ZOOMLION CRAWLER CRANE ZCC800HWG Maintenance Manual

Vision creates future
Profession Heavy-industry Science & technology
Maintenance and Service Manual
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:410131
Service-hotline:400-800-1680
Fax:0086-0731-85585850
E-mail:sc@zoomlion.com
Website:www.zoomlion.com
ZCC800H
800H CRAWLER CRANE
MAINTENANCE AND SERVICE

MANUAL
The 1st edition (April, 2013)
Crawler Crane
For you
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.
Crawler Crane
Special information
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.
ZCC800HWG Crawler Crane
Contents
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
III
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
IV

for Crawler Crane
Chapter 1 About this manual
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

01 - 1
Chapter 1
1.1 General
Chapter 1
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
instructions involved in the book are only the conventional contents.
, the safety
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.
01 - 2

for Crawler Crane
Chapter 2 Safety instructions
2.1 Safety guidelines
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.
02 - 1
Chapter 2
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.
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.
Chapter 2
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.
02 - 2

for Crawler Crane
Chapter 3 Description of the crane
3.1 Description of main components
Tip boom
Main boom anchoring rods
Auxiliary
load hook
Wire rope for hoisting winch 1
Main load hook
Chapter 3
Wire rope for hoisting winch 2

Derricking pulley block
Main boom
A-frame
Main
boom
tilting-back support
Rear anchoring
rods of A-frame
Travel gear
Fig. 3-001 Overview of crawler crane
03 - 1
Left crawler
carrier
Slewing mechanism
Operators
cab
Fuel tank
Chapter 3
Main valve
Hoisting
winch 1
Oil cooling fan
Hoisting
winch 2
Hydraulic oil
tank
Engine system
Right crawler carrier

Main boom derricking
winch
Oil pump
Counterweight
Fig. 3-002 Overview of crane undercarriage
03 - 2
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
Hoisting
motor
winch
Reducer
Reducer
Traveling motor (R)
Engine
Triple valve
Hoisting
motor
winch
Derricking motor
Slewing pump
Triple gear pump
Slewing motor
Reducer
1
Chapter 3
Main pump
Dual valve
Traveling motor (L)
Reducer
Reducer
Reducer
Cooling motor
Control valve block
Fig. 3-003 Hydraulic system diagram
03 - 3
3.2.2 Arrangement of hydraulic elements in slewing table
Derricking brake valve
Ratchet control valve
Winch brake valve
Outer brake valve
Slewing valve
Slewing brake solenoid valve
Chapter 3
Slewing cushion valve
Hydraulic oil tank
Oil radiator
Control valve
Triple main valve
Dual main valve
Travel control valve
Control valve block
Energy
accumulator
Central revolving joint
Solenoid
valve
Pump unit
Pilot control valve
Clutch control solenoid valve
Fig. 3-004 Arrangement of hydraulic elements
03 - 4
Pilot oil filter
3.3 Electrical system
Chapter 3
3.3.1 Electrical system diagram
Fig. 3-005 Electrical system diagram
03 - 5
3.3.2 Arrangement of electrical elements in slewing table
Fig. 3-006 Arrangement of electric elements
Chapter 3
Junction box 2
Junction box 1
Video camera
Working floodlight
Main boom angle limit switch
03 - 6
To connector on boom
Horn
Traveling alarm
Slewing limit switch

Battery
Electrical
control box
Battery master switch
Oil level sensor
Lowering limiter for

hoisting winch 1
Lowering limiter for

hoisting winch 2
Junction box 3
Shutoff valve limit switch

Slewing alarm
Slewing alarm
03 - 7
Chapter 3
Inclinometer
Working floodlight
Chapter 3
Tricolor light
Junction box 3
03 - 8

for Crawler Crane
Chapter 4 Maintenance and service
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
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.
04 - 1
Chapter 4
General precautions during the maintenance work are described as follows:
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.
Use the clean lubricating grease.
Chapter 4
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.
04 - 2
(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
Chapter 4
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
04 - 3
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.
Prevent the intrusion of dusts.
Chapter 4
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.
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.
04 - 4
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.
Treatment of the waste oil
Unprofessional personnel are forbidden to servicing the cranes or replacing parts

for them.
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 1 st 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.
04 - 5
Chapter 4
Put the waste oil into the vessels and treat it as industrial emissions.
Table 4 - 001 Maintenance cycle

Operating time
(hours)
Maintenance type
Daily inspection (D)
Maintenance cycle
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
Maintenance
No.
Working task
Maintenance of
the power
system
Daily inspection of
4.5.1
the engine
Inspection of the
4.5.2 engine operation
status
Maintenance of
4.5.3
the engine
Cleaning of the air
4.5.4
suction filter
Replacement of
4.5.5 the air suction
filter elements
Inspection of the
cooling fluid
(antifreeze fluid)
4.5.6
level and
supplementation
of the cooling fluid
Change of the
4.5.7
cooling fluid
Inspection of the
4.5.8
fuel pipeline
Drainage and
discharge of the
4.5.9
oil-water
separator
Cleaning of the
4.5.10
fuel tank
Maintenance of
4.6
the reducer
Inspection of the
4.6.1
oil level
Change of the
4.6.2
gear oil
Inspection
Annual
Monthly
Quarterly Semiannual
Daily
Weekly
maintenance
maintenance maintenance maintenance
inspection inspection
M
M1
M3
M6
D
W
12
Chapter 4
4.5
04 - 6
(as required in the maintenance manual of the engine)
2 years
Maintenance
4.6.3
4.6.4
4.6.5
4.6.6
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7
4.9.8
4.10
Working task
Lubrication of
bearings of the
reducer
Inspection of
brakes of the
winch reducer
Inspection of
securing bolts
Inspection of
brake straps of
the hoisting winch
1 with free-fall
function
Maintenance of
the slewing ring
Routine
inspection
Lubrication of the
gear surface
Lubrication of the
raceway
Annual
Monthly
Daily
Weekly
maintenance
M
M1
M3
M6
D
W
12
Inspection of the
slewing ring bolt

Maintenance of
the crawler travel
Regular
inspection
Cleaning of the
crawler
Lubrication of the
crawler pin
Tension of track
pad
Maintenance of
hydraulic system
Routine
inspection of Multiple items
hydraulic system
Inspection of the
oil level of the
hydraulic tank
Replacement of
the return filter
Replacement of
the air cleaner
Cleaning of the
filter element
Change of the
hydraulic oil
Cylinder
inspection
Installation of the
pipeline
Maintenance of
the electrical
system
Chapter 4
No.
Inspection
2 years
In time
04 - 7
Maintenance
No.
Working task
Inspection
Annual
Monthly
Daily
Weekly
maintenance
M
M1
M3
M6
D
W
12
Inspection of the
lighting system
Inspection of
windshield wipers
4.10.2 in the operator's
cab as well as
cleaning solution
Inspection of the
4.10.3 video monitoring
system
4.10.1
4.10.4 Battery inspection

4.10.5
4.10.6
4.10.7
Chapter 4
4.11
4.11.1
Inspection of the
limit switch
Inspection of
cable terminals
and dust guards
Prevention of
electrical parts or
cables from
catching fires
Maintenance of
hooks and
pulleys
Daily
maintenance of
hooks
Upon the basic machine disassembly or site transition every time
Upon the basic machine disassembly or site transition every time
4.11.2 Pulley inspection
Inspection of
4.11.3 rolling bearings on
the pulleys
Replacement of
4.11.4
rolling bearings
4.11.5 Pulley lubrication
Inspection of the
safety catch
Inspection of each
4.11.7
hook body
Maintenance of
4.12
the wire rope
Cleaning of wire
4.12.1
ropes
Lubrication of wire
4.12.2
ropes
Inspection of wire
4.12.3
ropes
4.11.6
4.13
In time
In time
Air conditioner
Daily
4.13.1 maintenance of air
conditioners
Maintenance of air
4.13.2 conditioners in low
seasons
Regular
4.13.3 inspection of air Multiple items
conditioners
04 - 8
Maintenance
No.
Working task
4.15
4.15.1
4.15.2
Inspection
Annual
Monthly
Daily
Weekly
maintenance
M
M1
M3
M6
D
W
12
Structure
component
Rotary table
inspection
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.
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.
04 - 9
Chapter 4
Items to be inspected:
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.
Chapter 4
4.5.4 Cleaning of the air suction filter

When the engine is at the rated rotational speed, if the pointer of the air filters 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.
04 - 10
The schematic diagram for the cleaning process is as follows:
b) Blow the compressed air over the filter

element surface.
Chapter 4
a) Shack off the dusts on the filter element.
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.
04 - 11
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.
Chapter 4
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.
04 - 12
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
Chapter 4
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.
04 - 13
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.
Chapter 4
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
04 - 14
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.
Mechanism name
Hoisting winch
reducer
Derricking winch
reducer
Slewing reducer
Travelling reducer
Gear transfer box
Oil change cycle and oil change amount of each mechanism

