-
Vision creates futureProfession Heavy-industry Science &
technology
Zoomlion Heavy Industry Science and Technology Co., Ltd.
Add: Quantang Industrial Park, 2nd Yuanda Road, Changsha
Economic and Technological Development Zone, Hunan Province, China
PC:410131Service-hotline:400-800-1680Fax:0086-0731-85585850E-mail:[email protected]:www.zoomlion.com
Maintenance and Service Manual
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MAINTENANCE AND SERVICE
MAINTENANCE AND SERVICE
ZCC800H CRAWLER CRANE
MAINTENANCE AND SERVICE
800H CRAWLER CRANE
MAINTENANCE AND SERVICE MANUAL
The 1
800H CRAWLER CRANE
MAINTENANCE AND SERVICE MANUAL
The 1st edition (April, 2013)
800H CRAWLER CRANE
MAINTENANCE AND SERVICE MANUAL
edition (April, 2013)
800H CRAWLER CRANE
MAINTENANCE AND SERVICE MANUAL
edition (April, 2013)
800H CRAWLER CRANE
MAINTENANCE AND SERVICE
edition (April, 2013)
MAINTENANCE AND SERVICE
MAINTENANCE AND SERVICE
-
I
Crawler Crane
Our respectable users, thank you very much for choosing ZOOMLION
crawler crane. Before operating the crane, read these operating
instructions carefully.
Regular inspection, maintenance and service of crane are very
important to make full use of crane performance, ensure crane safe
operation and extend the service life of crane. Therefore, we offer
you this Maintenance & service manual to facilitate your
inspection, maintenance and service work.
This manual details the inspection, maintenance and service work
to ZOOMLION crawler crane, and lists some common problem occurred
and their solutions.
For safetys sake, do not maintain the crane before you fully
understand the contents in this manual, operating manual and other
technical documents. If there is anything in this manual you do not
understand, please contact local service engineer of Zoomlion, and
they will provide you efficient technical support in time. Any
risks associated with unspecified and improper use are the sole
responsibility of the cranes owner, operator or user.
Unauthorized person is not allowed to dismantle or adjust the
hydraulic elements during maintenance. When the hydraulic system of
crane fails or the components are damaged, please contact local
service engineer of Zoomlion.
Our products 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.
If there is any question, please contact the local service engineer
of Zoomlion.
For you
-
Crawler Crane
The following symbols appear in this manual:
Indicate an imminent threat or danger, which could lead to
life-threatening or fatal injury of one or more persons.
Indicate a danger, which could lead to serious injury of one or
more
persons.
Indicate a potential danger, which could lead to slight or minor
injury of
one or more persons.
Indicate a danger which could lead to severe damage to the
machine
or other assets.
Indicate a tip or hint in the machine operating
instructions.
Emphasize the importance of the information in operating
instructions.
Is located wherever an action that could create a dangerous
situation is prohibited.
Special information
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III
ZCC800HWG Crawler Crane
For you
.........................................................................................................................................
I
Special information
....................................................................................................................
II
Chapter 1 About this manual
.............................................................................................
01-1
1.1 General
.........................................................................................................................
01-1
1.2 Product identification
....................................................................................................
01-1
1.3 Illustration and symbols
................................................................................................
01-2
1.4 Hazard indicator
...........................................................................................................
01-2
Chapter 2 Safety instructions
.............................................................................................
02-1
2.1 Safety guidelines
..........................................................................................................
02-1
2.2 Environmental protection disposal
................................................................................
02-2
Chapter 3 Description of the crane
....................................................................................
03-1
3.1 Description of main components
..................................................................................
03-1
3.2 Hydraulic system
..........................................................................................................
03-3
3.3 Electrical system
...........................................................................................................
03-5
Chapter 4 Maintenance and service
...................................................................................
04-1
4.1 General
.........................................................................................................................
04-1
4.2 Precautions
...................................................................................................................
04-1
4.3 Cycle description
..........................................................................................................
04-5
4.4 Maintenance plan
.........................................................................................................
04-6
4.5 Maintenance of the power system
................................................................................
04-9
4.6 Maintenance of the reducer
........................................................................................
04-15
4.7 Maintenance of the slewing ring
.................................................................................
04-19
4.8 Maintenance of the crawler travel
..............................................................................
04-20
4.9 Maintenance of hydraulic system
...............................................................................
04-22
Contents
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IV
ZCC800HWG Crawler Crane
4.10 Maintenance of the electrical system
.......................................................................
04-29
4.11 Maintenance of hooks and pulleys
...........................................................................
04-33
4.12 Maintenance of wire ropes
.......................................................................................
04-36
4.13 Maintenance of air conditioning equipment
..............................................................
04-40
4.14 Maintenance of the lubricating system
.....................................................................
04-41
4.15 Appearance inspection for structure components
.................................................... 04-45
Chapter 5 Troubleshooting
.................................................................................................
05-1
5.1 Troubleshooting of mechanical drive
............................................................................
05-1
5.2 Troubleshooting of power system
.................................................................................
05-1
5.3 Troubleshooting of hydraulic system
............................................................................
05-4
5.4 Troubleshooting of electrical system
............................................................................
05-7
5.5 Troubleshooting of air conditioning system
.................................................................
05-11
Chapter 6 Application of oil
.................................................................................................
06-1
6.1 Antifreeze coolant
.........................................................................................................
06-1
6.2 Lubricating oil
...............................................................................................................
06-1
6.3 Diesel oil
.......................................................................................................................
06-2
6.4 Gear oil of reducer
........................................................................................................
06-3
6.5 Hydraulic oil
..................................................................................................................
06-3
6.6 Lubricating grease
........................................................................................................
06-5
Chapter 7 Appendix
.............................................................................................................
07-1
7.1 Tightening torque of threaded parts
..............................................................................
07-1
7.2 Tightening torque of thread parts at pipe orifices
......................................................... 07-2
7.3 Attached tools for maintenance
....................................................................................
07-3
7.4 Checklist for periodic inspection
...................................................................................
07-4
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Chapter 1 About this manual
Maintenance and Service Manual for Crawler Crane
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ZCC800HWG Crawler Crane
1.1 General
This manual is compiled for crane maintenance personnel to carry
out daily maintenance and periodic service. Read and understand the
content in this manual before crane maintenance and service
work.
Perform the crane maintenance and service work in accordance
with the requirements
stipulated in this manual, especially the information about
,
and .
This manual does not include all requirements for maintenance
and service. They are only for reference to help maintenance
personnel to do the work. It is no substitute for official
training.
This manual is compiled according to the working status of
crane. However, it may be different from the actual status of crane
due to technical improvements. Therefore, you can contact us if you
want to know about more accurate information about the crane.
1.2 Product identification
The crane name plate is located in a prominent position at the
outside of cab. The following figure shows the detail position of
name plate.
The user can distinguish this crane from the other via the name
plate. The information on it is helpful for crane maintenance and
service. Please keep it in a good condition within the service life
of crane.
The serial number on the name plate is for crane identification.
The users can confirm the crane components and relevant technical
data by this serial number. The serial number of this crane shown
in the following figure is ZCC80-0001.
Fig. 1-001 Position of name plate
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ZCC800HWG Crawler Crane
1.3 Illustration and symbols
This manual has a mass of illustrations, which are schematic.
The meanings of illustrations are as follows:
Position of working mechanism to be operated
Sequence of operation
Correct operating way
Unpermitted or dangerous operating way
The illustrations in this manual may be different from the
actual condition of crane. However, this does not hinder the user
from understanding the meanings of illustrations.
1.4 Hazard indicator
The content with respect to the safety is marked with , the
safety instructions involved in the book are only the conventional
contents.
The following terms that are used in this manual CAUTION,
WARNING, and DANGER are intended to point out certain important
rules of conduct to all persons who maintain and service the
crane.
Indicate a potential danger, which could lead to slight or minor
injury of one
or more persons.
Indicate a danger, which could lead to serious injury of one or
more persons.
Indicate an imminent threat or danger, which could lead to
life-threatening
or fatal injury of one or more persons.
