mounting bolts for the slewing ring, slewing reducer and winch reducer are
properly seated at least once a year.
Slewing ring connection mounting bolts are pre-stressed at the factory, so that no loosening of
the bolted connections will occur during normal crane operation.
However, the bolted connection may become overloaded and the bolts may be permanently
stretched if the crane is overloaded or if a fixed load is pulled free. It is therefore important to
check these bolts for proper seating during the annual crane inspection or after an overload
has occurred.
Completely remove loose bolts, plus the two adjacent ones, and immediately check for
damage.
Inspect the bolts, particularly for cracks or permanent distortion. Replace any bolts that have
stretched more than 2% (referred to their original length) or that have cracks or other damage.
If any bolts have stretched or are otherwise damaged, also replace the two adjacent bolts.
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8.2.9 Inspecting the oil and fuel reservoirs
Oil and fuel reservoirs shall be inspected at least once a year and checked all around for
leakage during the periodic inspections every year.
Repairs shall only be carried out by trained and knowledgeable specialists.
Improper repairs; e.g., welding, hard or soft soldering is not permitted, particularly if the
Customer Service Department at ZOOMLION has not been consulted!
8.2.10 Inspecting the hydraulic system
Check whether all elements and pipe lines in the hydraulic system are in good condition from
the following aspects:
a) Check whether mounting bolts for hydraulic pump are properly seated, and whether
abnormal vibration, noise and leakage occur during load application;
b) Check whether air filters in hydraulic oil tank and oil return pipe line are blocked and
whether oil inlet/outlet of flange leaks oil;
c) Check whether slewing and hoisting motors leak oil, stop running or run abnormally, and
check their housings for deformation and cracks;
d) Check each connection at pipe lines in the hydraulic system for tightness and oil leakage;
check pipe clamps for tightness and cracks; check hoses for aging, distortion and
damages;
e) Check motions:
1) Check connected oil pipe fittings for proper seating;
2) Check mounting bolts for proper seating;
3) Check for leaks.
f) Check hose drum:
1) Check mounting bolts for proper seating;
2) Check whether telescoping out /in motions are seized;
3) Check for leaks.
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8.2.11 Inspecting the electrical system
Regular inspection can not only prolong service life of the vehicle, but also can improve safety
and comfort for the operation of vehicle.
Regularly inspected components listed in the following table are for vehicles which work in
dustless environment for 250h per month in temperatures between -10 - 35℃. Once the
crane is used in harsh conditions or is used in coastal, desert and cold region, shorten the
inspection and maintenance intervals according to actual conditions.
Inspection interval
Component
New vehicle Every Every Every Every Every
inspected Every Every
three six 250 500 1000
60 250 month year
months months hours hours hours
hours hours
Electrical system
Battery acid levels ○ ○ ○

Battery acid
○
proportion
Starter commutator
○
and electrical brush
Generator ○
Caution:
Dismantle and inspect the starter and generator, and then replace damaged components.
The process of assembly, disassembly, dismantling and re-assembly should be preceded
carefully and stably, and proper tools should be used in an attempt to avoid causing
damages to them.
Check electrical
wiring joints for tight ○
fit and damage
Check lighting
system for its
○ ○
function and
damage
Check horn, air
conditioning, heater
○ ○ ○
and defroster for
their functions
Check wiper,
windshield
water-injector for ○ ○ ○
their functions and
liquid quantity
Check each
instrument and
○ ○
control lights for
their functions
Check every type of
switches for ○
functional work
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Inspection interval
Component
New vehicle Every Every Every Every Every
inspected Every Every
three six 250 500 1000
60 250 month year
months months hours hours hours
hours hours
Check
displacement
○
sensor for its
waterproof property
Check cable drum
for its waterproof
○
property and check
whether it is seized
Note:
Check the component marked with “○" within corresponding intervals.
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8.2.11.1 Key inspection and maintenance
a) Battery
Superstructure and chassis are all equipped with two batteries connected in series (12V
for each battery). Single wire system is adopted in the complete vehicle and the negative
terminal is grounded through main power switch. Batteries of this vehicle meet the
national standard GB5008.1-85.
In normal situations, if there are no malfunctions in electrical devices, batteries are
charged when the generator is supplying electricity for electrical devices.
If the battery is found not be charged or under-charged which has affected the starting of
starting motor, the generator and the voltage regulator should be inspected to release the
defects immediately.
Furthermore, keep batteries surface dry and clean. Clear off contamination and
electrolyte with a piece of cloth dampened with 10% density soda water and wipe them
with a piece of dry cloth.
If the crane is not in use for a long time, remove the batteries and charge them once
every month. If it is not used within one month, cut off the circuit to avoid self-discharging.
b) Starting motor
Starting motor is a key component for the starting of engine. Therefore, often inspect
fastener of starting motor for firm connection, inspect conductive wire for tight contact and
inspect insulation of conductive wire for damage.
Clear off contamination and grease it for corrosion protection.
In addition, remove dust cover from the motor regularly to inspect whether surface of the
commutator is smooth, whether carbon brush inside the bracket is seized, and whether
pressure of carbon brush spring is normal and clear off accumulated dust.
Once the carbon brush wears excessively or surface of commutator is burnt seriously or
other failures occur, remove it to repair.
c) Generator
Integrated commutating and pressure regulating type
Rated operating current: 80A
Voltage: 28V
Maintenance should be applied to the engine every 1000 hours. Clear off dust and oil on
the surface of generator (especially on the terminal post), keep ventilation channel on,
often observe contact condition of carbon brush ring and check carbon brush for wearing
and tightening condition. Do not use megohm meter or power higher than 30V to test the
engine and only use universal meter to detect it.
d) Displacement sensor
Displacement sensor is a key component in telescoping system.
Lay down the boom to check it at the tail end of the boom. Inspect its three coiling-out
holes for their waterproof property. (Only use one of the three holes, and connect the
other two with a small section of shielded wire to prevent water from entering); put the
coiling-out port of waterproof rectangular 5-core plug face down and tighten all the
waterproof PG connector; check screws on the end cover for proper seating; check that
the coiling-out height of displacement sensor must be consistent with the height of fixing
end for bracing wire and no inclined pull occur in vertical and horizontal directions.
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e) Cable drum
Cable drum is a key component in telescoping system.
Lay down the boom to check it at the tail end of the boom. Check that the coiling-out
height of cable drum must be consistent with the height of fixing end for cable and check
friction between cable or bracing wire and pin removal plate. Check the coiling-out
position at the fixing end of cable for completeness of waterproof cement; check
waterproof rectangular 16-core connector connected between this cable and slewing
table harness for reliable connection and tighten waterproof PG connector at two ends;
check whether cable drum is seized when the boom is telescoped-in slowly.
8.2.12 Inspecting the safety devices
Function test shall be carried out on safety devices, such as load moment limiter, hoisting limit
switch and lowering limit switch before each operation of crane.
a) The inspection of load moment limiter can be carried out as follows:
– Telescope out the boom to its maximum length; Use hook as the testing weight. Lift
the boom from its minimum working radius to its maximum working radius; Check the
display of weight in load moment limiter to ensure that weight deviation does not
exceed 5% of load weight.
– Telescope out the boom to its maximum length; Measure actual radius at its
minimum working radius; Measure the actual radius at its 45°; Compare the two
values; and the deviation between them shall not exceed 10%.
b) The inspection of hoisting limit switch can be carried out as follows:
– Install hoisting limit switch and lift the hook without load slowly.
– Do not stop lifting until the hook reaches the limit weight of hoisting limit switch.
– Observe whether the hoisting limit switch is activated.
c) The inspection of lowering limit switch can be carried out as follows:
– Telescope out the boom to its maximum length;
– Lift the boom to its maximum angle and reel off the wire rope slowly;
– Require another person to observe rope guiding condition;
– Check whether the lowering limit switch is activated when only 3 hoist rope windings
are left on the winch.
Check main / auxiliary winch in the same method.
Danger:
Risk of serious accident due to abnormal operation of safety devices!
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Appendix: inspection checklist
Inspection category 1: Crane document