Gear oil grade
L-CKD220 industrial enclosed

gear oil
gear oil
gear oil
gear oil
gear oil
Inspection
interval
(hours)
Oil change
interval (hours)
Oil change
amount
(L/each)
250
1,000
250
1,000
250
1,000
5.5
250
1,000
10
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.
04 - 15
Chapter 4
Table 4 - 003
4)
Inspect the cleaning status and tighten the plug screw of the oil filler at the
upper end.
Inject oil after the plug screw is unscrewed.
When oil is injected, this plug screw at the sight hole
shall 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.
Fig. 4 - 010
Chapter 4
b)
Schematic diagram for change of the gear oil
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.
Unscrew the oil drain rubber

tube plug screw
Inspect the oil level
Fig. 4 - 011
04 - 16
Schematic diagram for change of the gear oil
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.
The oil cup for lubricating
grease injection
Fig. 4 - 012
Chapter 4
Direction A (enlarged)
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.
04 - 17
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.
Chapter 4
The adjusting nut and

con-rod of the brake strap
Rivet
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.
04 - 18
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.
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 1 st 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.
04 - 19
Chapter 4
4.7.3 Lubrication of the raceway
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.
Chapter 4
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.
04 - 20
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.
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.
04 - 21
Chapter 4
Adjustment steps:
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
S/N
1
2
3
4
5
6
Chapter 4
7
8
9
10
11
12
Inspection and
maintenance items
Oil level inspection of
hydraulic oil
Sediment inspection of
hydraulic oil tank
Replace the return oil
filter element
Replace the pilot filter
element
Replacement of the air
cleaner
Replacement of the
hydraulic oil
Oil leak and damage
inspection of pipelines
and joints
Air cleaner block
inspection
Oil leak of oil cooler and
damage inspection
hydraulic motor, oil leak
of pump and unusual
sound inspection
Oil leak of hydraulic
valve inspection
Oil leak of accumulator
and damage inspection
Inspection period of the hydraulic system

8
100
Inspection interval (hours)

250
500
1000
1500
2000
Remarks
800 L
Note: The sign indicates initial replacement. The sign indicates that the
inspection is required. The sign indicates periodic replacement.
04 - 22
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.
Dust and
metal
powder
from outside
Mixing
of
foreign
objects
Water
Degradation
Spares
Test tube
(transparent)
and fresh
hydraulic oil
Decision of hydraulic oil status
Determination
Determination method
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.
Test tube or
transparent
containers,
fresh oil
Appearance
comparison
and heating
estimation
Test tube or
transparent
containers,
fresh oil
Appearance
estimation
and sensation
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.
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
items
Inspection after starting the engine
Inspection method
Determination
Hydraulic oil
temperature
Visual inspection hydraulic

oil tank thermometer
Normal temperature from +

30 C to + 80 C
Oil leakage
Visual inspection
No leakage allowed
Purpose
Find the abnormality of the
hydraulic system at early
stage, and extend the
service life of hydraulic
components.
Find the leakage at early
stage.
04 - 23
Chapter 4
Table 4 - 005
Inspection
items
Pump
temperature
Inspection method
Determination
Purpose
Infra-red thermometer
Temperature is 5 C higher
than the oil tank
Pump noises
Sensation
(volume/acoustic)
Abnormal sound/change of
noises
Find the abnormality of

pump at early stage.
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
Remarks
Find the abnormality of the

motor at early stage.
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.
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.
Chapter 4
a)
Return filter
Air cleaner
Liquid
thermometer
Oil tank
Butterfly
valve
Fig. 4-015 Diagram of hydraulic oil tank
04 - 24
Cleaning cover of
return filter, unscrew
and replace the filter
element.
Fig. 4 - 016 Diagram of return filter
When replacing the filter element, do not install it reversely to avoid serious
consequences.
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.
1. Open the cover of the air

cleaner while injecting the
hydraulic oil.
2. Check the air cleaner

after injecting the hydraulic
oil.
Fig. 4 - 017 Diagram of air cleaner
04 - 25
Chapter 4
4.9.4 Replacement of the air cleaner
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
Chapter 4
S/N
Inspection items and replacement cycle for hydraulic oil
Inspection of the oil

level
Oil tank cleaning
Change of the
hydraulic oil
1
2
3
Inspection and replacement cycle (hour)

5
500
2,000
Inspection items
Remarks
Main oil
tank
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.
04 - 26
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.
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
04 - 27
Chapter 4
Precautions for replacement:
b)
Ensure sufficient radius of bending.
Incorrect
Incorrect
Correct
Correct
Fig. 4 - 019
c)
Use elbow and other connectors when necessary.
Chapter 4
Incorrect
Correct
Fig. 4 - 020
d)
Allow certain looseness to offset the shrinkage of the hose under pressure.
Correct
Incorrect
Fig. 4 - 021
e)
04 - 28
Ensure fixed position of a hose with a clamp.
Incorrect
Correct
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)
Chapter 4
Fig. 4-023
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.
Fig. 4 - 024
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 - 025
04 - 29
4.10.4 Battery inspection
Chapter 4
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.
04 - 30
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.
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.
04 - 31
Chapter 4
1Hoisting winch 1 over-winding alarm
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.
Chapter 4
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.
04 - 32
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.
Pulley
Pulley
spindle
Side plate
Bearing
Safety catch
Hook body
Hook
Chapter 4
Fig. 4 - 026
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.
04 - 33
4.11.2 Pulley inspection
Fig. 4 - 027
Pulley
Check all pulleys for damages like fractures, diagonal plane or similar damages.
Chapter 4
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.
04 - 34
4.11.5 Pulley lubrication
Oil filling
nozzle
Fig. 4 - 028
Oil passage
Rolling bearing
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
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.
Deformation
inspection
Wear/crack inspection
Fig. 4 - 029
Schematic diagram for hook body inspection
04 - 35
Chapter 4
The safety catch must be complete and undamaged so that it can limit the loose lifting
slings and other lifting devices on the hook.
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
Chapter 4
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:
04 - 36
By cotton yarn
By brush
Fig. 4 - 030
By cotton yarn
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.
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.
04 - 37
Chapter 4
Parts to be inspected:
Chapter 4
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).
04 - 38
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)
Fracture of rope strands: In case an entire rope strand fractures, it is caused

by the damage of rope core resulting in reduced rope diameter;
g)
Reduction of elasticity: Rope diameter reduces, the lay length of a wire rope
extends, parts press tightly against each other and space between wires and
between ropes is inadequate. These phenomena indicate the reduction of
elasticity. At this moment, although no fractured wire exists, the wire rope is
obviously difficult to be bended, which may abruptly break and should be
discarded immediately;
h)
Corrosion: When severe corrosion occurs at inside and outside of a wire

rope;
i)
Distortion: Distortion of wire ropes are disposed of by the following means:
Wave
In case of d14d/3, with the

length of a wire rope not
more than 25d, the wire rope
should be discarded as
useless, where d is the
nominal diameter of the wire
rope; and d1 is the envelope
diameter after the wire rope
distorts.
Cage distortion
Discard as useless
immediately
Strand extrusion
Discard as useless
immediately
Single wire strand

extrusion
Discard as useless in case

distortion is severe
Multiple wire strands

extrusion

distortion is severe
The diameter of rope

increases at some
positions
In case the diameter of rope

increases greatly at some
positions, the rope should be
discarded as useless without
delay
The diameter of rope

reduces at some
positions
In case the diameter of rope

reduces greatly at some
positions, the rope should be
discarded as useless without
delay
Part positions are

flattened

the flattening is severe
Twist

the flattening is severe
Bending
Discard as useless
immediately
04 - 39
Chapter 4
Table 4 - 008 Disposal of distortion of wire ropes
Damages caused by
the action of heating
or electric arc

of any color change
4.13 Maintenance of air conditioning equipment
Chapter 4
4.13.1 Daily maintenance

a)
Regularly inspect the refrigeration equipment of the air conditioning system,

especially check whether pipe joints are loose, whether oil stains exist at the oil
seal of a compressor, and whether coupling screws are loose. If any, repair should
be performed in time;
b)
Regularly inspect wire joints to prevent looseness and exfoliation and avoid
accidents;
c)
Regularly remove dirty, sundries, etc. from the cooling fin of the condenser to
maintain a good heat dissipation effect;
d)
Keep the air interchange outlet unimpeded and do not put any substance at the air
outlet to prevent air circulation from being impacted which will lower the
evaporability of the evaporator and the refrigeration effect.
e)
Observe whether refrigerant is charged properly via the liquid window of the
reservoir (when the environment temperature is 30-35 C, and the engine speed is
1,600-1,800 RPM).
Appropriate
Excessive
Insufficient
Fig. 4 032
04 - 40
Schematic diagram for whether refrigerant injection is