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Chapter 2 Safety instructions
Maintenance and Service Manual for Crawler Crane
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ZCC800HWG Crawler Crane
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2.1 Safety guidelines
Since various dangerous factors exist during maintenance and
service of crane, the following are the safety guidelines for
service technician to maintain and service crane superstructure and
undercarriage. Read and understand these safety guidelines before
maintenance and service work.
a) The maintenance work must be done by qualified personnel who
have received training in crane technology, especially in
electrical and hydraulic systems of crane.
b) The service technician must read and understand the operating
manual, acquainting himself with crane and its operation.
c) Do not perform any maintenance work if the service technician
is in low spirits, or he has drunk, or he has taken medicine which
may affect the work.
d) No unauthorized personnel are accessible to crane during
maintenance and service.
e) Make sure that the platforms, handrails, ladders and slewing
table are free from dust, snow and ice.
f) The service technician must wear tight-fitting protective
clothing when servicing the crane, together with the correct
personal protective gear such as safety goggles, breathing mask for
the particular activity.
g) Correctly use auxiliary equipment and set up working platform
before performing high-level operation.
h) Do not reach into moving drives or parts of the crane. The
service technician must remove the ignition key and hang the
Prohibit sign on the control device before operating these drives
or parts.
i) Do not touch hot components, hot pipelines, hot liquid and
engine when the engine just stops. Only when the engine is cooled
down for more than one hour, can the relevant maintenance work be
carried out.
j) Depressurize all pipelines or containers before demounting
the fittings or disconnecting the pipeline. Take preventive
measures to protect personnel against injuries due to escaping
hydraulic oil or air under high pressure.
k) The customer must use original spare parts which meet with
technical requirements, and must use standard components which
comply with the technical standards in Spare Parts Catalogue so
that the designed service life of crane can be fulfilled and the
crane safety can be guaranteed.
l) Cut off the grounding terminal of battery and turn off mast
power switch before dismantling battery and welding operation on
the crane.
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ZCC800HWG Crawler Crane
2.2 Environmental protection disposal
Some harmful substances such as engine oil, lubricating grease,
fuel, antifreeze coolant, hydraulic oil and refrigerant will be
produced during maintenance. These substances and relevant things
will damage the environment and peoples health, therefore, they
must not get into the ground, into water or into the sewer system,
and they must be recycled and disposed of according environmental
protection regulations.
Dispose harmful substances according to the following
regulations:
a) The maintenance personnel must wear suitable protective gear
such as protective clothing, protective gloves, safety goggles,
breathing mask for the particular activity, since the polluted
substance is corrosive and poisonous.
b) When supply the crane with oil or lubricating grease which
can pollute the environment, proper filling equipment such as
refueling pump, oil filling device, hose, container and funnel must
be used to prevent these substances from coming contact with the
natural environment.
c) Some lubricating oil may flow out when dismantling and
changing the components. Some oil may get into ground or into sewer
system when changing oil. This will severely pollute the
environment. Therefore, a proper container must be used to collect
the waste oil and other waste materials. The refrigerant can not be
released into the air.
d) The pollutant must be gathered together and preserved
according to different categories for follow-up disposal, thus
reducing the costs. During this time, take measures to prevent loss
of pollutant.
e) Use special container to move the pollutant from one position
to another. Ask specialized company to recycle the pollutant.
Dispose of the waste materials according to relevant environmental
protection regulations.
f) If the pollutant comes into contact with the natural
environment or persons skin due to unexpected conditions, some
emergency measures must be taken. If the pollutant falls down on
the ground, collect it into a container to avoid it permeating into
soil or sewer system. If the pollutant is sprayed on the skin, it
must be rinsed away as quickly as possible with a lot of clean
water. In the event of eye injuries, use an eye-bath to rinse the
eyes, and seek medical attention.
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Chapter 3 Description of the crane
Maintenance and Service Manual for Crawler Crane
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ZCC800HWG Crawler Crane
3.1 Description of main components
Fig. 3-001 Overview of crawler crane
Main boom anchoring rods
Wire rope for hoisting winch 2
Wire rope for hoisting winch 1
Main boom
Tip boom
Main load hook
Auxiliary load hook
Travel gear
Rear anchoring rods of A-frame
Derricking pulley block
Main boom tilting-back support
A-frame
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ZCC800HWG Crawler Crane
Fig. 3-002 Overview of crane undercarriage
Operators cab
Left crawler carrier
Main valve
Oil cooling fan
Hydraulic oil tank
Counterweight
Main boom derricking winch
Oil pump
Engine system
Hoisting winch 2
Hoisting winch 1
Fuel tank
Right crawler carrier
Slewing mechanism
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ZCC800HWG Crawler Crane
3.2 Hydraulic system
The hydraulic system consists of main pump, triple gear pump,
main valve, motor and so on. The pump-control hydraulic system is
applied in the crane.
3.2.1 Hydraulic system diagram
Fig. 3-003 Hydraulic system diagram
Engine
Main pump Triple gear pump
Dual valve Triple valve
Slewing pump
Cooling motor
Control valve block
Slewing motor Reducer
Hoisting winch 1 motor
Derricking motor Reducer
Reducer
Hoisting winch 1 motor
Reducer
Traveling motor (L) Reducer
Traveling motor (R) Reducer
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3.2.2 Arrangement of hydraulic elements in slewing table
Fig. 3-004 Arrangement of hydraulic elements
Hydraulic oil tank Oil radiator Control valve Triple main valve
Dual main valve
Travel control valve
Control valve block
Central revolving joint
Pilot oil filter Clutch control solenoid valve Pilot control
valve Pump unit Solenoid valve
Energy accumulator
Derricking brake valve Ratchet control valve Winch brake valve
Outer brake valve
Slewing valve
Slewing brake solenoid valve
Slewing cushion valve
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3.3 Electrical system
3.3.1 Electrical system diagram
Fig. 3-005 Electrical system diagram
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ZCC800HWG Crawler Crane
3.3.2 Arrangement of electrical elements in slewing table
Fig.
3-
006
Arr
ange
men
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ric e
lem
ents
Junction box 2
Junction box 1
Video camera
Working floodlight
Main boom angle limit switch To connector on boom
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Fig.
3-
007
Arr
ange
men
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ric e
lem
ents
Shutoff valve limit switch
Inclinometer
Electrical control box
Horn Traveling alarm
Slewing limit switch Battery
Battery master switch
Oil level sensor
Lowering limiter for hoisting winch 1
Lowering limiter for hoisting winch 2
Junction box 3
Slewing alarm Slewing alarm
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ZCC800HWG Crawler Crane
Tricolor light
Working floodlight
Junction box 3
Fig.
3
-008
Arr
ange
men
t of e
lect
ric e
lem
ents
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Chapter 4 Maintenance and service
Maintenance and Service Manual for Crawler Crane
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ZCC800HWG Crawler Crane
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4.1 General
A crane should be maintained regularly to ensure that it is
always in a good state for safe use.
In addition to oil inspection and change, the maintenance work
also involves frequent inspections to ensure that components are in
good state.
Appropriate workshop equipment shall be available for the
lubrication and maintenance work.
The regulations and instructions in the Operating Manual for
Crawler Crane shall be followed.
When being removed during the maintenance, safety devices should
be reinstalled and inspected upon completion of the maintenance
work.
Fuels, lubricants and replaced parts must be safely treated in
compliance with the regulations for environmental protection.
4.2 Precautions
General precautions during the maintenance work are described as
follows:
a) Wear work clothes when conducting the maintenance.
b) Put a crane on a firm and flat site and set a warning board
marked with Crane in inspection.
c) Working at a position higher than 2m is considered as work at
heights. Use ladders and safety belts in such a situation.
d) Act in accordance with the commander's signal when moving a
crane for maintenance.
e) Prevent dusts and dirty articles from entering the hydraulic
system which is in inspection or maintenance.
f) If any items have to be maintained and adjusted immediately,
maintain and adjust them immediately.
g) If repair is necessary, contact the local office of Zoomlion
Mobile Crane Branch Company.
h) In order to ensure the performances of a crane, use the
accessories and lubricating grease designated by Zoomlion.
i) Replace consumables, such as filter elements, in time as
specified to avoid faults.
j) When any problems are difficulty to be determined in
inspection or maintenance, contact the local office of Zoomlion
Mobile Crane Branch Company.
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ZCC800HWG Crawler Cranes
To ensure safety, pay attention to the following points during
the maintenance:
l When a crane is in inspection and maintenance, drop the boom
to the ground, stop the engine, lock the engine and remove the
switch key to prevent other operators from starting up the engine
during the inspection and maintenance work.
Failing to follow this instruction may cause personnel injury or
death.
l Set up a warning board for the inspection and maintenance
process.
In inspection and maintenance, a warning board marked with In
Inspection and Maintenance, Please Do not Start it Up should be set
at the key switch.
l Use the clean lubricating grease.
