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 safety’s 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
crane’s 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.
I
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.
Ⅱ
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
1.1 General
Chapter 1
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
1.3 Illustration and symbols

Chapter 1
This manual has a mass of illustrations, which are schematic. The meanings of illustrations
are as follows:
― Position of working mechanism to be operated

― Sequence of operation
― Correct operating way
― Unpermitted or dangerous operating way
The illustrations in this manual may be different from the actual condition of crane.
However, this does not hinder the user from understanding the meanings of illustrations.
1.4 Hazard indicator
The content with respect to the safety is marked with “ ”, the safety
instructions involved in the book are only the conventional contents.
The following terms that are used in this manual “CAUTION”, “WARNING”, and
“DANGER” are intended to point out certain important rules of conduct to all persons who
maintain and service the crane.
Indicate a potential danger, which could lead to slight or minor injury of one
or more persons.
Indicate a danger, which could lead to serious injury of one or more persons.
Indicate an imminent threat or danger, which could lead to life-threatening

or fatal injury of one or more persons.
01 - 2
for Crawler Crane
Chapter 2 Safety instructions
2.1 Safety guidelines
Since various dangerous factors exist during maintenance and service of crane, the
following are the safety guidelines for service technician to maintain and service crane
superstructure and undercarriage. Read and understand these safety guidelines before
maintenance and service work.
a) The maintenance work must be done by qualified personnel who have received
training in crane technology, especially in electrical and hydraulic systems of crane.
Chapter 2
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
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 people’s health, therefore, they must not
get into the ground, into water or into the sewer system, and they must be recycled and
disposed of according environmental protection regulations.
Dispose harmful substances according to the following regulations:

Chapter 2
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 person’s 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

Wire rope for hoisting winch 2
Chapter 3
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
Operator’s Slewing mechanism

cab
Fuel tank
Main valve
Chapter 3
Hoisting
winch 1
Oil cooling fan
Hoisting
winch 2
Hydraulic oil Engine system

tank
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
Traveling motor (L) Reducer

Dual valve
Hoisting winch 1 Reducer

Main pump
motor
Traveling motor (R) Reducer

Triple valve
Chapter 3
Hoisting winch 1 Reducer
motor
Engine
Derricking motor Reducer

Slewing pump
Slewing motor Reducer

Triple gear pump
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
Slewing cushion valve

Chapter 3
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
Pump unit Pilot control valve Clutch control solenoid valve Pilot oil filter
valve
Fig. × 3-004 Arrangement of hydraulic elements
03 - 4
3.3 Electrical system
3.3.1 Electrical system diagram
Chapter 3
Fig. ×3-005 Electrical system diagram
03 - 5
3.3.2 Arrangement of electrical elements in slewing table
Junction box 2
Fig. ×3-006 Arrangement of electric elements

Chapter 3
Junction box 1
Video camera
Working floodlight
Main boom angle limit switch To connector on boom
03 - 6
Horn
Traveling alarm
Slewing limit switch

Battery
Electrical
control box
Battery master switch
Inclinometer
Chapter 3
Fig. ×3-007 Arrangement of electric elements
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
Working floodlight
Tricolor light
Fig. × 3-008 Arrangement of electric elements

Chapter 3
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
General precautions during the maintenance work are described as follows:
a) Wear work clothes when conducting the maintenance.
Chapter 4
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
ZCC800HWG Crawler Cranes
To ensure safety, pay attention to the following points during the maintenance:
l When a crane is in inspection and maintenance, drop the boom to the ground, stop
the engine, lock the engine and remove the switch key to prevent other operators
from starting up the engine during the inspection and maintenance work.
Failing to follow this instruction may cause personnel injury or death.
l Set up a warning board for the inspection and maintenance process.
In inspection and maintenance, a warning board marked with “In Inspection and
Maintenance, Please Do not Start it Up” should be set at the key switch.
l Use the clean lubricating grease.
Keep the rooms for storing the lubricating grease clean. Do not make dusts, water,
or other things enter the vessels. Ensure that the lubricating grease is free of water.
Chapter 4
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
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.
Chapter 4
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
l Pay attention to the water and oil temperature.
It is dangerous to drain water, drain oil or replace filter elements when the engine is
just stopped. For this reason, drain water, drain oil, or replace filter elements only
after the temperatures have dropped. When the oil temperature is too low, the oil
shall be heated properly (to the temperature ranging from 20 - 50 °C) before being
drained.
Fig. × 4 - 006
l Inspect the drained waste oil and the old filter elements.
When changing the oil or filter elements, pay attention to inspecting whether there
are metal chips or foreign articles.
l Prevent the intrusion of dusts.
Protect the dismantled hydraulic oil pipes and hydraulic elements with plugs or seal
covers against the intrusion of dusts.
Chapter 4
Fig. × 4 - 007
l Clean joint surfaces.
After removing O-rings or other gaskets, clean the sealing surfaces, and replace
the seal parts with new ones. When reassembling them, coat the sealing with a thin
layer of oil.
l Pay attention to the internal pressure
When dismantling the pipelines, connectors or other relevant components with