appropriate
4.13.2 Off season maintenance

After the off season of air conditioner (winter) comes, air conditioners should be started
every week and operate for ten minutes to make refrigerant circulate so as to prevent
refrigerant leakage caused by dry shaft seal of compressor to keep the compressor in a
good condition and prevent such components as expansion valve, etc. from rusting.
When summer comes each year, the assembly of refrigerating system should be
comprehensively inspected, cleaned, checked for leakage and refrigerant should be
applied to ensure normal operation of the refrigerating system.
4.13.3 Contents of regular inspection and adjustment for air conditioners
Table 4 - 009 Contents of regular inspection and adjustment for air conditioners
Evaporator
cooling fin
Content
Inspect the looseness and damage conditions of pipelines and pipe
joints, and whether oil dirt exists on pipe joints. Oil dirt indicates
microscale leakage, and repair should be conducted.
Inspect whether dust and muddiness exist on the cooling fin, and
high pressure water should be utilized for washing if necessary
Inspect whether cleaning dirt exists and utilize compressed air to
blow off it
Compressor
Inspect the oil level of compressor and replace refrigerant oil
Once two
quarters
Check the pressure of high & low pressure ends
Once a quarter
Inspect, and adjust if necessary
Once a quarter
Inspect the operation condition of blower, charge lubricating oil and

no abnormal sound should exist on components during operation
Inspect whether bolts of assembly parts are loose, and if any,
fasten them.
Once three
quarters
Piping joint
Condenser
Pressure of high
& low pressure
ends
Electrical
components
Blower
Assembly parts
Time
Weekly
Weekly
Once a quarter
Once a quarter
4.14 Maintenance of the lubricating system

The basic machine lubricating system is a manual lubricating system, and lubrication
needs to be completed manually by an oil gun.
Precautions for oil filling:
a)
Mineral high quality grease which is pressed into oil gun or utilized mainly to
lubricate equipment should not be liquefied when temperature raises and should
not condense under freezing point;
b)
Lubricating grease with the same grade is required to be utilized, and it is forbidden
to utilize grease of different grades.
Before grease (lithium-based grease) is charged, the grease nipple should be

wiped to be clean.
04 - 41
Chapter 4
Inspection items
4.14.1 Grades of lubricating grease

Table 4 - 010 ZL-2 and ZG-3 lubricating grease recommended by our company
Parameters
Dropping
point
(C)
Type
Appearance
ZL-2 lubricating
grease
ZG-3 lubricating
grease
Smooth ointment with color from

light yellow to brown
Uniform ointment with color from
light to dark brown
Working
penetration
(1/10mm)
Moisture,
(%)
Max.
175
265~295
90
220~250
2.5
4.14.2 Injection method
Chapter 4
Daubing or injection by oil gun.
Fig. 4 - 031 Schematic diagram of lubricating grease injection

4.14.3 Injection position and cycle
Lubrication and maintenance for lubricating positions should be performed regularly to
ensure good operation of equipment.
4.14.3.1 Basic machine
The basic machine includes superstructure and lower structure. Lubricating points and
cycle are shown in the following table and figure:
Table 4 - 011
Super and lower structures lubricating grease injection table
S/N
Oil filling position
Ratchet latching
mechanism
Slewing ring
Winch bearing
4
5
6
Track carrier roller

Track roller
Driven sprocket
04 - 42
10/day
Oil filling interval (hour)

50/week 200/month 500/quarter
Remarks
Lubricating grease,
daub
Lubricating grease,
daub
Lubricating grease, oil
gun injection
GL-5 85W/90
GL-5 85W/90
GL-5 85W/90
Every week or 25
hours
Every week or 25
hours
Every day or 5
hours
Chapter 4
Every quarter or 500

hours
Fig. 4 - 032 Super and lower structures lubricating grease injection

4.14.3.2 Boom
Table 4 - 012
S/N
1
2
3
4
5
6
7
8
9
Boom system lubricating grease injection
Oil filling position

Main boom pivot section pin
spindle
A-frame movable pulley pin
spindle
Main boom tilting-back support
pin spindle
Hinge joint position of derricking
anchoring rod and A-frame shaft
Main winch, auxiliary winch and
derricking wire rope
Derricking pulley and pin spindle
Auxiliary hook shaft and bearing
Main hook shaft and bearing
Boom pulley and pin spindle
Oil filling interval (hour)

10/day
50/week
200/month
Remarks
Based on service
conditions
04 - 43
Chapter 4
Each month or 200 hours

According
to
service
conditions
Each week or 50 hours
Every day or 10 hours
Fig. 4 - 033 Boom system lubricating grease injection
(1) Before oil filling, wipe the oil cup and the surface where oil is to be applied to
make them clean.
(2) Lubricating grease should be also applied regularly for the sliding surface
which is not listed in the table.
(3) Lubricating grease with different grades should not be mixed to each other.
(4) For bush, axle and bearing, lubricating grease should be injected till the
original grease is extruded.
(1) Shut down the engine before lubricating.

(2) When one climbs a crane, it should be ensured that the ladder, platform and
railing are clean and dry, and he should wear safety belt to avoid
high-altitude falling resulted from wet and slippery conditions.
(3) Running counter to this stipulation may cause severe casualty.
04 - 44
4.15 Appearance inspection for structure components

Structure members are the bearing components of basic machine, hence structure work
inspection is necessary to be performed.
Recommended inspection cycle:
a)
Normally, inspection should be conducted once half a month or a month.
b)
When load of lifting operation 90% of the rated load, inspection should be
performed once respectively before and after the operation.
c)
Experts must be invited each year to inspect the anchoring rod once
Inspection items:
a)
Crack
b)
Distortion
The straightness tolerance of the main chord member of boom section shall be in line
with the attached table, and the straightness tolerance per meter of the web member of
boom section shall not be greater than 1.5mm.
Table 4 - 013
Rated value of boom section main chord member straightness
Length of boom section

Local straightness
tolerance
Overall length
straightness tolerance
3,000
3,000 6,000
Chapter 4
tolerance
>6,000
2 per meter
3
Attached:
Method to test boom section chord member straightness
u
Local straightness of chord member

As shown in the figure, put a 1-meter ruler close to the boom section chord
member from two directions with an angle of 90, and the difference between the
maximum space and the minimum space between the ruler and the pipe wall
should not be more than 2mm.
Maximum
Ruler
Minimum
Chord member
Ruler
Fig. 4 - 034 Chord member local straightness test schematic diagram
04 - 45
Overall length straightness of chord member

As shown in the figure, arrange a 0.49 - 0.52 mm wire rope along the direction of
length outside the chord member and 30mm away from the pipe end, with the
tension as 147 N.
Measure the horizontal distance from the wire to the chord pipe. The difference
between the maximum and the minimum should be in line with the requirements of
Table 4 - 013.
Minimum
Maximum
Turn the boom by 90, and repeat the above test for the same chord member.
Chord Wire rope

member
Chapter 4
Fig. 4 - 035 Chord member overall length straightness test schematic diagram
4.15.1 Turntable inspection
Key inspection position:
a)
Lug connecting to the boom, A-frame rear anchoring rod and front A-frame;
b)
Counterweight hanging point;
c)
Base plate connecting to the slewing ring;
d)
Joints of left & right wallboards and upper & lower cover plates;
e)
Reinforce the joints of U-bar and left & right wallboards (upper & lower cover
plates).
04 - 46
Fig. 4- 036 Turntable inspection schematic diagram
Chapter 4
4.15.2 Inspection of lower structure parts
Fig. 4 - 037 Crawler frame inspection schematic diagram
04 - 47
Fig. 4 - 038 Crawler frame lug

inspection schematic diagram
Fig. 4 - 039
Slewing ring bottom
inspection schematic diagram
4.15.3 Boom inspection
Chapter 4
Routine inspection:
a)
whether the rope support of boom head rotates smoothly;
b)
whether the boom pin spindle, anchoring rod and spring bolt are damaged or come
off;
c)
whether the phenomena of peeling and coming off exists on boom paint;
d)
whether the structure member distorts;
e)
whether the structure member possesses any crack;
f)
Other abnormities.
Corrosion prevention and lubrication:

a)
Paint surface: painting make-up should be performed based on needs;
b)
Mating surface: apply lithium-based grease.
(1) Before injecting lithium-based grease, wipe the grease nipple to make it clean;
(2) Before painting make-up, clean the surface.
04 - 48
Chapter 4
Fig. 4 - 040 Main boom welding line inspection schematic diagram
Fig. 4 - 041 Fixed jib welding line inspection schematic diagram
04 - 49
4.15.4 Anchoring rod inspection
Chapter 4
Overall length inspection must be performed for the anchoring rod when installation and
connection are conducted including the hidden surface and inner bores. The positions
of anchoring rod needing inspection are shown in the following figure.
Fig. 4 - 042 Anchoring rod inspection schematic diagram