Keep the rooms for storing the lubricating grease clean. Do not
make dusts, water, or other things enter the vessels. Ensure that
the lubricating grease is free of water.
Fig. 4 - 001
l Keep the body clean.
Clean the body with water to inspect for oil leakage, cracks,
looseness of connectors, and other abnormalities. Especially, keep
grease nipples, vent holes and dipsticks clean to prevent dusts
from entering them.
Fig. 4 - 002
(1) After cleaning the body, lubricate the transmission shafts
and slewing connectors of the crane.
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(2) Clean the steering wheels, central consoles, control panels,
base plates, and the decorations in the stained cab only with the
warm water that contains cleaning agents.
(3) Do not use corrosive cleaning agents.
l Treatment of oil stains
When fuel, hydraulic oil, lubricating grease are injected or
changed, or filter elements are replaced, the oil might splash out.
Therefore, wipe off the oil having splashed out in time to avoid
fires. When cleaning the machine, do not spray water on the
electric elements and connectors.
Fig. 4 - 003
l Pay attention to fire prevention
Put oil stained or other combustible stained garbage in safe
places, and be familiar with the places of storing and methods of
using the fire extinguishers.
Fig. 4 - 004
l Pay attention to the rotating parts
When inspecting fan belts or pump, stop the engine in advance to
avoid dangers of being caught.
Fig. 4 - 005
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l Pay attention to the water and oil temperature.
It is dangerous to drain water, drain oil or replace filter
elements when the engine is just stopped. For this reason, drain
water, drain oil, or replace filter elements only after the
temperatures have dropped. When the oil temperature is too low, the
oil shall be heated properly (to the temperature ranging from 20 -
50 C) before being drained.
Fig. 4 - 006
l Inspect the drained waste oil and the old filter elements.
When changing the oil or filter elements, pay attention to
inspecting whether there are metal chips or foreign articles.
l Prevent the intrusion of dusts.
Protect the dismantled hydraulic oil pipes and hydraulic
elements with plugs or seal covers against the intrusion of
dusts.
Fig. 4 - 007
l Clean joint surfaces.
After removing O-rings or other gaskets, clean the sealing
surfaces, and replace the seal parts with new ones. When
reassembling them, coat the sealing with a thin layer of oil.
l Pay attention to the internal pressure
When dismantling the pipelines, connectors or other relevant
components with internal pressure, such as the hydraulic system,
compressed air system, and fuel system, release the pressure in
advance.
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Fig. 4 - 008
l Precautions for the welding process
Turn off the power, disconnect power lines of the batteries, do
not apply a voltage of more than 200V successively, set the
grounding within 1m from the welding points, and set no sealing or
bearings between the welding points and the grounding points.
Dismantle the load torque limiter or controller for welding around
it to avoid damage.
l Treatment of the waste oil
Put the waste oil into the vessels and treat it as industrial
emissions.
l Unprofessional personnel are forbidden to servicing the cranes
or replacing parts for them.
l Record inspection
In order to learn about the correct working status of a crane
and its components, perform regular inspections and recordings
(Upon the use for the 1st time, use for the 1st time after a
long-term out-of- service or maintenance, perform inspection
according to the following requirements.).
For the record list recommended for inspection, see section
7.3.
4.3 Cycle description
All maintenance work is conducted intermittently and the
interval is the maintenance cycle which is determined according to
the operation status of the crane.
The maintenance cycle shall be subject to the following
aspects:
a) The specific operating time (hours) of functional parts of
the crane
b) The calendar time (date, month and year) when the crane is in
operation and storage
In the maintenance of the crane, the maintenance cycle usually
determined according to the first method and the special items are
determined according to the second method.
Operation hours of the maintenance cycle refer to the operation
hours of the engine, which can be read on the main display of the
operators cab.
The maintenance cycle can be classified as follows according to
duration of the interval.
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ZCC800HWG Crawler Cranes
Table 4 - 001 Maintenance cycle
Maintenance type Operating time (hours) Maintenance cycle
Daily inspection (D) 10 Before being started up every day Weekly
maintenance (W) About 50 Weekly
Monthly maintenance (M1) About 200 Monthly
Quarterly maintenance (M3) About 500 Every 3 months
Semiannual maintenance (M3) About 1,000 Every 6 months
Annual maintenance (M12) About 2,000 Yearly
4.4 Maintenance plan
Table 4 - 002 Maintenance plan
No. Working task
Maintenance Inspection
Monthly maintenance
M1
Quarterly maintenance
M3
Semiannual maintenance
M6
Annual maintenance
M 12
Daily inspection
D
Weekly inspection
W
4.5 Maintenance of
the power system
4.5.1 Daily inspection of the engine
4.5.2 Inspection of the engine operation
status
4.5.3 Maintenance of the engine (as required in the maintenance
manual of the engine)
4.5.4 Cleaning of the air suction filter
4.5.5 Replacement of the air suction filter elements
4.5.6
Inspection of the cooling fluid
(antifreeze fluid) level and
supplementation of the cooling fluid
4.5.7 Change of the cooling fluid 2 years
4.5.8 Inspection of the fuel pipeline
4.5.9
Drainage and discharge of the
oil-water separator
4.5.10 Cleaning of the fuel tank
4.6 Maintenance of the reducer
4.6.1 Inspection of the oil level
4.6.2 Change of the gear oil
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No. Working task
Maintenance Inspection
Monthly maintenance
M1
Quarterly maintenance
M3
Semiannual maintenance
M6
Annual maintenance
M 12
Daily inspection
D
Weekly inspection
W
4.6.3 Lubrication of
bearings of the reducer
4.6.4 Inspection of brakes of the winch reducer
4.6.5 Inspection of securing bolts
4.6.6
Inspection of brake straps of
the hoisting winch 1 with free-fall
function
4.7 Maintenance of the slewing ring
4.7.1 Routine inspection
4.7.2 Lubrication of the gear surface
4.7.3 Lubrication of the
raceway
4.7.4 Inspection of the slewing ring bolt
4.8 Maintenance of the crawler travel
4.8.1 Regular inspection
4.8.2 Cleaning of the crawler
4.8.3 Lubrication of the crawler pin
4.8.4 Tension of track pad
4.9 Maintenance of hydraulic system
4.9.1 Routine
inspection of hydraulic system
Multiple items
4.9.2 Inspection of the
oil level of the hydraulic tank
4.9.3 Replacement of the return filter
4.9.4 Replacement of the air cleaner 2 years
4.9.5 Cleaning of the filter element In time
4.9.6 Change of the hydraulic oil
4.9.7 Cylinder inspection
4.9.8 Installation of the pipeline
4.10 Maintenance of
the electrical system
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No. Working task
Maintenance Inspection
Monthly maintenance
M1
Quarterly maintenance
M3
Semiannual maintenance
M6
Annual maintenance
M 12
Daily inspection
D
Weekly inspection
W
4.10.1 Inspection of the lighting system
4.10.2
Inspection of windshield wipers in the operator's cab as well
as
cleaning solution
4.10.3 Inspection of the video monitoring
system
4.10.4 Battery inspection
4.10.5 Inspection of the limit switch
4.10.6 Inspection of
cable terminals and dust guards
Upon the basic machine disassembly or site transition every
time
4.10.7
Prevention of electrical parts or
cables from catching fires
Upon the basic machine disassembly or site transition every
time
4.11 Maintenance of
hooks and pulleys
4.11.1 Daily
maintenance of hooks
4.11.2 Pulley inspection
4.11.3 Inspection of
rolling bearings on the pulleys
4.11.4 Replacement of rolling bearings
4.11.5 Pulley lubrication
4.11.6 Inspection of the safety catch
4.11.7 Inspection of each hook body
4.12 Maintenance of the wire rope
4.12.1 Cleaning of wire ropes In time
4.12.2 Lubrication of wire ropes In time
4.12.3 Inspection of wire ropes
4.13 Air conditioner
4.13.1 Daily
maintenance of air conditioners
4.13.2 Maintenance of air conditioners in low
seasons
4.13.3 Regular
inspection of air conditioners
Multiple items
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No. Working task
Maintenance Inspection
Monthly maintenance
M1
Quarterly maintenance
M3
Semiannual maintenance
M6
Annual maintenance
M 12
Daily inspection
D
Weekly inspection
W
4.15 Structure component
4.15.1 Rotary table inspection
4.15.2 Inspection of substructures
4.15.3 Boom inspection
4.15.4 Inspection of the anchoring rod
4.5 Maintenance of the power system
4.5.1 Daily inspection of the engine
Inspect appearances of the engines components to ensure that all
parts are intact and function normally.