Component inspected A B C D E Comments
Maintenance manual
Operating instructions
Spare parts catalog
Attached spare parts list
Attached tools list
Inspection category 2: Signs / labeling

Factory name plate
Operating specifications label
Warning labels and instructions
Other safety labels
Inspection category 3: Driving and traveling mechanism

Chassis frame
Slewing bearings
Axles
Wheels
Tires
Bearings
Transmission
Propeller shaft for universal-joint
Non hydro-pneumatic
Leaf springs
suspension axle
Shock absorbers
Steering
Brakes
Hydro-pneumatic suspension
Inspection criteria:
A: preset / complete B: condition / maintenance C: function
D: repair / replace E: re-inspection required
Assessment: Satisfactory = × Unsatisfactory = － Not required = 0
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Inspection category 4: Chassis

Platform
Treads
Counterweight holders
Attached tools
Ladders
Fixing device for hook
Boom bracket
Inspection category 5: Chassis - driver's cab
Doors
Windows (curtain)
Windshield wipers
Rearview mirror
Seat
Air conditioning, air venting device
DVD player
First-aid kit
Emergency lamp
Warning triangle
Warning & protecting label
Assessment:
Satisfactory = × Unsatisfactory = － Not required = 0
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Inspection category 6: Chassis - driving

Engine
Exhaust system
Fuel tank
Fuel filter
Soundproofing
Engine mounting
Oil levels
Fuel lines
Inspection category 7: Chassis - hydraulic system

Oil reservoirs
Hydraulic oil filters
Pumps
Motors
Valves
Piping
Hoses
Pressure relief valves
Inspection category 8: Chassis - air pressure system

Air compressor
Air reservoir
Valves
Piping
Hoses
Assessment:
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Inspection category 9: Chassis - electrical system

Motors
Generators / Alternators
Battery
Wiring
Fuses
Resistors
Lighting
Brake lights
Indicator lights
Tail lights
Working lights
Signaling devices
Monitoring lights
Battery switch
Limit switches: drive devices,
steering, driving
Outrigger pressure indicator
Assessment:
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Inspection category 10: Chassis - control systems

Engine speed regulator
Drive device
Clutch
Shift of gear
Brakes
Steering
Monitoring indicators
Engine braking performance
Outrigger controls
Axle suspension
Crane leveling
Rear axle steering
Inspection category 11: Superstructure

Telescopic boom
Slewing table
Counterweights lifting device
Counterweights
Positioning device for slewing table
Slewing ring: Tilting free play
Slewing ring: Mounting bolts
Slewing ring: Gearing
Slewing reducer: Mounting bolts
Slewing reducer: Gearing
Assessment:
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Inspection category 12: Superstructure - operator’s cab

Doors
Windows / Windshield
Windshield wipers
Seat
Air conditioning
Ventilation
Function control button
Tilting control
Emergency hammer
Inspection category 13: Superstructure - hand-hold and protection devices

Grab handles and ladders/treads
Hood
Doors
Baffle
Inspection category 14: Superstructure - drive system

Engine
Exhaust system
Fuel tank
Filters
Soundproofing
Engine mounting
Fuel lines
Assessment:
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Inspection category 15: Superstructure - hydraulic system

Oil reservoirs
Oil filters
Pumps
Motors
Valves
Piping
Hoses
Oil cylinders
Pressure relief valves
Hoisting mechanism
Slewing mechanism
Inspection category 16: Superstructure - electrical system
Motors
Generators/alternators
Batteries
Switches
Wiring
Fuses
Resistors
Lighting
Assessment:
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Inspection category 17: Superstructure - control system

Engine control
Control devices
Engine braking performance
Monitoring indicators
Inspection category 18: Driving system for wire rope

Main winch
Auxiliary winch
Wire rope pulley
Wire rope end connection
Wire rope for main winch
Wire rope for auxiliary winch
Inspection category 19: Superstructure-hook

Pulleys
Wire rope guide rod on pulley
Hook safety device
Assessment:
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Inspection category 20: Superstructure - safety and control devices

Hoisting limit switch
Lowering limit switch
Load moment limiter
Angle indicator
Pressure sensor
Wind gauge
Outrigger monitoring
Length detector
Emergency stop
Engine stop
Inspection category 21: Boom