Contents to be inspected include:
a)
Inspect whether any crack exist on the anchoring rod

1)
Regularly inspect whether any crack exist on the anchoring rod;
2)
The surface crack test should be conducted for at least yearly, such as
magnetic particle testing;
3)
In case any crack is found, the anchoring rod must be replaced in time;
4)
In case any bow A-frame possesses cracking welding line, it should be

replaced in time.
Do not perform repair work.
04 - 50
b)
Inspect the length of the anchoring rod

The length of anchoring rod must be measured to inspect the extension of the
anchoring rod. The maximum allowable extension of the anchoring rod is 0.2% of
the original length. For example, for the anchoring rod with the length as 5700mm,
the maximum extension is 11.4mm.
For the original length of each anchoring rod, please refer to Maintenance
and Service Manual for ZCC800H Crawler Crane.
c)
Inspect the abrasion of anchoring rod

Inspect whether any abrasion trace exists on the anchoring rod pin hole and
connecting pin spindle, including the spring bolt which is utilized to fasten the pin
spindle.
d)
Inspect the paintcoat of anchoring rod

Regularly inspect whether corrosion and coming off exist on the paintcoat of
anchoring rod, and in case of any corrosion pit, paint in time.
Inspect the plastic deformation of anchoring rod
Inspect whether the anchoring rod possesses twist, and in case of any twist, the
anchoring rod should not be utilized any more and should be replaced without
delay.
Inspection cycle:
Inspection should be conducted based on the conditions of operation area and the
actual operation situation. If utilization is frequent, the inspection cycle should be
shortened accordingly, and experts must be invited annually to conduct inspection
for anchoring rods.
In case the damages described above exist, replacement must be performed

immediately. An anchoring rod with any defect will cause a severe accident.
04 - 51
Chapter 4
e)

for Crawler Crane
Chapter 5 Troubleshooting
Some irregular phenomenon may occur during crane operation, therefore, checks must be
done in time to find true causes, and maintain the crane if necessary.
5.1 Troubleshooting of mechanical drive
The following table shows the troubles of mechanical drive and their solutions.
Table 5-001
Troubles
When crane is
traveling in straight
line, it deviates to one
side.
The traveling
resistance is large.
The crawler slips.
The track roller leaks

oil or it does not
rotate.
The drive sprocket is

meshed with track
pad irregularly
Causes
Solutions
1. The crawler tensions on

both sides are different from
each other.
1. Adjust the crawler tension.
2. The crawler is slack.
1. The crawler is tight.
2. The ground is soft.
2. Fill up the ground to make

it solid and flat.
2. The track pad is worn.
2. Change the track pad.
The track roller is mounted

unevenly, thus leading to the
deformation of sealing ring of
track roller.
Unscrew the bolt, pad a

1mm-thick iron plate under
the track roller, and then
tighten the bolt.
1. Tighten the crawler.
2. The drive sprocket is

meshed with track pad
improperly.
2. Grind and correct the top

edge of drive sprocket.
5.2 Troubleshooting of power system

Chapter 5
X
X
X
X
X
X
No.
The following table shows the troubles of power system and their solutions.
Table 5-002
No.
Troubles
Causes
The starting motor

does not rotate or it
rotates weakly.
1. The battery is charged

insufficiently.
2. The wire connected to
starting motor has come
loose.
3. The solenoid switch of
starting motor fails.
1. The fuel tank is empty.
The engine can not

start up, or the engine
stops suddenly after it
starts.
2. The fuel filter is clogged.

3. The fuel pipe, coarse filter
or filtering screen is clogged.
4. The fuel supply system or
fuel filter leaks oil.
Solutions
1. Charge the battery.
2. Tighten the wire of terminal
on the motor. Weld a new
terminal if necessary.
3. Make a check by special
personnel.
1. Add oil.
2. Change the filter cartridge
of fuel coarse filter.
3. Clean the fuel pipe, coarse
filter or filtering screen.
4.
Check
the
sealing
elements of fuel supply
system or fuel filter.
05 - 1
No.
Troubles
Causes
5. The fuel has
cold-resisting property.
Solutions
not
The fuel loop leaks oil or the

pressure of fuel loop is too
low.
The fuel loop leaks oil, or the
pressure of fuel loop is lower,
or the oil pump drive is
invalid.
The engine
difficultly.
starts
The engine
suddenly.
stops
The engine outputs

weakly.
The fuel supply system is

clogged or leaks oil.
The fuel consumption

is severe.
The fuel temperature is too

high.
oil
is
The charge indicator

light lights up when
the engine is running.
Chapter 5
The
engine
consumption
severe.
The temperature of
engine is too high.
1. There is leakage at the

outside of engine.
2. The engine oil is
unqualified or it is dirty.
3. The oil seal of turbocharger
leaks.
1. The conveying belt is
slack.
Check the fuel loop for leaks.

Make pressure test by
qualified repair plant.
Check the fuel supply system
for oil leaks, and consult the
Change the fuel temperature
sensor, and consult the
1. Check and repair the
leaking points.
2. Change engine oil and oil
filter.
3. Check the sealing
elements of turbocharger,
and repair oil seal by a
special person.
1. Check the tension of
conveying belt. And change
the driven sprocket if
necessary.
2. The conveying belt is worn.
2. Change the conveying belt.
3. The generator or voltage

stabilizer fails.
3. Check the generator or

voltage stabilizer, and consult
the qualified repair plant.
1. The antifreeze coolant

temperature sensor fails.
2. The antifreeze coolant is
insufficient or the cooling
system does not discharge
air completely.
3. The conveying belt is
damaged.
4. The outside and inside of
radiator are dirty or the
radiator is blocked by lime
deposit.
5. The thermostat fails.
05 - 2
5. Check the sealing

elements. Clean the fuel
coarse filter. Change the fuel
filter. Use the fuel suitable for
cold climate.
Check the fuel loop for leaks.
Make pressure test by
1. Change the sensor.

2. Add antifreeze coolant,
and discharge air completely.
3. Change the conveying belt.
4. Clean the radiator or
remove the lime deposit.
5. Check the thermostat, and
change it if necessary.
Consult the qualified repair
plant.
X
X
X
X
X
X
Troubles
Causes
1. The injector fails.
10
The engine emits the

black smoke.
11

blue smoke.
12

white smoke.
13
Knocking of engine
2. The exhaust turbocharger

or air intake pipe fails, or the
air filter is not clean.
The oil level in the engine is
too high, and thus the engine
oil flows into combustion
chamber.
There is leakage at the
cylinder head or the
cylinder-head gasket, thus
making antifreeze coolant
enter into combustion
chamber.
Burning failure
1. There is leakage in air
intake pipe and exhaust pipe.
14
X
X
X
X
X
X
15
16
Abnormal sound is
made.
The consumption of
antifreeze coolant is
severe.
The temperature of
antifreeze coolant is
lower than the normal
temperature.
Solutions
1. Consult the qualified repair
plant.
2. Make a visual check, and
consult the qualified repair
plant about the problem.
Set proper oil level, and
check oil level by qualified
repair plant.
Use compressed pressure to
test the cylinder, and consult
the qualified repair plant
about the problem.
Consult the qualified repair
plant.
1. Repair the leaking points.
And change the sealing
elements if necessary.
2. The turbine or air

compressor is scraped with
the cover, or the object enters
into turbine or air
compressor, or the bearing
gets stuck into the rotary
components.
2. Change the exhaust

turbocharger by a qualified
repair plant.
1. Some components may

leak antifreeze coolant.
1. Check the engine, oil

pipeline and radiator for
leaks. Repair the leaking
points by special person.
2. The temperature of engine

is too high, and the
temperature of antifreeze
coolant is higher than the
normal temperature.
2. Eliminate the failure by

special person.
1. The temperature sensor

fails.
1. Detect the signal output

from the temperature sensor,
and change the sensor if
necessary.
2. The thermostat fails.
2. Repair it by special person.
05 - 3
Chapter 5
No.
5.3 Troubleshooting of hydraulic system

The following table shows the troubles of hydraulic system and their solutions.
Table 5-003
No.
1
Troubles
The engine runs
normally, however, no
pilot pressure is
generated.
The engine runs
normally, however,
the pilot pressure is
too low.
Causes
The shutoff valve of oil
suction pipe is not opened.
1. There is leakage of pilot
system.
2. The pressure release valve
fails.
4. The valve or oil pipeline is

blocked.
5. The circuit is out of order.
5. Change the circuit.
6. The control lever fails.
6. Change control lever.
7. An amount of air enters

into the pipeline after
maintenance.
8. The shutoff valve on
hydraulic oil tank is not
opened.
1. The shutoff valve of oil
suction pipe is not opened.
7. Run the engine without

load for 5 minutes to
discharge the air.
2. The pressure release valve

fails.
Chapter 5
3. The main overflow valve of

main valve malfunctions.
2. The slewing valve

malfunctions.
3. The slewing pump fails.
4
05 - 4
No slewing
movements are
performed.
Open the shutoff valve.