Items to be inspected:
a) Inspect whether each part of the air suction pipeline is
securely connected and free of breakage and leakage.
b) Inspect whether the circulating cooling water way, the fuel
pipeline and the engine oil are all free of leakage.
c) Inspect whether the fan blades are free of damage and whether
fan blades and other parts are not scraped.
d) Inspect whether the belts are not worn or torn and whether
their tensions are within in the normal range.
e) Inspect whether there is water or materials of the sludge
state in the transparent glass cup of the oil-water separator.
f) Inspect whether installation bolts (screws) of the engines
and its subsidiary systems are reliably tightened and free of
looseness.
4.5.2 Inspection of the engine operation status
Inspect the engine oil manometer, water temperature gauge,
revolution counter and fault alarm indicator to make sure that the
engine operates normally.
Inspection steps:
a) Start up the engine with the key switch and idle for 3 - 5
minutes.
b) Accelerate the engine slowly to increase the rotational speed
of the engine to about 1500RPM.
c) Observe whether readings on the revolution counter change
correspondingly during the acceleration.
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d) Read the values displayed on the engine oil manometer from
the display screen, and the values are not less than 0.5bar in the
idling process and not more than 6.5bar at the rated rotational
speed. Inspection is required and repair is also required if
necessary when the values are out of the ranges mentioned
above.
e) When the engine has operated normally for about 10 minutes,
the water temperature readings on the instrument panel shall
increase; if the engine has operated for 30 minutes and the water
temperature still remains below 70C, corresponding service is
required.
f) When the engine operates normally, it is normal if the alarm
indicator of the engine does not flash.
(Note: For detailed operation methods, refer to the Operating
Manual for Cranes.)
4.5.3 Maintenance of the engine
The engine shall be maintained according to requirements of the
Operating Manual and Maintenance and Service Manual prepared by the
engine manufacturer and provided together with the engine.
4.5.4 Cleaning of the air suction filter
When the engine is at the rated rotational speed, if the pointer
of the air filter s blocking indicator points at the read zone, it
indicates that filter elements of the air filter are seriously
blocked and need to be cleaned.
Inspection steps:
a) Loosen the bolts at tails of the air filters and dismantle
the tail covers to pick out the external filter elements.
b) Pat on the filter elements to shake off the dusts and dirt on
the external filter elements. Connect the compressed air with hoses
and blow the compressed air out to the filter elements until all
dusts are blown away.
c) Install the external filter elements back into the air filter
and install the tail covers as before.
d) Nip the dust nozzle of the air filter open and knock on the
shell of the air filter lightly to shake off the accumulated
dusts.
e) Reset the air suction filter.
f) Start up the engine and stabilize the rotational speed to the
rated rotational speed to confirm that the pointer of the blocking
indicator points at the green zone.
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The schematic diagram for the cleaning process is as
follows:
a) Shack off the dusts on the filter element. b) Blow the
compressed air over the filter element surface.
c) Blow the compressed air over the filter surface.
d) Clean the sealed supporting surface.
Fig. 4 - 009 Schematic diagram for the cleaning process
Do not damage the filter elements when cleaning the external
filter elements. Do not clean the internal filter elements (safety
filter elements). Do not clean external filter elements for more
than 5 times.
Do not start up the engine during the cleaning work.
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4.5.5 Replacement of the air suction filter elements
The external filter element must be replaced when it is cleaned
for many times to avoid degradation of its filtering
performance.
When changing the external filter element, replace the internal
filter element (safety filter element) at the same time.
The replacement cycle for filter elements is 2,000 hours which
will be shortened in the severe dust environment.
When changing the filter element, dismantle and install it in
the method described in section 4.5.4.
Purchase the internal and external filter elements (safety
filter elements and main filter elements) according to part
numbers.
To ensure the quality of filter elements, purchase the filter
element accessories from the basic machine manufacture.
4.5.6 Inspection of the cooling fluid level and supplementation
of the cooling fluid
The cooling fluid (antifreeze fluid) of the engine might reduce
continuously due to causes such as leakage and evaporation. Severe
lose of the cooling fluid will result in poor capability for heat
dissipation of the engine, causing damages to the engine.
Inspection of the cooling fluid level: unscrew the water tank
cap to check the fluid level in the upper water chamber of the
water tank, which shall be higher than 1/3 of the upper water
chamber.
Supplementation of the cooling fluid: unscrew the water tank cap
and add appropriate cooling fluid into the water tank to make the
fluid level between 1/3 and 1/2 of the upper water chamber.
For requirements for performances of the cooling fluid, refer to
section 6.1.
(1) Before adding the cooling fluid, stop the operation of the
engine and make the engine cool naturally for a certain time.
(2) When unscrewing the expansion water tank cap, avoid getting
burnt.
(3) Ensure that the added cooling fluid is the same as the
original one.
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4.5.7 Replacement of the cooling fluid
When the cooling fluid has been used for 2 years, it must be
changed. Even though the engine has not operated for a long time,
the cooling fluid also needs to be changed.
Change steps:
a) Put a proper vessel under the cooling water tank to collect
the cooling fluid.
b) Unscrew the water drain plug screw at the lower end of the
cooling water tank to let the water flow into the collection
vessel.
c) Install the plug screw at the water drain hole and inject
about 43L of cooling fluid in total from the water inlet of the
water tank.
d) Start up the engine and let it operate for several minutes to
make the cooling fluid free of air bubbles before the fluid level
is inspected again.
For the change cycles of the cooling fluid, refer to section
4.4.
Do not drain the cooling fluid to the natural environment.
4.5.8 Inspection of the fuel pipeline
Items to be inspected:
a) Each welding line on the diesel tank shall be free of oil
leakage marks.
b) Fuel hoses shall be free of leakage due to damages.
c) Connectors of the pipeline shall be free of oil leakage.
d) The diesel pump, injection nozzle, etc. of the engine shall
be free of oil leakage.
e) The accumulated water in the transparent shell of the
oil-water separator shall be checked. In the case of much water
accumulated in it, drainage is necessary.
Once leakage is found, corresponding maintenance treatment is
necessary.
For requirements for the fuel quality, see section 6.3.
Use the approved fuel to extend the service life of the
engine.
4.5.9 Drainage and discharge of the oil-water separator
The water contained in the fuel is separated in the oil-water
separator and the impurities with a large particle size (more than
30 micrometers) are filtered and settled down in the water
collection cup at the bottom of the oil-water separator to form the
sludge. When the water is accumulated a lot, it shall be discharged
outside to prevent it from entering the engine cylinder together
with the fuel. When a lot of sludge is formed, it will increase the
resistance to the fuel system, thus reducing the output power of
the engine and even making it unable to start up the engine when it
get serious.
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The drainage process is as follows:
a) Put a proper vessel under the oil-water separator to collect
the residual water.
b) Rotate the water drain valve at the lower end of the
oil-water separator in the counter-clockwise direction to make the
accumulated water flow out slowly.
c) When the diesel begins to flow out, rotate (close) the water
drain valve in the clockwise direction until no diesel flows
out.
The discharge process is as follows:
a) Disconnect the fuel tube between the oil-water separator and
the fuel tank.
b) Put a proper vessel under the oil-water separator to collect
the fuel.
c) Rotate the water drain valve at the lower end of the
oil-water separator in the counter-clockwise direction to drain the
fuel in it.
d) Unscrew off the oil-water separator shell in the
counter-clockwise direction with a special-purpose belt wrench with
the sludge accumulated in the shell cleaned.
e) When the water drain valve is closed, install the oil-water
separator shell in the opposite direction and tighten it with the
belt wrench.
f) Connect the fuel tube between the oil-water separator and the
fuel tank.
g) Open the outlet of the oil-water separator (unscrew the plug
screw).
h) Pump oil with the manual fuel pump and close the outlet when
there is oil flowing out at the outlet.
i) Continue pumping oil with the manual fuel pump and stop it
until it feels heavy on the hands.
4.5.10 Cleaning of the fuel tank
When the fuel tank has been used for half a year, oil sludge and
water will be accumulated in the fuel tank. In order to keep the
fuel tank clean, the fuel tank needs to be cleaned.
The cleaning method is as follows:
a) Put a proper vessel under the fuel tank.
b) Unscrew the oil drain bolts at the bottom of the fuel tank to
make the residual oil flow out.
c) Dismantle the air filter over the oil tank and clean the
filter screen.
d) Clean the internal surface of the oil tank with brushes and
then flush it clean with diesel.
e) Reinstall the plug screw of the oil drain hole at the bottom
of the fuel tank as well as the air filter.
f) Inspect whether there is any leakage at the plug screw of the
oil drain hole after the
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diesel is injected and whether the oil level is normally
indicated on the main display.
g) Install the cleaning cover for the fuel tank.