internal pressure, such as the hydraulic system, compressed air system, and fuel
system, release the pressure in advance.
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.
l Treatment of the waste oil
Put the waste oil into the vessels and treat it as industrial emissions.
l Unprofessional personnel are forbidden to servicing the cranes or replacing parts

for them.
Chapter 4
l Record inspection
In order to learn about the correct working status of a crane and its components,
perform regular inspections and recordings (Upon the use for the 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 operator’s cab.
The maintenance cycle can be classified as follows according to duration of the interval.
04 - 5
Table × 4 - 001 Maintenance cycle
Operating time
Maintenance type Maintenance cycle
(hours)
Daily inspection (D) 10 Before being started up every day
Weekly maintenance (W) About 50 Weekly
Monthly maintenance (M1) About 200 Monthly
Quarterly maintenance (M3) About 500 Every 3 months
Semiannual maintenance (M3) About 1,000 Every 6 months

Annual maintenance (M12) About 2,000 Yearly
4.4 Maintenance plan
Table × 4 - 002 Maintenance plan
Maintenance Inspection
Annual
No. Working task Monthly Quarterly Semiannual Daily Weekly
maintenance
maintenance maintenance maintenance inspection inspection
M
M1 M3 M6 D W
12
Maintenance of
4.5 the power
system
Daily inspection of
4.5.1 ●
the engine
Chapter 4
Inspection of the
4.5.2 engine operation ●
status
Maintenance of
4.5.3 (as required in the maintenance manual of the engine)
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 2 years
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
04 - 6
Annual
maintenance
M
M1 M3 M6 D W
12
Lubrication of
4.6.3 bearings of the ●
reducer
Inspection of
4.6.4 brakes of the ●
winch reducer
Inspection of
4.6.5 ●
securing bolts
Inspection of
brake straps of
4.6.6 the hoisting winch ●
1 with free-fall
function
Maintenance of
4.7
the slewing ring
Routine
4.7.1 ●
inspection
Lubrication of the
4.7.2 ●
gear surface
Lubrication of the
4.7.3 raceway ●
Inspection of the
4.7.4 ●
slewing ring bolt
Maintenance of
4.8
Chapter 4
the crawler travel
Regular
4.8.1 ●
inspection
Cleaning of the
4.8.2 ●
crawler
Lubrication of the
4.8.3 ●
crawler pin
Tension of track
4.8.4 ●
pad
Maintenance of
4.9
hydraulic system
Routine
4.9.1 inspection of Multiple items
hydraulic system
Inspection of the
4.9.2 oil level of the ●
hydraulic tank
Replacement of
4.9.3 ●
the return filter
Replacement of
4.9.4 2 years
the air cleaner
Cleaning of the
4.9.5 In time
filter element
Change of the
4.9.6 ●
hydraulic oil
Cylinder
4.9.7 ●
inspection
Installation of the
4.9.8 ●
pipeline
Maintenance of
4.10 the electrical
system
04 - 7
Annual
maintenance
M
M1 M3 M6 D W
12
Inspection of the
4.10.1 ●
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
4.10.4 Battery inspection ●
Inspection of the
4.10.5 ●
limit switch
Inspection of
4.10.6 cable terminals Upon the basic machine disassembly or site transition every time
and dust guards
Prevention of
electrical parts or
4.10.7 Upon the basic machine disassembly or site transition every time
cables from
catching fires
Maintenance of
4.11 hooks and
pulleys
Daily
4.11.1 maintenance of ●
Chapter 4
hooks
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
4.11.6 ●
safety catch
Inspection of each
4.11.7 ●
hook body
Maintenance of
4.12
the wire rope
Cleaning of wire
4.12.1 In time
ropes
Lubrication of wire
4.12.2 In time
ropes
Inspection of wire
4.12.3 ●
ropes
4.13 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
Annual
maintenance
M
M1 M3 M6 D W
12
Structure
4.15
component
Rotary table
4.15.1 ●
inspection
Inspection of
4.15.2 ●
substructures
4.15.3 Boom inspection ●
Inspection of the
4.15.4 ●
anchoring rod
4.5 Maintenance of the power system
4.5.1 Daily inspection of the engine
Inspect appearances of the engine’s components to ensure that all parts are intact and
function normally.
Items to be inspected:
a) Inspect whether each part of the air suction pipeline is securely connected and free
of breakage and leakage.
b) Inspect whether the circulating cooling water way, the fuel pipeline and the engine
Chapter 4
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
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 70°C,
corresponding service is required.
f) When the engine operates normally, it is normal if the alarm indicator of the engine
does not flash.
(Note: For detailed operation methods, refer to the Operating Manual for Cranes.)
4.5.3 Maintenance of the engine
The engine shall be maintained according to requirements of the Operating Manual and
Maintenance and Service Manual prepared by the engine manufacturer and provided
together with the engine.
4.5.4 Cleaning of the air suction filter
When the engine is at the rated rotational speed, if the pointer of the air filter’s blocking
indicator points at the read zone, it indicates that filter elements of the air filter are
Chapter 4
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