1. Determine the leaking
point.
2. Check and adjust the
overflow pressure.
1. Check and repair the main
pump, and change it if
necessary.
2. Check pressure release
valve.
overflow pressure of main
overflow valve.
4. Clean the oil pipeline or
valve.
1. The hydraulic pump fails.
The engine runs

normally, however, no
crane movements are
performed after
moving the control
lever.
Solutions
4. The slewing brake is not

actuated.
8. Check the shutoff valve

and open it.
1. Open the shutoff valve.
overflow pressure of slewing
valve.
slewing pump, or change it if
necessary.
4. Check if the pressure is
output from slewing brake
solenoid valve.
5. The fuse of controller fails.
5. Change the fuse.
6. Check if the brake is

electrified. And change the
circuit if necessary.
7. The slewing control lever

fails.
7. Change the control lever.
X
X
X
X
X
X
Troubles
The slewing
movements are
performed weakly.
No traveling
movements are
performed or the
traveling movements
are carried out
weakly.
Causes
1. There is leakage at the
inside of slewing motor.

motor, or change it if
necessary.
2. The crane is overloaded.
2. Reduce the load.
3. The valves and oil pipeline

of slewing hydraulic system
are blocked.
1. The traveling resistance is
large.
2. The central revolving joint
or oil pipeline of travel gear
hydraulic system is blocked.
3. The traveling motor leaks
oil.
5. The fitting of travel gear
hydraulic system is not
screwed tightly.
7 The travel gear pedal fails.
X
X
X
X
X
X
The speed of
actuating assembly is
low.
1. The pump or motor leaks

oil.
The hydraulic system

makes the noise.
3. Clean the oil pipeline and

valves.
1. Reduce the traveling
speed.
2. Clean the central revolving
joint or oil pipeline of travel
gear hydraulic system.
motor, or change it if
necessary.
pump, or change it if
necessary.
5. Tighten the fitting with
special wrench.
7. Change the travel gear
pedal.
1. Check and repair the pump
or motor, or change them if
necessary.
2. The oil pipeline is blocked.
2. Clean the oil pipeline.
3. The pilot pressure is not

enough.
3. Detect the pilot pressure.

pump, or change it if
necessary.
No movements are
performed by hoisting
winch 1 (or 2), or the
movements of
hoisting winch 1 (or 2)
are carried out
weakly.
Solutions
2. The oil pipeline is blocked.
2. Clean the oil pipeline.
3. The crane is overloaded.
3. Adjust the load.
5. The hoisting winch 1 (or 2)

control lever fails.
6. The brake cylinder is not
actuated.
7. The quick-release coupling
is not screwed tightly.
8. The pressure of overflow
valve on main valve is too
low.
6. Detect the starting

pressure of brake cylinder.
7. Screw the quick-release
coupling tightly.
8. Detect the pressure of
overflow valve. Reset the
pressure if necessary.
1. The oil viscosity is too low.
1. Change hydraulic oil.
2. The oil temperature is too

low.
3. The back pressure of oil
return pipe is too high.
2. Preheat the hydraulic

system.
3. Modify the hydraulic
pipeline.
05 - 5
Chapter 5
No.
No.
Troubles
The oil temperature is

too high.
10
The hydraulic pipeline

vibrates fiercely.
11
The pipe fitting leaks

oil.
12
13
The hose bursts.
Causes
1. The radiator or oil pipeline
is blocked.
1. Clean the radiator or oil

pipeline.
2. The radiator is damaged.
2. Change the radiator.
3. The brand of hydraulic oil

is wrong.
4. The hydraulic oil
deteriorates.
5. The oil in the hydraulic oil
tank is insufficient.
6. The solenoid valve of
cooler fails.
1. There is an amount of air in
hydraulic system.
Chapter 5
14
3. Change the hydraulic oil.

4. Change the hydraulic oil.
5. Add oil to specific value.

6. Change the solenoid valve.
1. Discharge the air.
2. The pipe clamp is loose.
2. Adjust the pipe clamp and

fix the pipeline.
3. The overflow valve or

safety valve is blocked.
3. Clean the valve.
4. The pump, motor or valve

fail.

pump, motor or valve, or
change them if necessary.
1. The pipe fitting is not

screwed tightly.
2. The sealing element is
damaged.
1. The hose does not match
the applied pressure.
2. The hose is aging and
scratched.
3. The fitting of hose is
blocked.
1. The reducer leaks gear oil.
The connectors of
hydraulic pump and
hydraulic motor leak
oil.
Solutions
2. The hydraulic pump and

hydraulic motor leak oil.
1. Tighten the fitting.

2. Change the sealing
element.
1. Change the hose.
2. Change the hose.
3. Clean the hose and fitting.
1. Change the oil seal of
reducer.
2. Detect the pressure of oil
drain hole of pump and
motor. If it exceeds 3bar,
modify the oil drainage
pipeline, and change the oil
seal of pump and motor.
If the component marked with fails, never dismember or adjust it. You must
contact the crane manufacturer.
05 - 6
X
X
X
X
X
X
5.4 Troubleshooting of electrical system

5.4.1 Troubleshooting of cab electrics
Table 5-004
Troubles
Causes
Solutions
1. The wiper switch is

damaged.
1
The wiper does not

work.
1. Change the wiper switch.

2. Check and repair the wiper
motor. Or change it if
necessary.
3. Check and repair the drive
device of wiper.
1. Check and repair the fan
motor. Or change it if
necessary.
circuit.
2. The wiper motor fails.

3. The drive device of wiper
gets stuck or damaged.
The electric fan does

not work.
1. The fan motor fails.

1. The safety fuse is broken.
The cigarette lighter

does not work.
2. The resistance wire blows

out.
3. The circuit connection is
incorrect.
4. Poor contact of switch.
X
X
X
X
X
X
CD player does not

work.
The interior light of
cab fails.
Nothing is shown in
the LCD of monitor.
The rocker switch is

not in functional work.
The
switch
on
dashboard is not in
functional work.
The control lever is
not in functional work.
2. Change the wire.

circuit.
4. Check or change the
switch.
circuit.
2. The CD player is damaged.
2. Change the CD player.

circuit.
2. The interior
damaged.
light
is

6
1. Change the fuse.
2. The relevant video camera

is damaged.
3. The LCD is damaged.
switch

circuit.
2. Change the relevant video
camera.
3. Change the LCD.
circuit.

2. The rocker
damaged.
2. Change the interior light.
is
2. Change the rocker switch.

circuit.
2. The switch is damaged.
2. Change the switch.

circuit.
2. The control
damaged.
lever
is
05 - 7
Chapter 5
No.
No.
Troubles
10
The horn switch on

control lever can not
work normally.
11
The buzzer can not

sound.
Causes
Solutions
circuit.

2. The horn
damaged.
switch
is

circuit.
2. The buzzer is damaged.
2. Change the buzzer.
3. No signal is output from the

control program.
3. Consult the after-sale

service man.
circuit.

12
The main screen fails.
2. Change the horn switch.
2. The screen is damaged.
2. Change the screen.
3. The communication to PLC

fails.
3. Check and repair the circuit

or consult the after-sale
service man.
5.4.2 Troubleshooting of slewing table electrics

Table 5-005
Chapter 5
No.
Troubles
The battery master

switch fails.
The rotational speed

sensor fails.
The pressure sensor

fails.
The inclination sensor

fails.
The traveling alarm

does not sound the
alarm.
The electric horn can

not sound.
Causes
Solutions
The battery master switch is

damaged.
2. The rotational speed
sensor is damaged.
2. The pressure sensor is
damaged.
2. The inclination sensor is
damaged.
05 - 8
LED acoustic control

light fails.
2. The traveling alarm is

damaged.
3. The controller can not
output the signal.
2. The electric
damaged.
horn
is
Change the battery master

switch.
circuit.
2. Change the rotational
speed sensor.
circuit.
2. Change the pressure
sensor.
circuit.
2. Change the inclination
sensor.
circuit.
2. Change the traveling
alarm.
service man.
circuit.
2. Change the electric horn.

circuit.
2. LED acoustic control light

is damaged.
2. Change
control light.
LED
acoustic
X
X
X
X
X
X
Troubles
Causes
Solutions

8
The slewing alarm

does not sound the
alarm.
The lowering
switch fails.
10
No fuel
shown.
11
The shutoff valve limit

switch fails.
12
13
14
X
X
X
X
X
X
15
16
limit
level
2. The slewing alarm is

damaged.
3. The controller can not
output the signal.
2. The lowering limit switch is
damaged.
is
The main boom angle

(80) limit switch fails.
The slewing limit
switch fails.