Treat the collected waste diesel according to relevant
environmental regulations, and do not discharge it to the
environment.
Take preventive measures to avoid fires when cleaning the oil
tank.
4.6 Maintenance of the reducer
4.6.1 Inspection of the oil level
Inspect the oil level frequently. In the case of the oil level
lower than the oil level mark, the gear oil shall be injected in
time. In addition, the recommended gear oil shall be used according
to different environmental temperatures.
Table 4 - 003 Oil change cycle and oil change amount of each
mechanism
Mechanism name Gear oil grade Inspection
interval (hours)
Oil change interval (hours)
Oil change amount (L/each)
Hoisting winch reducer
L-CKD220 industrial enclosed gear oil 250 1,000 3
Derricking winch reducer
L-CKD220 industrial enclosed gear oil 250 1,000 3
Slewing reducer L-CKD220 industrial enclosed gear oil 250 1,000
5.5
Travelling reducer L-CKD220 industrial enclosed gear oil 250
1,000 10
Gear transfer box L-CKD220 industrial enclosed gear oil 250
1,000 3.5
4.6.2 Change of the gear oil
When the gear oil is changed, it shall be changed again after
the machine has operated for a long time. It shall be drained off
when the oil is hot and special-purpose tools are required when the
oil is injected.
a) Change of the gear oil for the lifting and derricking winch
reducers
1) Unscrew plug screws of the oil drain holes at the lower ends
of the winch reducers and those of the oil fillers at the upper
ends of the winch reducers to drain the original gear oil.
2) Open the oil filling plug screw and clean the gear with the
cleaning oil (warm and clean oil) to remove the abrasive matters
and foreign matters.
3) Tighten the oil drain plug screw, insert the head of a hopper
into the oil filler, inject the specified gear oil to the plug
screw of the sight hole, and then stop injecting the oil when the
oil level reaches the middle position of the plug screw of the
sight hole.
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4) Inspect the cleaning status and tighten the plug screw of the
oil filler at the upper end.
Fig. 4 - 010 Schematic diagram for change of the gear oil
b) Change of the gear oil for the slewing reducer
1) Unscrew the oil drain rubber tube plug screw at the lower end
of the slewing reducer and the screw plug of the oil filler at the
upper end of the slewing reducer to drain the original gear
oil.
2) Open the oil filling plug screw and clean the gear with the
cleaning oil (warm and clean oil) to remove the abrasive matters
and foreign matters.
3) Re-screw the oil drain rubber tube screw plug at the lower
end, insert the head of a hopper into the oil filler, inject the
specified gear oil to the plug screw of the sight hole, and then
stop injecting oil when the oil level reaches the middle position
of the plug screw of the sight hole.
4) Inspect the cleaning status and tighten the plug screw of the
oil filler at the upper end.
Fig. 4 - 011 Schematic diagram for change of the gear oil
When oil is injected, this plug screw at the sight holeshall be
screwed to inspect whether the oil level reaches the cock hole
edge
Drain oil after the plug screw of the oil drain hole is
screwed.
Inject oil after the plug screw is unscrewed.
Inspect the oil level
Unscrew the oil drain rubber tube plug screw
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4.6.3 Lubrication of bearings of the reducer
When the winch reducer operates every month or has worked for
200 hours, its bearings shall be lubricated with the lubricating
grease injected with an oil gun.
Fig. 4 - 012 Schematic diagram for lubrication of the winch
reducer
4.6.4 Inspection of brakes of the winch reducer
Inspect brakes of the hoisting winch reducer according to the
following order:
a) Start up the engine and make it operate at a slightly high
idle speed.
b) Apply a maximum load that the wire rope can bear to the
corresponding hoisting winch.
c) Operate the control lever to make the hoisting winch 1 (2)
lift the heavy objects up.
d) When the heavy object is suspended in the air, push the
control lever of the hoisting winch 1 (2) to the middle position
and then make a mark at a certain place on the winch drum.
e) Retain the heavy object suspended in the air freely for
several minutes and then observe whether the position of the mark
moves. In the case of no movement, it indicates that brakes of the
winch reducer are good.
Inspect brakes of the derricking winch reducer according to the
following order:
a) Start up the engine.
b) Pull out the oil tube at the brake cylinder of the derricking
winch reducer.
c) Operate the derricking erection action.
The oil cup for lubricating grease injection
Direction A (enlarged)
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d) If the holding pressure reaches the overflow pressure of the
main pump and the derricking winch does not operate, it indicates
that the derricking winch is effectively braked.
Assign only well-trained professionals to inspect the brake of a
winch reducer. Incomplete brake may cause accidents.
There are dangers of being dragged. When carrying out the
maintenance, inspection and installation work, and exercise caution
to avoid dangers of being drawn or dragged between the winch and
the winch wire rope.
4.6.5 Inspection of securing bolts
Inspect whether securing bolts of the winch are loose. If they
are loose, tighten them.
4.6.6 Inspection of brake straps of the hoisting winch 1 with
free-fall function
When selecting the hoisting winch 1 with free-fall function,
inspect the brake straps.
Fig. 4 - 013 Schematic diagram for inspection of brake straps of
the hoisting
winch 1 with free-fall function
a) When the hoisting winch 1 with free-fall function cannot be
braked, its brake strap shall be adjusted through its own adjusting
nut and con-rod. Prior to inspection of the brake strap, rivets
within the areas shown in the picture above shall be inspected. If
rivets have been worn or are to be worn, the brake strap shall be
replaced immediately.
b) Brake straps of the hoisting winch 1 with free-fall function
shall be inspected every week or after having worked for 50h. If
rivets have been worn or are to be worn, the brake straps shall be
replaced immediately.
The adjusting nut and con-rod of the brake strap
Rivet
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4.7 Maintenance of the slewing ring
4.7.1 Routine inspection
a) Inspect the flexibility of the slewing ring. If noises,
impacts and powers are found to increase suddenly, it shall be shut
down for inspection, troubleshooting and overhauling when
necessary.
b) Regularly inspect whether there are defects such as cracks or
damages on the slewing gear ring, seizing, bite and peeling of on
the gear surface.
c) Frequently inspect the perfection of the sealing. If the seal
belt is found to be damaged, replace it in time. If it is found to
peel off, reset it in time.
4.7.2 Lubrication of the gear surface
Gear rings of slewing rings have been coated with the rust
preventive oil before being delivered from the factory. This
rust-proof oils period of validity is usually 3 to 6 months. Upon
expiration of the period of validity, they shall be coated with the
rust preventive oil in time. At the same time, it is forbidden to
flush the slewing rings with water directly to prevent the water
from flowing into the raceway.
4.7.3 Lubrication of the raceway
Raceways must be injected with lubricating grease regularly
according to the work environment. After having worked for 50h,
raceways shall be injected with the lubricating grease. In special
work environment, such as tropical belts, large humidity, many
dusts and large temperature variation and having worked
continuously, the lubrication cycle shall be shortened and the
slewing ring must be injected with grease before and after a
long-term placement.
The grease should be injected when the slewing ring operates.
When the lubricating grease flows over from the seal, it indicates
that the injection is completed and the over flown grease will form
a thin film to seal it.
4.7.4 Inspection of the slewing ring bolt
Requirements for inspection:
a) When the slewing ring has been used for 100 working hours for
the 1st time, inspect the pre-tightening torque of the bolts for
once. If more than 10% of bolts get loose, tighten them and then
inspect them again at the 200th working hour.
b) Then inspect them every 500 working hours and the inspection
interval shall be shortened under poor working conditions.
c) When the equipment has worked for 2,000 hours accumulatively,
if a bolt has been loosened to less than 80% of the specified
torque, replace this bolt and its two adjacent bolts. If 20% of
bolts are found to get loosened to less than 80% of the specified
torque, replace all the bolts.
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d) Usually, it is necessary to replace all bolts every 7 years
or after having worked for 4,000 hours.
e) When bolts are replaced, wipe them clean and then tighten
them after coating them with the lubricating oil. The tightening
torque shall be 1800N.m.
4.8 Maintenance of the crawler travel
4.8.1 Regular inspection
Insufficient lubrication of the connecting pin of crawler,
improper tension degree of track pad, or smudginess on the crawler
will cause noises and premature wear. Therefore, inspect the
crawler at intervals of less than one month before each work or
after the crane has traveled for a long journey.