a) Shack off the dusts on the filter element.
element surface.
Chapter 4
c) Blow the compressed air over the filter d) Clean the sealed supporting surface.
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.
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
Chapter 4
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.
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).
Chapter 4
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.
Table × 4 - 003 Oil change cycle and oil change amount of each mechanism
Inspection Oil change
Oil change
Mechanism name Gear oil grade interval amount
interval (hours)
(hours) (L/each)
Hoisting winch L-CKD220 industrial enclosed
250 1,000 3
Chapter 4
reducer gear oil
Derricking winch L-CKD220 industrial enclosed
250 1,000 3
reducer gear oil
L-CKD220 industrial enclosed
Slewing reducer 250 1,000 5.5
gear oil
Travelling reducer 250 1,000 10
gear oil
Gear transfer box 250 1,000 3.5
gear oil
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
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 Schematic diagram for change of the gear oil
b) Change of the gear oil for the slewing reducer
1) Unscrew the oil drain rubber tube plug screw at the lower end of the slewing
reducer and the screw plug of the oil filler at the upper end of the slewing
reducer to drain the original gear oil.
2) Open the oil filling plug screw and clean the gear with the cleaning oil (warm
and clean oil) to remove the abrasive matters and foreign matters.
Chapter 4
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 Schematic diagram for change of the gear oil
04 - 16
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
Direction A (enlarged)
Chapter 4
Fig. × 4 - 012 Schematic diagram for lubrication of the winch reducer
4.6.4 Inspection of brakes of the winch reducer
Inspect brakes of the hoisting winch reducer according to the following order:
a) Start up the engine and make it operate at a slightly high idle speed.
b) Apply a maximum load that the wire rope can bear to the corresponding hoisting
winch.
c) Operate the control lever to make the hoisting winch 1 (2) lift the heavy objects up.
d) When the heavy object is suspended in the air, push the control lever of the
hoisting winch 1 (2) to the middle position and then make a mark at a certain place
on the winch drum.
e) Retain the heavy object suspended in the air freely for several minutes and then
observe whether the position of the mark moves. In the case of no movement, it
indicates that brakes of the winch reducer are good.
Inspect brakes of the derricking winch reducer according to the following order:
a) Start up the engine.
b) Pull out the oil tube at the brake cylinder of the derricking winch reducer.
c) Operate the derricking erection action.
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.
The adjusting nut and

Chapter 4
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 oil’s period of validity is usually 3 to 6 months.
Upon expiration of the period of validity, they shall be coated with the rust preventive oil
in time. At the same time, it is forbidden to flush the slewing rings with water directly to
prevent the water from flowing into the raceway.
4.7.3 Lubrication of the raceway
Raceways must be injected with lubricating grease regularly according to the work
Chapter 4
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
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.
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