2. The fuel level sensor is
damaged.
2. The limit
damaged.
switch
is
switch
is
switch
2. Change the limit switch.

circuit.

2. The limit
damaged.

circuit.

2. The limit
damaged.

circuit.
2. Change the slewing
sensor.
service man.
circuit.
2. Change the lowering limit
switch.
circuit.
2. Change the fuel level
sensor.
circuit.
is

circuit.
2. The engine oil pressure

sensor is damaged.
The water
temperature sensor
fails.

circuit.
2. The water temperature

sensor is damaged.
The
working
floodlights do not light
up.
The engine oil

pressure sensor fails.
2. The working floodlights are

damaged.

circuit.
2. Change the working
floodlights.
05 - 9
Chapter 5
No.
5.4.3 Troubleshooting of boom electrics

Table 5-006
No.
Troubles
The solar lamp can

not light up.
The wind speed is not

shown.
The warning icon

Hoisting limit for
H1/H2 flash
irregularly.
Causes
Solutions
The solar lamp is damaged.
Change the solar lamp.

circuit.
2. The anemometer is
damaged.
1. The circuit of boom is out
of order.
2. The hoisting limit switch is
damaged.
2. Change the anemometer.

circuit.
2. Change the hoisting limit
switch.
5.4.4 Troubleshooting of load moment limiter

Table 5-007
No.
The screen of load

moment
limiter
becomes black.
The data shown in the

screen is not correct.
Chapter 5
Troubles
05 - 10
No data is shown in
the screen.
Causes
Solutions
2. The circuit is not connected

well.

safety fuse.
circuit.
3. The screen is damaged.
3. Change the screen.
1. The safety fuse is broken.
1. The parameter is set

wrong.
2. The selected operating
mode is wrong.
3. The circuit is not properly
connected to the interface of
sensor.
1. Readjust the parameter.

2. Readjust the operating
mode.
3. Check and repair the circuit
and interface of sensor.
4. The sensor is damaged.
1. No data is downloaded.
1. Download the data again.
2. The main board of load

moment limiter is damaged.
3.
The
communication
between central unit of load
moment limiter and screen
fails.
2. Change the load moment

limiter.
3. Check the connecting
cable from central unit to
screen.
X
X
X
X
X
X
5.5 Troubleshooting of air conditioning system

The following table shows the troubles of air conditioning system and their solutions.
Troubles
The system can not

generate the hot air.
The system can not

generate the cold air.
Causes
1. The temperature control
switch is damaged, or the
cooling/heating rocker switch
is not pushed to heating
position.
2. The hot-water valve of air
conditioning system is not
opened.
3. The water temperature of
engine is too low.
1. Change the temperature

control switch, or push the
cooling/heating rocker switch
to heating position.
2. Open the hot-water valve.
3. Increase the rotational
speed of engine.
4. Wire connection is wrong.
4. Connect the earth wire.
1. The air compressor is

damaged.
2. The air compressor belt
slips.
3.
The
condenser
high-pressure pipe leaks gas.
1.
Change
compressor.
4. The switch is cut off.

5.
The
damaged.
X
X
X
X
X
X
Solutions
condenser
is
6. The temperature controller

is damaged.
7.
The
refrigerant
is
insufficient.
the
air
2. Change or adjust the belt.

3. Change the high-pressure
pipe.
4. Connect the switch or
adjust the pressure of
system.
condenser fan. Change it if
necessary.
6. Change the temperature
controller.
7. Add refrigerant
Chapter 5
No.
05 - 11

for Crawler Crane
Chapter 6 Application of oil
6.1 Antifreeze coolant

Antifreeze coolant, a mixed fluid of water and anti-freezing and anti-corrosion agent, plays
the following important roles in cooling system:
-
Corrosion protection;
Anti-freeze protection;
Lower the freezing point and raise the boiling point.
It is recommended that the pure water is used to make the antifreeze coolant. The water
and anti-freezing and anti-corrosion agent may mingle with each other in the proportion 1:
1. The proportion of anti-freezing and anti-corrosion agent can vary from 45% to 55%.
This kind of antifreeze coolant enable the crane to work in -37 temperature.
The anti-freezing and anti-corrosion agent must be added into the antifreeze coolant no
matter where the crane works, to protect the cooling system.
The high-quality water is most important to cooling system, since the ordinary water
has too much calcium and magnesium which will cause water scale formation, and
too much fluoride and nitrate that will corrode the cooling system.
Do not add sealing agent and soluble oil to cooling system. Otherwise, the cooling
system will be damaged.
It is advised to use the brand of anti-freezing and anti-corrosion agent approved by
Weichai Power. If you want to use other brand, please consult the service centre of
Weichai. Please buy the antifreeze coolant from Zoomlin.
The volume of antifreeze coolant is 43L. Change it every two years. If other kind of
antifreeze coolant is used, shorten the change interval.
6.2 Lubricating oil
The recommended lubricating oil brand is shown in the following table:
Table 6-001
Ambient
temperature
Brand of
lubricating oil
- 45
- 35
- 25
- 15
15
25
35
45
5W-40
10W-30
15W-40
06 - 1
Chapter 6
X
X
X
X
X
X
1. As to the high-quality lubricating oil, its quality grade is above CH-4.

2. The high-viscosity lubricating oil will reduce oil consumption and help the
engine to run well in cold climate.
The lubricating oil (15W-40) is widely used and it can keep its property when
crane is working in high temperature.
The low-viscosity lubricating oil (5W-40) can facilitate engine startup and ensure
oil fluidity when ambient temperature is below -5. However, long-time use of this
oil will shorten engine service life due to wear and tear.
3. Lubricating oil volume is 23 L.
6.3 Diesel oil
The common diesel oil is shown in the following table.
Table 6-002
Ambient
temperature
Brand of oil
-45
-30
-15
-5
10
20
30
40
50
5#
0#
-10 #
-20 #
-35 #
-50 #
The engine only uses vehicle diesel oil, which must comply with National Standard
GB19147-2009.
Chapter 6
The sulfur content of vehicle diesel oil must not exceed 350 ppm. If this sulfur content is
exceeded, the diesel oil is not allowed to use. If you have to use this kind of diesel oil, you
must shorten the oil change interval.
Do not add any special fuel additive into vehicle diesel oil. If a fuel additive is added, your
warranty will be limited.
The fuel tank capacity is 300L.
Top the crane up with diesel oil using the diesel pump attached to the crane or
special-purpose diesel pump. If the crane is fueled via oil drum or oil tank, the oil in fuel
system will not be pure, thus leading to failure of fuel system. Therefore, filter the oil before
fueling the crane.
06 - 2
X
X
X
X
X
X
1. Top the crane with clean fuel. Otherwise, it will cause severe damage to engine!
2. Do not use the diesel oil with gasoline, alcohol and other inflammable liquid.
Otherwise, it will result in explosion.
6.4 Gear oil of reducer
The gear oil of reducer is classified under two types: mineral oil and synthetic oil. These
two kinds of oil can not be mixed together to use.
The gear oil can not have any impurities such as water.
Select proper oil according to ambient temperature so as to meet the lubricating
requirements of reducer.
Check oil level regularly. If too much oil is in reducer, the oil pressure will increase, thus
leading to oil leakage, damage to the oil seal of half-shaft and braking failure. If the oil is
insufficient, the gear bearing will not be lubricated well, thus enhancing wear of bearing.
Check the performance index and pollution of gear oil. If it exceeds the standard value,
change the oil. During oil change, clean the gear box, and then add new oil. (For detailed
oil quantity, see section 4.6.1.)
Table 6-003 Prevailing gear oil
Brand of gear oil
Ambient temperature ()
L-CKD220 industrial closed gear oil
-25 - 40
6.5 Hydraulic oil