Items to be inspected:
a) The wear of crawler traveling devices, lubrication of crawler
pin, and tensity of track pad.
b) The wear of the track roller or track carrier roller of the
crawler, and lubrication of roller.
c) The wear of driving device, lubrication of reducer and
smudginess of the crawler.
4.8.2 Cleaning of the crawler
Clean the crawler when it is dirty. The cleaning involves wiping
off the dirt on track pad, sundries on the crawler carrier, and
soil being mingled in between the drive sprocket or track roller
and the track pad, etc.
4.8.3 Lubrication of the crawler pin
Put the crawler pin in a position that can be lubricated, and
spray the crawler pin at joint with lubricant. Move the crane
forward until the lower crawler pin is located on track carrier
roller, and spray the crawler pin at this part with lubricant. You
can also lubricate the crawler pin by daubing the waste oil.
4.8.4 Tension of track pad
Before checking the tensity of track pad driving, the track pad
must be cleaned. The tensity of track pad driving is estimated by
its relaxation around 15 5 millimeter, and the crawler components
must be tightened or loosened subject to their tightness.
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Fig. 4 - 014 Schematic diagram of relaxation estimation of the
crawler driving
The tensity of crawler must be adjusted when the machine is on
level ground. Slightly move the crane body forward before adjusting
to concentrate the loose parts of the crawler on the top of drive
sprocket, so that it can be easily adjusted.
Adjustment steps:
a) Unload the bolts and shields from both right and left
sides.
b) Align the hydraulic jacks with the push rods respectively
under nature state.
c) Press the handle of the hydraulic jack slowly to move its
driving axis and tension wheel forward, causing spacing between
crawler frames and gaskets.
d) After adjusting the crawler to appropriate tension, stop the
movement of hydraulic jacks and fill in the spacing between crawler
frames and gaskets with gaskets, and then mount the shield. After
adjusting the crawler to appropriate tension, stop moving forward
the tension cylinder.
e) If the wear of pin hole on of the track pad is relatively
larger, remove one track pad and tension it again when the track
pad still fails to be tensioned after the tense wheel block reaches
the end.
f) Mount the shield.
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4.9 Maintenance of hydraulic system
To ensure that the hydraulic system is in a good status for
long-term operation, maintain the hydraulic system on time.
4.9.1 Routine inspection of hydraulic system
For the inspection period of hydraulic system, see the following
table.
Table 4 - 004 Inspection period of the hydraulic system
S/N Inspection and maintenance items Inspection interval (hours)
Remarks 8 100 250 500 1000 1500 2000
1 Oil level inspection of hydraulic oil
2 Sediment inspection of hydraulic oil tank
3 Replace the return oil filter element
4 Replace the pilot filter element
5 Replacement of the air cleaner
6 Replacement of the hydraulic oil 800 L
7 Oil leak and damage
inspection of pipelines and joints
8 Air cleaner block inspection
9 Oil leak of oil cooler and damage inspection
10 hydraulic motor, oil leak
of pump and unusual sound inspection
11 Oil leak of hydraulic valve inspection
12 Oil leak of accumulator and damage inspection
Note: The sign indicates initial replacement. The sign indicates
that the inspection is required. The sign indicates periodic
replacement.
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4.9.2 Inspection of the oil level of the hydraulic tank
The level of hydraulic oil must be checked every 8 hours, and
the status of hydraulic oil is inspected as described the following
table.
Table 4 - 005 Decision of hydraulic oil status
Mixing of
foreign objects
Spares Determination Determination method Dust and
metal powder
from outside
Test tube (transparent)
and fresh hydraulic oil
Appearance comparison
In the state of starting up the engine, take the sample from
hydraulic oil tank or pipeline, and compare it with fresh oil for
its turbid condition.
Water
Test tube or transparent containers,
fresh oil
Appearance comparison and heating estimation
Oil within the hydraulic oil tank becomes opaque. Heat up the
opaque oil sample to see the settled
water at the bottom. Take out the opaque oil sample and insert
the red-hot bar iron. Then
sizzle is generated. Dropping the opaque hydraulic oil on a
heated iron plate will also
sizzle. Before starting the engine, unscrew the oil drain valve
of the hydraulic oil tank. Take out the
oil sample, and then observe the subsidence situation of
water.
Degradation
Test tube or transparent containers,
fresh oil
Appearance estimation
and sensation estimation
Take the oil sample from the hydraulic oil tank or the pipeline,
inject it into the container, and
compare its color and odor (smell) with the fresh oil. Oxidation
and deterioration oil will turn to black brown, and badly
degenerative oil will
stink.
a) Before starting the engine, check the oil level in the
hydraulic oil tank. The level displayed on the liquid level meter
below the visual position indicates insufficient hydraulic oil of
the hydraulic system. Fill the hydraulic oil till it reaches the
visual position, and then start the engine.
b) If the oil in the oil tank reduces fast, check the hydraulic
pipelines and elements, find the leak position, and stop the
leakage before starting the engine.
c) Over temperature (above 80 C) of hydraulic oil will
accelerate the degradation of hydraulic oil and shorten the service
life of hydraulic elements. Low temperature (below 20 C) indicates
that the flow of hydraulic oil is poor, and an overhasty operation
may damage hydraulic elements. Therefore, after starting the engine
at low temperature, preheat it to make the temperature of hydraulic
oil reach around 20 C.
d) Refer to the following table for the inspection after
starting the engine.
Table 4 - 006 Inspection after starting the engine
Inspection items Inspection method Determination Purpose
Hydraulic oil temperature
Visual inspection hydraulic oil tank thermometer
Normal temperature from + 30 C to + 80 C
Find the abnormality of the hydraulic system at early
stage, and extend the service life of hydraulic
components.
Oil leakage Visual inspection No leakage allowed Find the
leakage at early stage.
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Inspection items Inspection method Determination Purpose
Pump temperature Infra-red thermometer
Temperature is 5 C higher than the oil tank
Find the abnormality of pump at early stage.
Pump noises Sensation (volume/acoustic) Abnormal sound/change
of
noises
Find the abnormal change of the hydraulic oil,
entrained air, wear of pump and filter blocking.
Motor temperature and noises
Hand touch/sensation (volume/acoustic)
Abnormal sound/change of noises
Find the abnormality of the motor at early stage.
Remarks Hydraulic oil cannot be used permanently. Therefore, it
must be inspected and replaced in
accordance with whether impurities have been mixed into the
hydraulic oil or the degradation degree.
4.9.3 Replacement of the return filter
A signal on the pressure switch of a filter element of the
return filter indicates that the filter element is blocked. In such
a situation, replace the filter element.
a) Unscrew the filter cover (cleaning cover) of the return
filter, and replace the filter element or refuel the oil tank. Set
two M18*1.5 oil ports at the filter head, and install the pinger at
any part.
b) Replace the filter element of the return filter every 500
hours, with the initial replacement subject to 50 hours.
Fig. 4-015 Diagram of hydraulic oil tank
Air cleaner
Oil tank Liquid
thermometer
Butterfly valve
Return filter
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Fig. 4 - 016 Diagram of return filter
When replacing the filter element, do not install it reversely
to avoid serious consequences.
4.9.4 Replacement of the air cleaner
In hydraulic system, the air cleaner of oil tank needs to be
checked on time subject to every hydraulic oil adding for the
hydraulic system. Inspect the hydraulic system, clean the dirt on
it in time, and replace the damaged one if any.
Fig. 4 - 017 Diagram of air cleaner
1. Open the cover of the air cleaner while injecting the
hydraulic oil.
Cleaning cover of return filter, unscrew and replace the filter
element.
2. Check the air cleaner after injecting the hydraulic oil.
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4.9.5 Cleaning of the filter element
Inspect the filter, find the dirt on it, and then clean the
filter in time.
Steps for cleaning:
a) Take out the filter with a special-purpose wrench.
b) Clean the filter element with dedicated cleaning solution or
clean diesel.
4.9.6 Change of the hydraulic oil
Before delivery, the hydraulic oil tank of this product is
filled with 800-liter hydraulic oil whose oil grade is GB11118.1-94
L-HV32, L-HM46, L-HM68, or HS 0358-95 aviation hydraulic fluid 10#
subject to the regional work.