Welding joints
Rope pulleys
Derricking cylinders
Telescoping cylinders
Boom bracket
Assessment:
Note:
Inspection of the crane carrier vehicle roadworthiness is also fulfilled if it has already been
certified by the road traffic department certification authority. For mobile cranes that are not
certified for use on public roads, a competent or authorized inspector must conduct the tests
to validate the vehicle’s roadworthiness.
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Chapter 9 Diagnostics
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9.1 Crane superstructure
9.1.1 Instruments 2
1
1 – Display unit, superstructure 2 – Battery master switch, superstructure
9.1.1.1 Display unit

2 1
7 6 5 4 3
11 10 9 8
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Illuminates:
The counterweight power switch is switched on and the counterweight
can be operated by remote control box.
Extinguishes:
The power source of counterweight control system defects. Rectify at
once!
Illuminates:
Main / auxiliary winch approaches upper limit. Observe and inspect the
winch status.
Illuminates:
Main / auxiliary winch approaches lower limit. Observe and inspect the
winch status.
Illuminates:
Engine cooling water level is too low. Observe and inspect it at once.
Illuminates:
Engine coolant temperature is too high, greater than 98℃. Check the
engine cooling system.
Illuminates:
Crane superstructure engine detects engine defects. Never start off until
rectify it.
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7 Warning light Charge monitoring
Illuminates:
The ignition starter switch is turned to 1st position.
Extinguishes:
Crane superstructure engine has started off and the battery is charged.
Illuminates after engine starting:
Charge defects. Rectify at once.
Illuminates:
The lithium base grease level is too low. Check it at once.
Illuminates:
Engine oil level in superstructure generator is too low. Check the engine
oil level at once.
10 Warning light Engine oil pressure too low
Illuminates:
Oil pressure of crane superstructure engine is too low, lower than 0.5 bar
(idle speed), 2.5 bar (rated Rpm). Check the engine lubricating system.
Illuminates:
Superstructure engine error is found by controller ADM2. Stop engine
and rectify it at once.
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Caution:
When the warning lights “Engine defects” or “Engine stop owing to serious engine
defects” illuminates, you can use Minidiag2 to carry out diagnosis. For detailed operating
instructions, please refer to Minidiag2 Operating Manual. This operation should be done
by authorized specialists and the data set at the factory cannot be modified freely.
Illustration for Minidiag2:
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1145-000-09-20Y
(Following instructions are for crane equipped with Hirschmann computer system)
9.1.1.2 Superstructure battery master switch
Turn superstructure battery master switch on.

Result:
- The master power switch near the battery on slewing table is
automatically on;
- Its control light lights up.
If the control light does not light up, check the connection of
superstructure master power.
9.1.2 Load moment limiter and PLC controller input / output status
If errors are found during the operating process, you can switch to corresponding screens to
carry out related diagnosis and parameter set.
Press function key F5 in main screen to switch to Fig. 13 (See following figure).
Fig. 13 Error inquiry
Error inquiry screen includes:

a Load moment limiter error code inquiry, analog quantities inquiry, Boolean quantities
inquiry;
b Communication status inquiry for controllers;
c Output inquiry for controllers’ working status (Crane movements parameter checks);
d Engine error code inquiry.
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9.1.2.1 Load moment limiter
If there is an error, press function keys F1 – F6 shown in Fig. 13 to switch to corresponding

screen. The computer error list and relevant I/O module errors are shown in following screens
(See Fig.14, Fig. 15, and Fig.16).
If the monitor is defective, find the error cause according to these screens. For detailed
information, please refer to Load moment limiter instructions.
Fig. 14 Computer error list
Fig. 15 Boolean quantity output
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Fig. 16 Analog quantity
9.1.2.2 CAN bus state
Press function key F4 shown in Fig. 13 to switch to following screen (See Fig. 17). The
defective one will be highlighted in red and can be rectified according to the instructions.
Fig. 17 CAN bus state
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9.1.2.3 Output movements for controllers
Press function key F5 shown in Fig. 13 to switch to following screen (See Fig. 18). For detailed
information about the movements, press corresponding function keys F1 -- F4.
Note:
Each function key can carry out 2 movements’ checks.
For example:
If crane movements “Derrick” need to be checked, press F1 twice. Other checks are the same.
Fig. 17 PLC status
Test the actual I/O values of PLC in different crane movements. The analog quantities are
displayed in numerical figures. The arrow highlighted in red indicates whether the
corresponding movement is valid.
If the arrow is highlighted in red, it indicates the corresponding pointed switch is valid.
Otherwise, if the arrow is highlighted in grey, it indicates the corresponding pointed
switch is invalid. The analog quantity will be displayed with corresponding data
(numerical figures) (See Fig. 19).
From the flow charts, the operator can check the current parameters, do diagnosis and judge
For example:
In "Manual telescoping" operation (See Fig. 20), the switch “Pre-selection of derrick / telescope”
should be turned to “Telescope” and the Deadman switch should be pressed. Otherwise,
manual telescoping cannot be initiated.
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Crane movements “Derrick up / down” and “Spool up / Reel off main winch” etc. can monitor the
I/O values of PLC, so the operator can monitor and diagnose the parameters according to
Fig. 19 Working status for cylinder pin and boom pin
Fig. 20 Telescoping status
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9.1.2.4 Engine defects
Press function key F6 shown in Fig. 13 to switch to following screen (See Fig. 21).
The upper area of the screen is engine error code. 8 error codes can be displayed
simultaneously.
The lower area of the screen is engine error code list, from which you can find the description of
error, and its remedy method.
Press function keys F2 and F3 for page up and down.
Fig. 21 Engine defects
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9.1.2.4 PLC parameter
Press function key F4 shown in Fig. 13 to switch to following screen (See Fig. 22).
Fig. 22 Parameter set
Press corresponding icons to set time and parameter.
Before setting the parameter, enter password firstly (See Fig. 23).
If the password is passed, the screen “Parameter adjustment” will be displayed (See Fig. 24).
Fig. 23 Password entered
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Fig. 24 Parameter adjustment
Press function keys F1 - F4 to get and modify the corresponding controller’s parameter (See Fig.
25).
Press function keys F5 to get and modify the senior parameters (See Fig. 26).
Caution:
The parameters of controller 4 are the values for “hoist up / down”, “derrick”, “slew” and
“counterweight” movements;
The parameters of controller 7 are the values for “Telescope” movement.
Fig. 25 Parameter displayed
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Fig. 26 Senior parameter set
Warning:
The senior parameter set must be carried out by technicians. The controllers’ parameters
cannot be modified freely.
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If icon “Tele error” turns to red and icons and turn to green during automatic
telescoping, press function key F2 to call up the error description.
The information highlighted in red is current error.
Please carry out manual telescoping operation or maintenance according to the possible cause.
The diagnosis screen of boom telescoping error is shown as follows:
Tele error
Press function key F2 to enter following screen
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If:
- The 6 prerequisites for automatic telescoping are met;
- Icon “ ” is highlighted in red;
- Key is highlighted in grey
In this case:
- Set right switch from neutral position to right or left position;
- Return to neutral quickly.
Result:
- The stored error is cleared up.
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(Following instructions are for crane equipped with Hong An computer system)
9.1.1.2 Superstructure battery master switch
Turn superstructure battery master switch on
Result:
- The master power switch near the battery on slewing table is