Take a sample of hydraulic oil for periodic inspection. For crane working under normal
condition, its hydraulic oil must be checked every 3 months. For crane working in adverse
environment, its hydraulic oil must be checked every month. The inspected items and
hydraulic oil physical & chemical character variation limitation values are shown in the
following table. If the hydraulic oil does not meet the requirements, change it at once.
Inspected item
Kinematic viscosity
(40) (mm2/s)
Acid value addition
(mgKOH/g)
Moisture (%)
Flash point (C)
Solid grain pollution
grade
Hydraulic Oil Physical & Chemical Character Variation

Limitation Value
L-HS
L-HV
L-HM
10%
10%
10% - 15%
0.3
0.3
0.3
0.1
0.1
0.1
-76
-76
-76
20/16
20/16
20/16
06 - 3
Chapter 6
Table 6-004
X
X
X
X
X
X
Recommended brand of hydraulic oil used in different ambient temperature

Table 6-005
Ambient
temperature
Below -30
Above -30
The lowest
temperature
for cold start
(without load)
The lowest
temperature
for cold start
(with load)
The lowest
working
temperature
with load
The highest
temperature
of hydraulic
oil
-40
-35
-15
50
-35
-22
-5
60
-28
-15
70
Between
-20 and
-20
-10
-5
-3
20
SH 0358-95
10# aviation
hydraulic oil
GB11118.1-94
low condensed
hydraulic oil
L-HV32
* 80-85
GB11118.1-94
low condensed
hydraulic oil
L-HM46
** 100
GB11118.1-94
low condensed
hydraulic oil
L-HM68
40
Above 40
Hydraulic oil
brand
1. If the crane starts in cold area, it should first run without load for a while. After
the lowest working temperature is reached, the load can be added gradually and
the system can work.
2. The oil property should be identical with that of the original brand when
changing oil. The original oil should be washed away thoroughly. The hydraulic
oil of different types can not be mixed together!
3. The domestic brands of hydraulic oil mainly include Kunlun, the Great Wall,
Tongyi, Haibrand, Daqing, Hengyun, Guta, Jiali, Jiarun, Haili, etc. and foreign
brands such as ESSO, Mobil, etc. are also available in china.
Chapter 6
4. If you find any special working conditions which are not listed in the above table,
please consult the related departments of our company.
1. Check and measure oil temperature of system at any time!

2. The suitable temperature range for hydraulic system in working condition is
20 to 80. The 85 may occur for a short time or in some position.
3. When oil temperature is too high (nearly 100), pay attention to the cooling of
system. The working load should not be too heavy and the working frequency
should not be too high.
06 - 4
X
X
X
X
X
X
6.6 Lubricating grease

In order to keep crane in good working condition, all machinery parts should be supplied
with specified grease periodically.
Type
ZL-2
lubricating
grease
ZG-3
lubricating
grease
Table 6-006 Recommended lubricating greases

Drop
Work wimble
point
degree
Appearance
()
(1/10mm)
Smooth inunctum with
the color from pale
175
265 - 295
yellow to brown
Equal inunctum with the
color from pale yellow to
90
220 - 250
brown
Moisture (%) no
more than
2.5
Chapter 6
X
X
X
X
X
X
06 - 5

for Crawler Crane
Chapter 7 Appendix
7.1 Tightening torque of threaded parts
4.6
4.8
5.8
6.8
8.8
10.9
12.9
Stress (MPa)
230
310
380
440
600
830
970
M6
4-5
5-6
7-8
8-9
10 - 12
14 - 17
17 - 20
M8
10 - 11
13 - 15
16 - 18
18 - 22
25 - 30
34 - 41
41 - 48
M81
10 - 12
14 - 17
17 - 20
20 - 23
27 - 32
37 - 43
43 - 52
M10
19 - 23
26 - 31
31 - 36
36 - 43
49 - 59
68 - 81
81 - 96
M101
21 - 25
28 - 34
35 - 41
41 - 48
55 - 66
76 - 90
90 - 106
M12
33 - 39
45 - 53
55 - 64
64 - 76
86 - 103
119 - 141
141 - 167
M121.5
35 - 41
47 - 56
57 - 67
67 - 79
90 - 108
124 - 147
147 - 174
M14
53 - 63
71 - 85
87 - 103
103 - 120
137 - 164
189 - 224
224 - 265
M141.5
57 - 68
77 - 92
94 - 110
110 - 131
149 - 179
206 - 243
243 - 289
M16
82 - 98
111 - 132
136 - 160
160 - 188
214 - 256
295 - 350
350 - 414
M161.5
87 - 104
113 - 141
144 - 170
170 - 200
228 - 273
314 - 372
372 - 441
M18
113 - 135
152 - 182
186 - 219
219 - 259
294 - 353
406 - 481
481 - 570
M181.5
127 - 152
171 - 205
210 - 247
247 - 291
331 - 397
457 - 541
541 - 641
M20
160 - 192
216 - 258
264 - 312
312 - 366
417 - 500
576 - 683
683 - 808
M201.5
178 - 213
239 - 287
294 - 345
345 - 407
463 - 555
640 - 758
758 - 897
M22
218 - 261
293 - 351
360 - 431
416 - 499
568 - 680
786 - 941
918 - 1099
M201.5
239 - 286
322 - 386
395 - 473
458 - 548
624 - 747
863 - 1034
1009 - 1208
M24
277 - 337
373 - 446
457 - 547
529 - 634
722 - 864
998 - 1195
1167 - 1397
M242
301 - 360
406 - 486
497 - 595
576 - 689
785 - 940
1086 - 1300
1269 - 1520
M27
405 - 485
546 - 653
669 - 801
774 - 801
1056 - 1264
1461 - 1749
1707 - 2044
M272
437 - 524
589 - 706
723 - 865
837 - 1002
1141 - 1366
1578 - 1890
1845 - 2208
M30
550 - 658
741 - 887
908 - 1087
1052 - 1259
1434 - 1717
1984 - 2375
2318 - 2775
M302
608 - 728
820 - 982
1005 - 1203
1164 - 1393
1587 - 1900
2196 - 2629
2566 - 3072
M36
961 - 1150
1295 - 1550
1587 - 1900
1838 - 2200
2506 - 3000
3466 - 4150
4051 - 4850
M363
1017 - 1218
1371 - 1641
1680 - 2011
1946 - 2329
2653 - 3176
3670 - 4394
4289 - 5135
M42
1536 - 1839
2071 - 2479
2538 - 3039
2939 - 3519
4008 - 4798
5544 - 6637
6479 - 7757
M423
1653 - 1979
2228 - 2667
2731 - 3269
3162 - 3786
4312 - 5162
5965 - 7141
6921 - 8345
M48
2308 - 2763
3110 - 3723
3813 - 4564
4415 - 5285
6020 - 7207
8327 - 9969
9732 - 11651
M483
2513 - 3008
3387 - 4055
4152 - 4970
4807 - 5755
6556 - 7848
9069 - 10857
10598 - 12688
Specification of bolt
Performance grade
07 - 1
Chapter 7
Table 7-001 Tightening torque (N.m) of threaded parts (8.8-12.9 grade)
7.2 Tightening torque of thread parts at pipe orifices

Table 7-002 Tightening torque of thread parts at pipe orifices (applicable to light pipe
fittings)
Pipe
thread
Specification
Metric
of pipe orifice
taper
thread
Specification of oil pipe
(mm)
Pipe
thread
(light)
Tightening
torque
Metric
(N.m)
taper
thread
(light)
1/8
1/4
1/4
3/8
1/2
1/2
3/4
11/4
11/2
M10
M12
M14
M16
M18
M22
M26
M33
M42
M48
1.5
1.5
1.5
1.5
1.5
1.5
10
12
15
18
22
28
35
42
18
35
35
70
90
90
180
310
450
540
18
25
45
55
70
125
180
310
450
540
Table 7-003 Tightening torque of thread parts at pipe orifices (applicable to heavy pipe
fittings)
Chapter 7
Pipe
thread
Specification
Metric
of pipe orifice
taper
thread
Specification of oil pipe
(mm)
Pipe
thread
(heavy)
Tightening
torque
Metric
(N.m)
taper
thread
(heavy)
07 - 2
1/4
1/4
3/8
3/8
1/2
1/2
3/4
11/4
11/2
M12
M14
M16
M18
M20
M22
M27
M33
M42
M48
1.5
1.5
1.5
1.5
1.5
1.5
10
12
14
16
20
25
30
38
55
55
80
80
115
115
180
310
450
540
35
55
70
90
125
135
180
310
450
540
7.3 Attached tools for maintenance

Table 7-004 Attached tools for maintenance
ID code
1019900187
1019900189
1140102826
1140207054
1140102828
00663009100001010
1991100032
1090100043
1140102830
10
1102900001
Names of the
tools
Pressure gauge
Specification
QTY.
SPG063-00060-01-S-M04
Pressure gauge
Pressure testing
joint
Testing hose
Pressure testing
joint
Square timber
SPG063-00400-01-S-M04
SMK20-M14X1.5-PC
P20-PM14-3-1500
SMK20-G1/4-PC
Tool box assy.