Inspection and replacement cycle of hydraulic oil:
The normal replacement cycle for hydraulic oil is 2,000 working
hours. If it is obviously dirty, replace it immediately regardless
of the running time. Inspection items and replacement cycle for
hydraulic oil are as follows:
Table 4 - 007 Inspection items and replacement cycle for
hydraulic oil
S/N Inspection items Inspection and replacement cycle (hour)
Remarks 5 500 2,000
1 Inspection of the oil level Main oil tank
2 Oil tank cleaning
3 Change of the hydraulic oil 800 Liters
Oil level inspection of hydraulic oil:
Check the oil level when the crane is traveling. The liquid
thermometer is provided with scales through which you can check the
temperature of hydraulic oil and the oil level. The lowest oil
level line is the 0 C scale mark. Thus, an oil level of lower than
0 C scale mark indicates that the hydraulic oil should be
supplemented.
Oil change steps:
a) Drain the hydraulic oil in oil tank.
b) Dismantle the general return oil pipe, clean the oil tank and
filter carefully. Specifically, clean the oil tank and filter with
the chemical cleaning agent whose solid contamination degree does
not exceed 18/15. After cleaning and airing them, clean them with
fresh hydraulic oil whose solid contamination degree does not
exceed 18/15.
c) Drain the flushing oil and fill in fresh hydraulic oil
again.
d) Start the engine, run the engine in low velocity to energize
the oil pump.
e) Manipulate each mechanism respectively and drain the used oil
of each loop of the system one by one on the basis of fresh
hydraulic oil. The used oil drained cannot flow into the hydraulic
oil tank.
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f) Stop the oil pump when there is fresh oil flowing out from
the general return oil pipe.
g) Connect the general return oil pipe with oil tank and set
each element to initial working state at last.
h) Supplement hydraulic oil for the oil tank until it reaches
the visible window of the liquid level meter of hydraulic oil
tank.
Precautions for replacement:
a) Do not use the hydraulic oil for more than 24 months.
b) Filter or replace hydraulic oil in time upon heavily
contaminated hydraulic oil.
c) Select appropriate hydraulic oil in accordance with the
ambient temperature.
d) Do not mix the hydraulic oil of different grades.
e) When changing the oil, flush all of the original oil, and do
not allow sundries like sand and dirt entering the oil tank.
f) When changing oil at each loop, constantly add fresh oil into
the hydraulic oil to avoid empty oil pump.
g) When starting the engine at cold areas, ensure that the
minimum temperature for starting is reached, and start the engine
in no-load state. After the temperature of the no-load system
reaches the minimum temperature required for running, slowly apply
load to the system, and keep the system running at the temperature
on the minimum load.
4.9.7 Cylinder inspection
Check for the oil leakage at the installation oil port and
nearby pipelines of each hydraulic oil cylinder, and the scratches
on the extension of piston rod.
4.9.8 Installation of the pipeline
When installing a hydraulic pipeline, pay attention to the
following items:
a) Avoid distortion of a hose.
Fig. 4 - 018
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b) Ensure sufficient radius of bending.
Fig. 4 - 019
c) Use elbow and other connectors when necessary.
Fig. 4 - 020
d) Allow certain looseness to offset the shrinkage of the hose
under pressure.
Fig. 4 - 021
e) Ensure fixed position of a hose with a clamp.
Incorrect
Correct
Correct Incorrect
Correct
Incorrect
Incorrect
Correct
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Fig. 4 - 022
4.10 Maintenance of the electrical system
4.10.1 Inspection of the lighting system
Check for normal operation of the illumination system.
As shown in the figure on the right (e.g.: aviation lighting
devices)
4.10.2 Inspection of windshield wipers in the operator's
cab as well as cleaning solution
Check for normal operation of the windshield wiper weekly.
Location of sprayer is at the left rear side of the cab
seat.
Add water into the sprayer constantly, and add a little cleaning
agent when necessary.
4.10.3 Inspection of the video monitoring system
The monitor system is optional. If the monitor system is
equipped, check for normal operation of the monitor system camera
and the definition of LED image in the operators cab before using
vehicles.
Fig. 4-023
Fig. 4 - 025
Incorrect
Correct
Fig. 4 - 024
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4.10.4 Battery inspection
Batteries must be well maintained and kept for use, because they
function as the power supply of starting the engine, electrical
control system, illumination and electrical auxiliary devices of
the machine.
a) Store the battery (a filled and charged lead-acid battery) at
the temperature ranging from 5 C to 25 C and in a dry, clean and
ventilated environment. Do not expose the battery to direct
sunshine to avoid degradation of the performance caused by high
ambient temperature.
b) Do not inverse and place the battery horizontally. Do not
shock and press the battery mechanically.
c) Recharge the battery in time to avoid performance degradation
caused by the sulfating of the battery.
d) Do not overcharge the battery. Avoid premature failure of the
battery caused by too much water loss, growth of grid and drop of
diachylon.
e) Remove the batteries from the car and store them in a
well-ventilated and dry place if they are used for long time
(usually more than 15 days). Charge the batteries every 3-6 months
(see if the indicator is black or not).
This series of lead-acid batteries for cars is the dry charged
batteries produced in accordance with JIS Japan and DIN Germany.
Dry charged batteries can start the car in 30 minutes after
injecting the electrolyte. If possible, charging for 3 - 5 hours
before use will result in a better starting performance.
Preparation before use:
a) Make sure the level of electrolyte is 10 mm higher than the
minimum waterline.
b) Make sure the blow cock is crewed in case of acid
leakage.
c) Check the air hole of the blow cock to ensure a smooth
venting.
d) Pay attention to the positive and negative poles when
connecting wires to avoid reverse connections.
Storage and maintenance:
a) The storage battery should be stored in a clean, dry, and
ventilated storeroom at ambient temperature ranging from 5C to 40C.
Be sure not to unpack the sealing bar or blow cock of the dry
charged battery before use.
b) Under exceptional circumstances, the storage battery should
be stored in company with electrolyte and be charged monthly
through common charging method. The liquid level and density of
electrolyte should also be regulated as required, and the density
of electrolyte is 1.280.01g/cm3.
c) Do not prepare the electrolyte with river water, well water
or water containing impurities. When using a battery, keep the
external and wiring of the battery dry and clean.
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d) After discharging battery, charge it in time to avoid
long-term idleness.
e) Open the blow cock while it is charging and screw up the blow
cock before use.
f) Do not smoke and light fires at the charging site.
Exterior charging is required under the following
circumstances:
a) The density of electrolyte falls to 1.170 and below.
b) Brownout.
c) Under-voltage, the voltage of the battery is under 0.8 V.
4.10.5 Inspection of the limit switch
Provide references for crane operators by real-time monitoring
the working condition of the crawler crane, and displaying the
condition on the moment limiter. In abnormal working condition, the
crawler crane generates an alarm by an icon flashing on the system
display interface, and interrupts the operations that could
increase the danger.
1Hoisting winch 1 over-winding alarm
Over-winding of the hoisting winch 1 is also known as the main
hook reaching the upper limit. By this time, the corresponding
alarm indication blinks in the display, along with audible alarm.
Meanwhile, the reel in movement of hoisting winch 1 and reel out
movement of derricking winch will be cut automatically, and the
bypass key switch operation is effective.
2Hoisting winch 1 over-release alarm
Over-release of the hoisting winch 1 is also known as only three
circles of wire ropes left on the hoisting winch 1. By this time,
the corresponding alarm indication blinks in the display, along
with audible alarm. Meanwhile, the reel out movement of hoisting
winch 1 will be cut automatically, and the bypass key switch
operation is effective.
3Hoisting winch 2 over-winding alarm
Over-winding of the hoisting winch 2 is also known as the
auxiliary hook reaching the upper limit. By this time, the
corresponding alarm indication blinks in the display, along with
audible alarm. Meanwhile, the reel in movement of hoisting winch 2
and reel out movement of derricking winch will be cut
automatically, and the bypass key switch operation is
effective.
4Hoisting winch 2 over-release alarm
Over-release of the hoisting winch 2 is also known as only three
circles of wire ropes left on the hoisting winch 2. By this time,
the corresponding alarm indication blinks in the display, along
with audible alarm. Meanwhile, the reel out movement of hoisting
winch 2 will be cut automatically, and the bypass key switch
operation is effective.
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5Main boom 80 alarm
When the elevation angle of the main boom reaches 80, and limit
switch at the root of main boom is closed, the corresponding alarm
indication blinks in the display, along with audible alarm.
Meanwhile, the reel in movement of derricking winch will be cut
automatically, and the bypass key switch operation is
ineffective.