automatically on;
- Its control light lights up.
If the control light does not light up, check the connection of
superstructure master power.
9.1.2. Load moment limiter and input / output condition of PLC controller
Press key "System Check & Diagnose" in main screen to switch to the following screen. The
self-check is defaulted. The operator can press keys 3.1, 3.2, 3.3, and 3.4 to check and
diagnose the system.
3.1 3.2 3.3 3.4
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If the connection error of controller 0 (PLC) is found during the test, the monitor shows the
following screen (See Fig. 2).
Troubleshooting:
- Turn off the engine and ignition and rectify the errors (especially checking the connectors)
- Start again to perform self-test again.
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9.1.2.1 Control system test
For detailed information, please refer to Load Moment Limiter Operating Manual.
9.1.2.2 PLC checks
Test the actual I/O values of PLC in different crane movements. The white frame displays
analog quantities, and the brown frame displays Boolean quantities.
In the following flow charts, the grey frame will be highlighted in red and the white frame
will display the corresponding data if the data flow through them.
From the flow charts, the operator can check the current parameters, do diagnosis and judge
For example, when the remote control box is used, the "Counterweight switch" must be
activated. If the "Counterweight switch" is deactivated, the operation of remote control box will
be invalid and its frame color will not be highlighted in red.
The crane movements "Derrick up / down" and "Spool up / reel off main winch" etc. can monitor
the I/O values of PLC, so the operator can monitor and diagnose the parameters according to
PLC status checks - Slew monitoring
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PLC status checks – Control lights

9.1.2.3 Sensor checks
Check the real-time output values of sensor, see following illustration. For detailed information,
please refer to Load Moment Limiter Operating Manual.
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9.1.2.4 PLC parameters
Input password before switching to PLC parameter diagnosis screen. If the password is passed,
you will switch to the following screen shown as follows:
Warning:
This operation must be done by technicians. Do not modify parameters at freely.
Diagnosis screen of PLC parameter set
If the controller parameters need modifying during whole vehicle diagnosis, switch to the
following screen.
Save parameters
Choose parameters
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If key “Tele error” is highlighted in red and keys "Back" and “Manual" are highlighted in blue
during automatic telescoping, press key “Tele error” to call up the error description.
The information highlighted in yellow indicates the current error.
Please carry out manual telescoping operation or maintenance according to information line.
Diagnosis screen of telescoping error is as follows:
Press this key to switching to the following screen
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If:
- The 6 prerequisites for automatic telescoping are met;
- Icon “ ” is highlighted in red
- Key is highlighted in grey
In this case:
- Set right switch from neutral position to right or left position;
- Return to neutral quickly.
Result:
- The stored error is cleared up.
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9.1.4 Superstructure, troubleshooting
If failures occur during crane operation, carry out a thorough checks and analysis to find out the
causes, and remedy them. Troubleshooting for common failures is listed in the following tables
for reference.
Part Problem Cause Remedy

1. Bulb damaged. Replace
The working light does 2. Fuse burnt out. Replace
Electrical
not illuminate. 3. Poor grounding. Rectify
system
4. Conducting wire broken or Rectify or replace
switch invalid.
Vehicle length control 1. Bulb damaged. Replace
light does not 2. Switch invalid. Rectify or replace
illuminate. 3. Conducting wire broken. Replace
Interior illumination 1. Bulb damaged. Replace
does not light up. 2. Switch invalid. Replace
3. Conducting wire broken. Rectify
Instrument console 1. Bulb damaged. Replace
background lighting is 2. Switch invalid. Replace
not on. 3. Conducting wire broken. Repair
Control lights on 1. Switch invalid. Replace
instrument console do 2. Conducting wire broken. Rectify
not light up.
1. Fuse burnt out. Replace
Wiper does not work. 2. Switch invalid. Replace
3. Motor damaged. Replace
2. Switch invalid. Replace
Horn does not work. 3. Relay defects. Replace
5. Horn defects. Rectify or replace
2. Switch invalid. Replace
Buzzer does not work. 3. Relay defects. Replace
5. Buzzer defects. Rectify or replace
1. Main fuse burnt out or loose. Rectify or replace
The superstructure 2. Conducting wire broken or Rectify or replace
engine cannot be switch invalid.
started. 3. Electrical brush and slip-ring Rectify or replace
poorly connected.
Hoist limit switch does 2. Winding reel defects. Rectify or replace
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1145-000-09-20Y

not work 3. Conducting wire broken. Rectify
4. Limit switch invalid; Replace
5. Limit weight rope broken; Replace
6. Solenoid valve invalid; Rectify or replace
7. Solenoid valve poorly Rectify
grounded.
No crane movement 1. Fuse burnt out; Rectify PLC power
can be initiated. wire
2. PLC burnt out. Replace PLC
controller
1. Fuse burnt out; Replace
2. The power switch of LML Rectify or replace
Load moment limiter defects;
defects. 3. Relay invalid; Replace
4. Solenoid valve invalid; Rectify or replace
5. Solenoid valve poorly Rectify
grounded;
6. Others Notify our service
department
Control light for upper Hoist limit switch / lowering limit Rectify
limit / lower limit switch defects.
illuminates,
accompanying with
acoustic alarm
1. The oil in hydraulic pump is Fill oil
not sufficient;
2. Air enters into the oil suction Rectify
Abnormal noise. pipe;
3. Mounting bolts loose; Tighten
4. Hydraulic oil polluted; Change oil and filter
Hydraulic
5. Hydraulic pump defects. Rectified by trained
pump
specialists
1. Seal ring in connecting point Contact pump
The connecting point damaged; manufacturer for
between the pumps maintenance
leaks oil. 2. Bolts at connecting point Tighten the bolts
loose.
1. Brake lining is worn and has Replace
Slewing
Brake invalid. reached the wear limit;
mechanism
2. Brake cylinder damaged. Replace
The slewing movement 1. Solenoid valve for slewing Rectify solenoid
is not working. brake is not electrified or is valve
stuck. Brake is off;
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1145-000-09-20Y