Flexible belt with
two ends fastening
Pressure testing
joint
Screw jack
GJX70-91-0
ST009 2T-8000
SMK20-10L-PK
QL5
12
Chapter 7
No.
07 - 3
7.4 Checklist for periodic inspection

In order to keep the crane in safe condition during operation, the inspector must carry out
inspection to crane systems and components at regular intervals. For the sake of
convenience, we make the following checklist for periodic inspection. You can conduct the
inspections according to the inspection category.
This checklist is only for reference. The user can make your own checklist according to
actual conditions.
Table 7-005 Checklist for periodic inspection
Crane type: ZCC800H
Company:
Crane manufacturer:
Inspected by:
1. Inspection category: Power system

Components
Inspection
inspected
intervals
Engine
Engine mounting
fastening bolts and
engine housing
Fan blade and belt
Antifreeze coolant
level
Engine oil level
Radiator core
Serial Number:
Recorded by:
Result
Serial Number of user:

Date:
Remarks
Check rotational speed,
water temperature, oil
pressure and relevant
warning icons etc.
Check the bolts for tight fit
and the housing for oil
leakage
Check it for deformation and

water leaks
Wind drag of air filter

Air intake pipe
Chapter 7
Intercooler core
Fuel pipeline
Fuel pre-filter
Fuel tank
07 - 4
Check it for deformation and

wind leaks
Check it for oil leaks and
damage
Check if there is water in the
filter.
Check if there is sediment
and water in the tank.
Check the tank for
corrosion.
Crane type: ZCC800H Crane manufacturer:
Serial Number:
Company:
Recorded by:
Date:
Inspected by:
2. Inspection category: winch reducer

Inspection
Components inspected
intervals
Result
Remarks
Check if the load falls
down uncontrollable
after engine stops.
Status of load
Wire rope wound onto the
drum
Sound made by the reducer
when it is running
Brake
Gear oil level
Demount the seal

plate and check the
lubricating condition
of bearing.
Bearing of reducer
Lowering limiter
Check them for oil

leaks
Reducer and motor

Mounting screw (or bolts)
3. Inspection category: slewing mechanism
Inspection
intervals
Result
Remarks
Sound made by slewing

reducer and slewing ring
when they are running
Gear oil level
Slewing reducer
Check it for oil leaks
Slewing motor
Torque of mounting bolt of

slewing ring
Lubrication on the surface of
large and pinion gear
Wear on the surface of large
and pinion gear
07 - 5
Chapter 7
Brake
Serial Number:
Company:
Recorded by:
Date:
Inspected by:
4. Inspection category: travel gear

Inspection
intervals
Result
Remarks
Track pad
Check the convex

teeth of track pad for
wear
Pin spindles of track pad
Check them for cracks

Check the slot of drive
sprocket for wear
and cracks
Drive sprocket
Track roller
Tension of crawler
Traveling reducer
5. Inspection category: hydraulic system

Inspection
intervals
Result
Remarks
Oil level in the hydraulic oil

tank
Hydraulic oil tank
Oil return filter
Pipelines and pipe fittings
Air filter
Oil cooler
Check if there is
sediment in the tank.
Change
the
filter
cartridge
Check them for oil
leaks and damage
Check if the filter is
clogged.
and damage.
Hydraulic motor and pump
Chapter 7
Valves in the hydraulic

system
Energy accumulator
07 - 6
Check them for oil

leaks
and damage

Company:
Serial Number:
Inspected by:
Recorded by:

Date:
6. Inspection category: electrical system

Inspection
intervals
Result
Remarks
Load moment limiter
Check if the value shown is

correct and the warning icon
flashes when irregular condition
occurs.
Hoisting limit switch
Check it for functional work
Lowering limit switch
Tilting-back limit switch
Shutoff valve limit switch
Angle limit switch

Check if the wind speed is
shown or the sensor is
damaged.
Check if the inclination
shown is correct or the
sensor is damaged.
Check if the pressure
shown is correct or the
sensor is damaged.
Check the clearness of
image, and the video for
damage
Check if the plug and
socket are connected
tightly, or they are
damaged.
Check if the oil level is
shown or the sensor is
damaged.
Wind speed sensor

Inclination sensor
Pressure sensor
Monitoring system
Connector on the boom
and slewing table
Oil level sensor
7. Inspection category: load hook and pulley
Pulley
Pulley spindle
Hook shaft
Load hook
Inspection
intervals
Result
Remarks
Check the lubricating
condition of pulley
Check the sealing seat of
spindle and its roll
resistance
Check the sealing seat of
shaft and its roll resistance
Check it for cracks and
wear
07 - 7
Chapter 7

Company:
Inspected by:
Serial Number:
Recorded by:
Date:
8. Inspection category: wire rope

Inspection
intervals
Result
Remarks
Check rope end point,
number of wire breaks and
strand breaks
strand breaks
strand breaks
Check them for cracks and
deformation
Wire rope for hoisting

winch 1
Wire rope for hoisting
winch 2
Derricking rope
Rope thimble and rope
lock
9. Inspection category: safety equipment
Inspection
intervals
Result
Remarks
Check the spring for
functional work and the
tilting-back support for
deformation and corrosion.
Main boom tilting-back

support
Front tilting-back support
of fixed jib
Rear tilting-back support
of fixed jib
Mounting spindle of
tilting-back support
Check it for tight fit
10. Inspection category: Boom, jib and other load-bearing parts
Chapter 7
Main boom
Fixed jib
FA-frame
07 - 8
Inspection
intervals
Result
Remarks
Check the attachment
points on the boom, and
check the boom for
deformation, corrosion and
cracks.
points on the jib, and check
the boom for deformation,
corrosion and cracks.
Check the attachment points on
FA-frame, and check the boom
for deformation, corrosion and
cracks.
A-frame
Rope pulley on A-frame

Main boom anchoring
rods
Fixed jib front anchoring
rods
Fixed jib rear anchoring
rods
Inspection
intervals
Result
Remarks
points on A-frame, and
check the boom for
deformation, corrosion and
cracks.
Check the lubricating
condition of rope pulley
Check it for deformation,
Chapter 7
07 - 9

ZOOMLION CRAWLER CRANE ZCC800HWG Maintenance Manual

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Vision creates future

Profession Heavy-industry Science & technology

Maintenance and Service Manual

Zoomlion Heavy Industry Science and Technology Co., Ltd.

MAINTENANCE AND SERVICE

The 1st edition (April, 2013)

ZCC800HWG Crawler Crane

For you .........................................................................................................................................I

ZCC800HWG Crawler Crane

4.10 Maintenance of the electrical system ....................................................................... 04-29

Maintenance and Service Manual

ZCC800HWG Crawler Crane

Fig. 1-001 Position of name plate

ZCC800HWG Crawler Crane

1.3 Illustration and symbols

Maintenance and Service Manual

ZCC800HWG Crawler Crane

2.1 Safety guidelines

No unauthorized personnel are accessible to crane during maintenance and service.

Depressurize all pipelines or containers before demounting the fittings or

ZCC800HWG Crawler Crane

2.2 Environmental protection disposal

Dispose harmful substances according to the following regulations:

The pollutant must be gathered together and preserved according to different

Maintenance and Service Manual

ZCC800HWG Crawler Crane

3.1 Description of main components

Wire rope for hoisting winch 2

Fig. 3-001 Overview of crawler crane

ZCC800HWG Crawler Crane

Right crawler carrier

Fig. 3-002 Overview of crane undercarriage

ZCC800HWG Crawler Crane

3.2 Hydraulic system

Traveling motor (R)

Triple gear pump

Traveling motor (L)

Control valve block

Fig. 3-003 Hydraulic system diagram

ZCC800HWG Crawler Crane

3.2.2 Arrangement of hydraulic elements in slewing table

Derricking brake valve

Ratchet control valve

Winch brake valve

Outer brake valve

Slewing brake solenoid valve

Slewing cushion valve

Hydraulic oil tank

Triple main valve

Dual main valve

Travel control valve

Control valve block

Central revolving joint

Pilot control valve

Clutch control solenoid valve

Fig. 3-004 Arrangement of hydraulic elements

Pilot oil filter

ZCC800HWG Crawler Crane

3.3 Electrical system

3.3.1 Electrical system diagram

Fig. 3-005 Electrical system diagram

ZCC800HWG Crawler Crane