Chapter 4
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.
Adjustment steps:
a) Unload the bolts and shields from both right and left sides.
b) Align the hydraulic jacks with the push rods respectively under nature state.
c) Press the handle of the hydraulic jack slowly to move its driving axis and tension
Chapter 4
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
4.9 Maintenance of hydraulic system
To ensure that the hydraulic system is in a good status for long-term operation,
maintain the hydraulic system on time.
4.9.1 Routine inspection of hydraulic system
For the inspection period of hydraulic system, see the following table.
Table × 4 - 004 Inspection period of the hydraulic system

Inspection and Inspection interval (hours)
S/N Remarks
maintenance items 8 100 250 500 1000 1500 2000
Oil level inspection of
1 ★
hydraulic oil
Sediment inspection of
2 ★
hydraulic oil tank
Replace the return oil
3 ☆ ▲
filter element
Replace the pilot filter
4 ☆ ▲
element
Replacement of the air
5 ▲
cleaner
Replacement of the
6 ☆ ▲ 800 L
hydraulic oil
Oil leak and damage
7 inspection of pipelines ★
and joints
Air cleaner block
Chapter 4
8 ★ ▲
inspection
Oil leak of oil cooler and
9 ★
damage inspection
hydraulic motor, oil leak
10 of pump and unusual ★
sound inspection
Oil leak of hydraulic
11 ★
valve inspection
Oil leak of accumulator
12 ★
and damage inspection
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.
Table × 4 - 005 Decision of hydraulic oil status

Spares Determination Determination method
Dust and Test tube
In the state of starting up the engine, take the
metal (transparent) Appearance
sample from hydraulic oil tank or pipeline, and
powder and fresh comparison
compare it with fresh oil for its turbid condition.
from outside hydraulic oil
Oil within the hydraulic oil tank becomes opaque.
Mixing
Heat up the opaque oil sample to see the settled
of
water at the bottom. Take out the opaque oil
foreign
Test tube or Appearance sample and insert the red-hot bar iron. Then
objects
transparent comparison sizzle is generated. Dropping the opaque
Water
containers, and heating hydraulic oil on a heated iron plate will also
fresh oil estimation 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
Test tube or Appearance the pipeline, inject it into the container, and
transparent estimation compare its color and odor (smell) with the fresh
Degradation
containers, and sensation oil. Oxidation and deterioration oil will turn to
fresh oil estimation black brown, and badly degenerative oil will
stink.
a) Before starting the engine, check the oil level in the hydraulic oil tank. The level
Chapter 4
displayed on the liquid level meter below the visual position indicates insufficient
hydraulic oil of the hydraulic system. Fill the hydraulic oil till it reaches the visual
position, and then start the engine.
b) If the oil in the oil tank reduces fast, check the hydraulic pipelines and elements,
find the leak position, and stop the leakage before starting the engine.
c) Over temperature (above 80 °C) of hydraulic oil will accelerate the degradation of
hydraulic oil and shorten the service life of hydraulic elements. Low temperature
(below 20 °C) indicates that the flow of hydraulic oil is poor, and an overhasty
operation may damage hydraulic elements. Therefore, after starting the engine at
low temperature, preheat it to make the temperature of hydraulic oil reach around
20 °C.
d) Refer to the following table for the inspection after starting the engine.
Table × 4 - 006 Inspection after starting the engine

Inspection
Inspection method Determination Purpose
items
Find the abnormality of the
hydraulic system at early
Hydraulic oil Visual inspection hydraulic Normal temperature from +
stage, and extend the
temperature oil tank thermometer 30 °C to + 80 °C
service life of hydraulic
components.
Find the leakage at early
Oil leakage Visual inspection No leakage allowed
stage.
04 - 23
Inspection
Inspection method Determination Purpose
items
Pump Temperature is 5 °C higher Find the abnormality of
Infra-red thermometer
temperature than the oil tank pump at early stage.
Find the abnormal change
Sensation Abnormal sound/change of of the hydraulic oil,
Pump noises
(volume/acoustic) noises entrained air, wear of pump
and filter blocking.
Motor
Hand touch/sensation Abnormal sound/change of Find the abnormality of the
temperature
(volume/acoustic) noises motor at early stage.
and noises
Hydraulic oil cannot be used permanently. Therefore, it must be inspected and replaced in
Remarks accordance with whether impurities have been mixed into the hydraulic oil or the
degradation degree.
4.9.3 Replacement of the return filter
A signal on the pressure switch of a filter element of the return filter indicates that the
filter element is blocked. In such a situation, replace the filter element.
a) Unscrew the filter cover (cleaning cover) of the return filter, and replace the filter
element or refuel the oil tank. Set two M18*1.5 oil ports at the filter head, and install
the pinger at any part.
b) Replace the filter element of the return filter every 500 hours, with the initial
replacement subject to 50 hours.
Chapter 4
Return filter
Air cleaner
Liquid
Oil tank thermometer
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.
4.9.4 Replacement of the air cleaner
Chapter 4
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
4.9.5 Cleaning of the filter element
Inspect the filter, find the dirt on it, and then clean the filter in time.
Steps for cleaning:
a) Take out the filter with a special-purpose wrench.