2. Plug of solenoid valve for Rectify
slewing pump is not
electrified or loose;
3. Hydraulic motor damaged; Replace
4. Slewing reducer defects. Maintained by
trained specialists
1. Inner leakage of hydraulic Replace motor
The slewing movement motor is increased and
is abnormally slow. efficiency is decreased;
2. Pilot oil pressure is too low Rectify
and brake is not open
completely;
3. Slewing pump defects. Maintained by
trained specialists
Oil cylinder cannot be 1. Setting pressure of main relief Regulate
extended. valve is too low;
2. Main valve has inner oil Rectify
leakage;
3. Oil cylinder has inner oil Rectify
leakage.
Derricking 1. Derricking-control balance Rectify or replace
mechanism valve defects;
Oil cylinder cannot be
2. Electrical system defects; Rectify
retracted.
3. Pilot oil has no pressure. Rectify
Balance valve is not open.
Oil cylinder retracts 1. Oil cylinder has inner oil Rectify
automatically during leakage;
operation. 2. Balance valve defects. Rectify
1. Solenoid valve for hoist brake Rectify
is not electrified or is blocked.
Hook cannot be lifted. Brake is off;
Hoist 2. Hydraulic motor damaged; Replace
mechanism 3. Winch reducer defects; Maintained by
trained specialists
4. Main valve defects. Maintained by
trained specialists
1. Solenoid valve for hoist brake Rectify
is not electrified or is blocked.
Brake is off;
Hook cannot be 2. Pilot oil pressure is too low; Rectify
lowered. 3. Balance valve is blocked and Rectify
is not open;
trained specialists
9-25
1145-000-09-20Y

1. Brake lining is worn and has Replace
Brake invalid. reached the wear limit;
2. Brake cylinder is damaged. Replace
1. Hydraulic motor defects; Maintained by
Hoist up speed is trained specialists
abnormally slow. 2. Main valve defects. Maintained by
trained specialists
1. Electrical-controlled shutoff Rectify
gate valve is not electrified or
is blocked; Check
2. Boom pin is pinned;
Boom cannot be
3. Electrical system defects; Rectify
telescoped out.
4. Main valve defects; Maintained by
trained specialists
5. Oil cylinder is / has inner Rectify
leakage.
1. Electrical-controlled shutoff Rectify
gate valve is not electrified or
Telescoping
is blocked;
mechanism
Boom cannot be 2. Two balance valves are not Rectify
telescoped in. open;
3. Boom pin is pinned; Rectify
trained specialists
1. One of the balance valves is Rectify
Boom telescoping
not open;
speed is abnormally
slow.
trained specialists
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9.2 Crane chassis
9.2.1 Instruments
The diagnosis screens of chassis instruments and engine components are as follows:
1 2 3
现速负载 bar
0 5 10
3% V 18 24 32
Trip ODO
油门1： 8% 999.9km 999999km
1 15
bar
10
1/2 60 80 15 20
5
0
40 km/h 100 10 x100r/min 25 0
120 15
℃ bar
100
80
20 120 5 30 10
60 5
40 0
0 140 0 35
WIF WAIT WARN STOP
1 2 D P R N
STOP
4 5 6 7 8 9 10 11 12 13 14
1. Barometer I
2. Barometer II
3. Warning light Brake pressure too low
4. Warning light Engine coolant temperature too high
5. Warning light Charging monitoring
6. Warning light Oil pressure too low
7. Warning light Door not closed well
8. Warning light Seat belt unfastened
9. Warning light Engine stop owing to serious engine defects
10. Warning light Engine defects
11. Warning light ABS1 error
12. Control light Air filter soiled
13. Warning light Engine cooling water level too low
9-27
1145-000-09-20Y
1. Barometer I
15
bar
10
5
0 The two barometers display the air pressure of main air reservoirs for
front and intermediate / rear axle respectively. If the air pressure is less
than 0.55MPa, the warning light will illuminate and the buzzer will sound.
Never start off if buzzer sounds!
2. Barometer II
15
bar
10
5
0
3. Warning light Brake pressure too low
Illuminates:
Brake pressure too low. Do not drive the vehicle. Rectify the brake
system at once.
Extinguishes:
Brake pressure increased to specified value.
Never drive the vehicle if the warning light lights up.
4. Warning light Engine coolant temperature too high
Illuminates:
Engine coolant temperature is too high.
Extinguishes:
Check water thermometer and stop the vehicle to check engine cooling
system.
Troubleshooting:
Run the engine at idle speed for a few minutes before shutting down the
engine to avoid its cylinder being blocked caused by sudden decreased
temperature.
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5. Warning light Charge monitoring
Illuminates:
Key is in ON position.
Extinguishes:
Start engine to charge the battery.
Troubleshooting:
If the warning light does not extinguish during engine running, it indicates
generator defects or charging system fault. Stop to check at once!
6. Warning light Oil pressure too low
Illuminates:
Oil pressure is too low or oil filter is soiled.
Stop the vehicle at once to rectify, otherwise, the engine will be seriously
damaged. Driving the vehicle will cause engine damage.
7. Warning light Door not closed well
Illuminates:
The door is not closed well.
Do not drive the vehicle when the warning light lights up.
It will cause fatal injury!
8. Warning light Seat belt unfastened
Illuminates:
The seat belt is not fastened or not fastened well.
Make sure that all occupants put on the seat belts.
9. Warning light Engine stop owing to serious engine defects
Illuminates:
STOP
Stop the engine and rectify at once.
10. Warning light Engine defects
Illuminates:
Stop the engine and rectify at once.
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Illuminates:
Brake system of ABS1 error. Rectify it at once.
12. Control light Air filter soiled
Illuminates:
The air filter of the chassis engine is soiled.
Rectify it at once.
13. Warning light Engine cooling water level
Illuminates:
Stop the vehicle at once to check cooling system for leakage.
Fill cooling water till the cooling water is lowered to ambient temperature.
Do not fill cooling water at once to avoid engine being blocked.
Illuminates:
Brake system of ABS2 error.
Rectify it at once.
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Caution:
When the warning lights “Engine defects” or “Engine stop owing to serious engine
defects” illuminates, you can use Minidiag2 to carry out diagnosis. For detailed operating
instructions, please refer to Minidiag2 Operating Manual. This operation should be done
by authorized specialists and the data set at the factory cannot be modified freely.
Illustration for Minidiag2:
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9.2.2 Transmission
The transmission display is arranged on the instrument panel of driver's cab to display the
information and error codes for the transmission. The main information and error codes calling
up are as follows (For detailed information, please refer to AS-Tronic Transmission
Maintenance Manual attached to crane).
x100
kP a 0 5 10
公司商标
V 18 24 32
图案 Tr ip ODO
9 99.9km 999999 km
15
FR
x100kP a
10
60 80 15 20 5
40 km/ h 100 10 x100 r/min 25 0
15
RR
x100kP a
20 120 5 30 10
5
0
0 140 0 35
1 2 D P R N
WA IT
WIF WARN
TOP
S
ST O
P
5
J
ZF diagnosis display
Calling up the error codes:

a Switch on ignition.
b Turn rotary switch to "N".
c Hold control lever in "+" position.
System self check (with ignition ON)
Transmmission in neutral
Setting off gear or driving gear selecting (here: 5th gear)
System error. Restricted further travel possible.
System error! Stop.
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Lo air pressure
Foot away from accelerator pedal
Clutch overload
Communication error with display
Clutch wear display. Replace it.
Shift from 10th to 8th gear (1 bar apply as 1 gear)
Lo reverse gear engaged
Hi reverse gear engaged
Example of error code: 53
Example of error code: 153 (4 bars apply as "100")
Example of error code: 227 (4 bars and 2 arrows apply as "200")
Note:
For other explanations about the error codes, please refer to AS-Tronic Transmission
Maintenance Manual.
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9.2.3 Chassis, troubleshooting
(If the engine defects cannot be eliminated according to Engine operating manual and the
following tables, send the vehicle to factory for repairing.)
9.2.3.1 Propeller shaft
Problem Cause Remedy

Universal joint cross trunnion, needle roller wear Replace
and loose or needle roller broken. damaged one
Abnormal noise during
Propeller shaft spline and expansion joint Replace
vehicle start, accelerating
splineway have reached wear limit. damaged one
and decelerating.
Spline in the 2nd shaft of transmission and flange Replace
splineway have reached wear limit. damaged one
Periodical noise during Propeller shaft bent or propeller shaft flange is not Replace
traveling. The higher the welded correctly to axle tube. propeller shaft
speed is, the louder the Bolts of intermediate support hanger loose or are Tighten or
noise is. In a serious not properly seated. replace
condition, the whole Bolts connecting adjacent propeller shafts loose. Tighten
vehicle flutters and Propeller shaft balance block falls off. Replace or
steering wheel is not repair
flexible.
Intermediate support is not properly seated or has Regulate or
Abnormal noise during
reached wear limit. replace
driving. The higher the
Bearing balls in the intermediate support fall off. Replace bearing.
speed is, the louder the
Intermediate support lacks of grease. Fill 2# lithium
noise is.
base grease
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9.2.3.2 Intermediate and rear axles, troubleshooting

Noise sounds like "si" during accelerating or Adjust
decelerating: meshing clearance of gears too small or
poorly meshed.
New gear poorly meshed Observe after break-in.
Noise sounds like "clash" on descending gradients or Adjust or replace gear.
during changing vehicle speed jerkily. Noise fades
away or decreases during normal driving: meshing
clearance of gears too large.
Abnormal Continuous noise during traveling. The higher the Adjust or replace bearing.
noise speed is, the louder the noise is. But noise fades away
or decreases during sliding: the bearings (on hub,
main reducer or differential) wear and loose.
Gear oil level too low or oil viscosity do not meet Fill oil to required level.
requirements. Replace with required oil.
No noise during straight driving but noise sounds Adjust and replace
during turning: clearance of bearings on both sides of
reducer too large. Differential gear or thrust bearing
shim wears.
Bearing installed too tightly. Meshing clearance too Adjust
small.
Heat
Oil level too low. Fill oil to required level.
generation
Lubricant viscosity too low. Replace with required
lubricant.
Oil seal invalid. Replace it
Axle journal wear. Replace damaged one.
Oil level too high Drain oil to required level.
Oil leakage Sealing gasket damaged. Replace it
Bolt loose. Tighten
Vent cap soiled. Clean
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9.2.3.5 Steering system, troubleshooting