4.10.6 Inspection of cable terminals and dust guards
Every dismantling of the basic machine and site transport
requires the inspection for whether the cable terminal is aligned
and plugged tightly and whether the dust guard is well covered.
4.10.7 Prevention of electrical parts or cables from catching
fires
Fire of the electrical parts or cables can be prevented, and
effective measures can be taken to avoid such danger.
Precautions:
a) Inspect or exam the electrical devices of the crane
regularly. Find out the cause for faults like loose connection and
cable heat, etc., and troubleshoot these devices immediately.
b) Check all cables, connectors and terminals for looseness or
damages (see if there is any oxides formed on both poles of the
terminal or battery), and rectify all confirmed faults
immediately.
c) Use the original spare parts and original fuse in compliance
with the specified rigidity only.
d) Close the crane immediately in case the power fails.
e) No unauthorized replacements, supplements or modifications
toward the electrical system are allowed unless approved by the
manufacturer.
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4.11 Maintenance of hooks and pulleys
Since the service condition of the main hook varies from day to
day, inspection is required every day (starting with duty
shifting). Pay attention to observe any defect that could affect
the security before and in the process of the operation.
4.11.1 Daily maintenance of hooks
Daily inspection and maintenance involve the following
items:
Wipe the main hook clean.
a) Lubricate the pulleys, rotating parts and other parts with
the grease nipples.
b) Inspect all bolts and screws, and make sure all cotter pins
are complete and the openings are opened.
c) Check for the uniformity of pulley race and rim wear, the
matching of wire rope and pulley race and looseness or shaking of
the pulley.
d) Make sure that the rotating part of the hook moves freely and
the spacing is not large. Any feeling of difficulty or jamming
requires the inspection for bearing and shaft sleeve damage or
insufficient lubrication.
e) Inspect the overload damage of the main hook.
f) Inspect the elongation of side plate, extension of bore
diameter, and bending, elongation or cracking of bolt.
g) Inspect the safety catch.
Fig. 4 - 026 Hook
Pulley
Pulley spindle
Safety catch
Hook body
Side plate
Bearing
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4.11.2 Pulley inspection
Fig. 4 - 027 Pulley
Check all pulleys for damages like fractures, diagonal plane or
similar damages.
Scrap or replace the pulleys immediately upon the following
damages:
a) Cracks, rim damages or relatively serious wear.
b) The wear extent of the pulley groove wall reaches 80 % of the
original wall thickness.
c) The wear extent of the pulley groove bottom exceeds 25 % of
the diameter of the wire rope.
d) Other defects that damages the wire rope.
Pulley groove must be larger than the diameter of the wire rope.
Too thick a wire rope will fracture the rim of pulley and increase
the wear of the wire rope and the pulley.
4.11.3 Inspection of rolling bearings on the pulleys
The following inspections are conducted annually for all
pulleys:
a) Surplus of grease.
b) Sealing socket for bearing.
c) Running noise and rolling resistance.
The corresponding rolling bearing must be replaced in case
defects are detected.
4.11.4 Replacement of rolling bearings
We suggest a maximum running of 1,000 hours or replacing all the
rolling bearings of pulley in every 5 years.
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4.11.5 Pulley lubrication
Fig. 4 - 028 Schematic diagram for pulley lubrication
Each pulley has only one oil filling nozzle. Before the pulley
lubrication, wipe the nozzle, clean and inject the grease with
grease gun until the fresh grease overflows from the end face of
bearing.
4.11.6 Inspection of the safety catch
The safety catch must be complete and undamaged so that it can
limit the loose lifting slings and other lifting devices on the
hook.
Safety catch cannot bear the load. Therefore, lifting slings and
other lifting devices cannot be hung on the safety catch.
4.11.7 Inspection of each hook body
The hook body must be inspected at least yearly using liquid
penetrate test, magnetic particle testing, ultrasonic flaw
detection or X - ray inspection, etc.
Fig. 4 - 029 Schematic diagram for hook body inspection
Wear/crack inspection
Deformation inspection
Oil passage
Rolling bearing
Oil filling nozzle
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Check the hook for deformation, local cold deformation and
extrusion, crack, wear and rust of clamping jaw. Lock the joint of
hook nut.
Deformation: The hook must be replaced if the falcula has
increased more than 10 % in comparison with the original size y.
The original size y is recorded on the hook. Conduct measurement
one by one.
Corrosion: Check the thread and shaft being operated for
corrosion and wear. Therefore, unscrew the hook nut on shaft.
If reprocessing is required to remove the corrosion, such
process should not make the diameter of the threaded core exceeds 5
%, otherwise the hook must be replaced.
(1). Do not use the hook with defects.
(2). Do not repair the hook by welding.
4.12 Maintenance of wire ropes
4.12.1 Cleaning of wire ropes
For dirty wire ropes, their external surface should be cleaned
frequently. Especially, for the wire ropes that are used in a
corrosive environment or near chemical substances, dirt on the
surface should be removed in time.
4.12.2 Lubrication of wire ropes
The manufacturer has sufficiently lubricated wire ropes during
manufacture to prevent corrosion and reduce friction between wire
rope strands, wire ropes and pulleys, and wire ropes and drums.
When black spots or rust exist on the surfaces of wire ropes,
the wire ropes need secondary lubrication. Timely secondary
lubrication plays a positive role in extending the operating life
of wire ropes. The lubricating oil for secondary lubrication can
hardly penetrate and flow into wire ropes, so it should not be
applied excessively. Excessive lubricating oil will stay on the
surface of a wire rope, making the check for wire rope fracture
relatively difficult. It would be best to adopt acid-free grease as
the lubricating oil and the grease should be heated and diluted
before utilization.
Lubricating oil should be applied by the following means:
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Fig. 4 - 030 Schematic diagram for wire rope lubricating oil
application method
4.12.3 Inspection of wire ropes
The working life of a wire rope is different based on the
operating condition of the machine. Wire ropes for both lifting and
derricking must be strictly inspected regularly to find abrasion
and damage in time.
Parts to be inspected:
a) Overall length of a wire rope;
b) The part which bends most frequently on a pulley or drum;
c) The parts which bend on pulleys or drums at the moment when
load is lifted;
d) In the multi-layer winding system, the part where a wire rope
contacts a drum flange, and the transboundary zone where the upper
wire rope crosses the lower wire rope.
Inspection interval
It is recommended to inspect whether damage exists on wire ropes
and ending joints.
For the beginning weeks after new wire ropes are installed and
the fracture occurs for the first time, the inspection interval is
shorter than that in other time periods. When overload occurs or
suspicious damage which can not be seen is detected, the inspection
interval should be shortened accordingly.
In addition, when operation ceasing duration is extended and the
wire rope transmission gear is re-installed, or when winch
equipment is disassembled and re-installed at a new location, or
when an accident happens or damage exists during the operation of
wire ropes, the inspection must be performed.
4.12.4 Replacement standards of wire ropes
Wire ropes are always damaged as a result of the combination and
accumulation of kinds of factors. The executive staff should judge
the cause and decide whether the wire rope should be discarded or
be used continuously.
For the damage of a wire rope, inspection personnel should
firstly investigate whether it is caused by the defect of
equipment, and if so, such defect should be eliminated before the
wire rope is replaced.
By brush By cotton yarn By cotton yarn
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Whether the wire rope should be replaced may be decided based on
the following factors. Refer to relevant Chinese National Standards
(GB/T 5972) and ISO standards (ISO 4309).
a) Fractured wire: In case more than 10% of the single wires
(excluding filling wires) of a wire rope within one lay length
fracture, for the wire rope with multilayer strands (typical multi
strand structure), fractured wires mainly exist inside, making such
fracture invisible. In case lubrication at any local position
becomes dry or deteriorated, special attention should be paid;
b) Fractured line: In case fractured wires exist at or near the
end of the rope, even in a small number, it indicates that the
stress at such position is great. If the length of the rope
permits, the position of fractured wires should be cut out and
re-installation should be performed properly;
c) Local aggregation of fractured wires: In case fractured lines
cling together and aggregate in the range of the rope length less
than 6d (d: diameter of wire rope) or exist almost in one strand,
even though the number of fractured wires is small;
d) Increase of fractured wires: Fractured wires would appear
after a wire rope has been used for a period of time, the number of
fractured wires will increase gradually, and the interval will be
shorter and shorter.
e) Abrasion: Abrasion reduces the sectional area of a wire rope
resulting in lower strength; when the external wires are abraded to
4% of its diameter, or when the diameter of the wire rope is
reduced by 7% compared with the nominal diameter;
f) Fr