Oil level and oil viscosity are too low, resulting in Check the oil level and fill
insufficient steering power. Air enters into the required oil. Deaerate. Check oil
system. level and pipe fittings for
tightness.
Oil pump serious inner wear results in hard steering Replace and check
Seal elements of oil pump damaged, resulting in oil Replace seal elements
leakage
Drive elements of oil pump damaged Check and replace
Spring of safety valve in oil pump is fatigue or Repair safety valve and replace
Hard steering breaks, resulting in oil over-returned. spring.
Oil pipe fittings have oil leakage and pipes are Check, clean and replace the
blocked or bent. pipes and fittings.
Filter soiled, poor cleanliness Clean filter and cartridge. Oil
change.
Steering gear has seriously inner leakage. Rectify or replace sealing ring
Front wheels blocked (brake cannot be pulled back) Rectify the blocked parts
Steering knuckle main pin, thrust bearing and Replace bearing and adjusting
adjusting shim damaged, resulting in clearance too shim. Adjust clearance.
large or small.
Oil pump supply insufficient. Oil level in oil reservoir is too
low. Fill oil and rectify oil pump.
Quick Oil suction pipe of oil pump blocked. Replace pipes
steering is Both sides of piston in steering gear have oil Replace oil seal
hard leakage. The sealing ring is damaged or has
reached wear limit.
Air enters in. Deaerate and check connecting
parts for tightness.
Floating brass bush of steering pump is blocked and Rectify oil pump.
does not contact with wheel end-face tightly all the
time.
Sealing ring of piston in steering gear is polluted. Check. Lift up front axles.
Operate steering wheel. If the
Steering is
steering gear is active without
sometimes
starting the diesel engine, the oil
hard or
pump is defective.
sometimes
Thrust bearing in screw rod of steering gear Replace bearing.
uncontrolled
damaged.
Hydraulic oil is polluted or air enters into the system. Oil change or deaerate.
Bearing of knuckle spindle damaged. Replace bearing.
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Left steering Oil leakage of the two sides of piston in steering Replace seal ring.
is gear is not the same.
uncontrolled Air enters into one of the chambers. Deaerate
while right Mounting screws in steering gear and power Check and tighten the screws.
steering is cylinder bracket loose.
hard, and Clearance between ball head pins of drive rod is too Check or replace
vice versa large.
Tire pressure of left / right steering wheel does not Check and inflate to specified
meet the specified one. pressure.
One of the steering wheels is in brake state for a Adjust or rectify brakes.
long time.
The clearance of left / right steering wheel are not Adjust bearing clearance or
same (one is too loose while the other is too tight or replace bearing.
The vehicle
blocked).
cannot drive
Steering axles are blocked. Check the blocked parts. Check
in straight
whether input shaft is blocked by
line
radial resistant force.
Air enters into oil and direction is not stable. Check and eliminate.
Steering wheels uneven wear Tire rotation.
Vehicle axles are not properly seated, such as Check and adjust.
steering axles do not aligned with the intermediate /
rear axles or improperly seated.
Steering drive rod is improper adjusted or has Adjust clearance or replace
reached wear limit. rods.
Drive pair in steering gear wear makes large Loosen the locking nuts in the
Free clearance. side cover of steering gear.
clearance of Tighten it to proper clearance.
steering Tighten torque is 130 to 180N.m.
wheel too Mounting screws in steering gear or tightening Check and tighten the screws.
large screws in suspension bracket loose.
Clearance between ball head pins of drive rod is too Check and replace.
large.
Clearance of angle drive gear is too large. Check and adjust.
Oil level is too low or air enters into the system. Fill oil equalizing reservoir up to
Front wheel
overflow on filler neck or
swings.
deaerate.
Oil line is poorly sealed and air enters into it. Check the oil line and tighten it.
Check air pressure. Inflate the
Left / right steering wheel are not inflated equally. left / right wheel in same
pressure.
U-bolt of front leaf spring loose. Check and tighten.
Wheels loose. Check and tighten.
Connecting components of drive rod loose. Check and tighten.
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Connecting components of drive rod lacks of Check and fill lubricant.
lubricant.
Steering gear is inner blocked. Check and rectify.
Steering Distribution valve is polluted, resulting in slide valve Clean and rectify.
wheel cannot being blocked.
rebound Centering spring damaged. Replace spring.
smoothly
Oil seal damaged and leakage. Check and replace oil seal.
O-ring has oil leakage. Check and replace O-ring.
Steering gear
Oil pipe has leakage or damaged. Check and replace oil pipes.
has oil
Connecting parts of oil pipe fitting has oil leakage. Check the leakage point.
leakage
Oil viscosity too low. Use specified oil.
Joint face of hydraulic parts loose. Check and tighten.
Oil pipes in hydraulic pipe lines blocked. Check oil line and replace
Abnormal
damaged one.
noise during
Displacement of oil pump is unstable. Replace oil pump.
steering
Oil level in the oil tank too low. Fill oil.
The vehicle Flow control valve blocked. Clean flow control valve.
does not
have firm
control of the
ground when
steering at
high speed
Hydraulic oil Pipes are not tightened and air enters in. Check pipes for tightness.
tank bubbles
9-38
1145-000-09-20Y
9.2.3.6 Brake system, troubleshooting

Uneven brake force. Check and adjust brake. The
clearance between brake
drum and brake shoe is about
Brake bias 0.3 to 0.5mm.
The air pressure inflated to the tires is not same. Check and inflate pressure.
Brake shoe does not wear synchronously. Check and replace brake
shoe.
The clearance between brake shoe and brake wheel Check and adjust brake. The
hub is too small. clearance between brake
drum and brake shoe is about
Brake 0.3 to 0.5mm.
locked. Brake chamber push rod returns un-smoothly. Repair and replace
Brake main valve and relay valve are inter-connected. Repair and replace
Parking brake is unreleased. Check and release parking
brake.
Brake main valve, parking brake valve, relay valve and Repair and replace
Brake is spool of quick-release valve blocked.
invalid and Brake chamber has inner leakage. Repair and replace
responses Pipe line and valve has air leakage. Repair and replace
lag. Air drier invalid. Repair and replace
Four-circuit protection valve invalid. Repair and replace
Spool of PTO solenoid valve blocked. Repair and replace
PTO is not Coil of PTO solenoid valve damaged. Repair and replace
working. End cover and pipe line of PTO are air leakage. Repair and replace
PTO control cylinder invalid. Repair and replace
Coil of transversal and longitudinal solenoid valve Repair and replace
damaged.
Differential Spool of transversal and longitudinal solenoid valve Repair and replace
lock is not blocked.
working. End cover and pipe line of transversal and longitudinal Repair and replace
solenoid valve are air leakage.
Actuating cylinder of differential lock invalid. Repair and replace
9-39
1145-000-09-20Y
9.2.3.7 PTO, troubleshooting

Oil seal or paper gasket breakage. Replace
Paper gasket is not sealed or just one face is sealed Seal the two faces with
Oil
with sealant. sealant.
leakage
The PTO side cover is not contacted with end-face of Remove the side cover of PTO
the housing of transmission rear cover tightly. and rectify.
End cover and pipe line of PTO solenoid valve are air Repair or replace
leakage.
PTO is
Spool of PTO solenoid valve blocked. Repair or replace
not
Coil of PTO solenoid valve damaged. Repair or replace
working
PTO control cylinder invalid. Repair or replace
Intermediate shaft of transmission damaged. Check and replace
Gear is pitting corrosion seriously or broken. Replace
Abnormal Bearing is pitting corrosion seriously or needle roller or Replace bearing
noise ball broken.
Bolts in hollow shaft end loose. Tighten or replace
9-40
1145-000-09-20Y
9.2.3.8 Tires, troubleshooting

Toe-in too small or in negative value. Adjust the tie rod of front axles
The insides of for steering along the
steering wheels are stretching direction and
seriously worn increase the toe-in value to
specified one.
Toe-in too large. Adjust the tie rod of front axles
The outsides of for steering along the
steering wheels are retracting direction and
seriously worn decrease the toe-in value to
specified one.
Steering axles and driven axles are not Adjust the axles in proper
aligned or the axles are improperly seat.
The insides of
seated.
steering wheels on
When one steering wheel is in Adjust the drag rod of front
one side are seriously
straight-line driving, another steering steering axles to make the two
worn, while the
wheel is not in straight-line driving. steering wheels drive in
outsides of steering
straight line.
wheels on another
Caution:
side are seriously
If the crane is only equipped with
worn
one steering axle, this kind of
fault will not occur.
Tires are standing wave: wheels Reinstall wheels or replace.
deformed.
Saw-tooth wear
Tires are standing wave: wheels not Check whether too much
rotating in equalization. talcum powder in tires.
Wheels are in brake or semi-brake Adjust the brake clearance to
mode for a long time. specified one.
One side wheels
The specification and size of wheels on Replace
seriously wear
this side does not meet the
requirements.
Driven axles are not aligned Adjust
Transversal or longitudinal differential Close transversal or
lock is not closed, resulting in the driven longitudinal differential lock
Tires of drive wheel
wheels in locking mode for a long time. during normal driving.
seriously wear
Transversal or longitudinal differential Check and repair, or replace
lock is defective, resulting in the driven the defective one.
wheels in locking mode for a long time.
Overloading caused by putting weight Remove the weight and
on the crane during driving. replace wheels.
Vehicle is driving at high speed for a Replace. Do not drive the
Tire bursting long time. vehicle at high speed for a
long time.
Tires damaged. Replace
Tires reach the wear limit. Replace
9-41
1145-000-09-20Y
9.2.3.9 Hydraulic system, troubleshooting

Oil level too low. Fill oil.
Air enters into the oil suction pipe. Rectify
Mounting bolts loose. Tighten
Hydraulic oil polluted. Change oil or filter. Replace oil
Oil pump noise filter or cartridge.
Propeller shaft vibration. Rectify
Universal joint wear. Replace
Hydraulic oil pump defects. Contact trained specialists for
maintenance.
The pressure of relief valve of hydraulic Adjust
changeover control valve block for
steering / outrigger is improperly
Outriggers are not adjusted.
working Solenoid valve plug loose. Solenoid Rectify plug and power
valve is not electrified. source.
Spool of chassis solenoid valve blocked. Clean it or contact trained
specialists for maintenance.
Chassis solenoid valve has inner Rectify or replace.
Outrigger moves too leakage.
slowly and vertical The setting pressure of relief valve of
cylinder retracts changeover control valve block for Adjust
automatically when steering / outrigger is too low.
lifting load
Two-way hydraulic lock invalid. Rectify or replace.
Oil cylinder has inner leakage. Rectify
Outrigger vertical Two-way hydraulic lock invalid. Rectify

cylinder sinks down Oil cylinder has inner leakage. Rectify
automatically during Oil cylinder leaks. Rectify
driving
9-42

Qy130v633 Operation Manual

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QY130V633 / F 20Y

ZOOMLION ® Truck Crane

0 Foreword …………………………………………………………………… 1145-000-00-20Y

4.5.6 Rope reeving

7.5.5 Cleaning and replacing the fuel filter

1.1 Model and name plate

z Model in auto industry: ZLJ5550JQZ130V

1.1.2 Name plate

1.1.2.1 Installation location

The name plate is installed on the left side of operator's cab.

1.1.2.2 Name plate

The VIN of ZLJ5550JQZ130V is L5E6H5D4×××××××××, and is stamped in the name

1.1.4 Engine model and its manufacturer

Engine model: OM501LA.Ⅲ/18 (for chassis)

The second engine

1.2 Main components and configurations

The numbers stand for the following components of the crane.

1.2.1.1 Crane chassis

1.2.1.2 Crane superstructure

1.2.2.1 Crane chassis

Including main boom, jib and extension.

1.2.3.1 Main boom

1 basic boom and 5 telescopic sections.

Fully extended main boom with jib (2 offsets: 0°, 30°)

Main boom M=57.5 m

Fully extended main boom with jib (2 offsets: 0°, 30°)

1.3 Technical data

1.3.1.1 Overall view (Unit: Metric mm)

1.3.1.2 Rope diameter & length

Main hoist rope φ19 300

Auxiliary hoist rope φ19 190

130000 4860 2080 743.1

1.3.3.1 Axle loads

- Crane in driving position

1.3.3.2 Lifting equipment

1.3.3.3 Max. support strength per outrigger

Front (kN) Rear (kN)

1.3.4.1 Driving speeds (km/h)

Road 12 R Maximum gradeability

Speed 74 5.1 40%

Minimum braking distance: ≤ 10 m (Driving speed = 30 km/h)

The drives on crane superstructure can realize infinitely variable control.

Drives Speeds Remarks

1.3.5 Energy consumption and environmental protection

Limits for exhaust pollutants and

Superstructure GB3847-2005 GB17691-2005 Tier 2

1.3.5.2 Workplace-related emission value

Sound pressure level at Stationary noise (db)

nominal RPM Left ear Right ear

Driver's cab, driver's side 90 90

Driver's cab, passenger’s 90

1.3.6 Lifting height chart

1.3.6.1 Main boom

1.3.6.2 Main boom + 11 m jib

1.3.7.1 Notes for the lifting capacity table

Table 1 - 1 Unit: Metric ton

Working Main boom (m)

Working Main boom (m)

Working Main boom (m)

Working Main boom (m)