b) Clean the filter element with dedicated cleaning solution or clean diesel.
4.9.6 Change of the hydraulic oil
Before delivery, the hydraulic oil tank of this product is filled with 800-liter hydraulic oil
whose oil grade is GB11118.1-94 L-HV32, L-HM46, L-HM68, or HS 0358-95 aviation
hydraulic fluid 10# subject to the regional work.
Inspection and replacement cycle of hydraulic oil:
The normal replacement cycle for hydraulic oil is 2,000 working hours. If it is obviously
dirty, replace it immediately regardless of the running time. Inspection items and
replacement cycle for hydraulic oil are as follows:
Table × 4 - 007 Inspection items and replacement cycle for hydraulic oil
Inspection and replacement cycle (hour)
S/N Inspection items Remarks
5 500 2,000
Inspection of the oil
1 ○
Chapter 4
level
Main oil
2 Oil tank cleaning ○
tank
Change of the
3 ○ 800 Liters
hydraulic oil
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.
Precautions for replacement:
a) Do not use the hydraulic oil for more than 24 months.
b) Filter or replace hydraulic oil in time upon heavily contaminated hydraulic oil.
c) Select appropriate hydraulic oil in accordance with the ambient temperature.
d) Do not mix the hydraulic oil of different grades.
e) When changing the oil, flush all of the original oil, and do not allow sundries like
sand and dirt entering the oil tank.
f) When changing oil at each loop, constantly add fresh oil into the hydraulic oil to
avoid empty oil pump.
g) When starting the engine at cold areas, ensure that the minimum temperature for
starting is reached, and start the engine in no-load state. After the temperature of
Chapter 4
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
b) Ensure sufficient radius of bending.
Incorrect
Incorrect
Correct
Correct
Fig. × 4 - 019
c) Use elbow and other connectors when necessary.
Incorrect Correct
Chapter 4
Fig. × 4 - 020
d) Allow certain looseness to offset the shrinkage of the hose under pressure.
Correct
Incorrect
Fig. × 4 - 021
e) Ensure fixed position of a hose with a clamp.
04 - 28
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)
Fig. ×4-023
Chapter 4
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
operator’s cab before using vehicles.
Fig. × 4 - 025
04 - 29
4.10.4 Battery inspection
Batteries must be well maintained and kept for use, because they function as the power
supply of starting the engine, electrical control system, illumination and electrical
auxiliary devices of the machine.
a) Store the battery (a filled and charged lead-acid battery) at the temperature ranging
from 5 °C to 25 °C and in a dry, clean and ventilated environment. Do not expose
the battery to direct sunshine to avoid degradation of the performance caused by
high ambient temperature.
b) Do not inverse and place the battery horizontally. Do not shock and press the
battery mechanically.
c) Recharge the battery in time to avoid performance degradation caused by the

sulfating of the battery.
d) Do not overcharge the battery. Avoid premature failure of the battery caused by too
much water loss, growth of grid and drop of diachylon.
e) Remove the batteries from the car and store them in a well-ventilated and dry place
if they are used for long time (usually more than 15 days). Charge the batteries
every 3-6 months (see if the indicator is black or not).
This series of lead-acid batteries for cars is the dry charged batteries produced in
Chapter 4
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 5°C to 40°C. 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 1.28±0.01g/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.
1—Hoisting winch 1 over-winding alarm
Over-winding of the hoisting winch 1 is also known as the main hook reaching the upper
limit. By this time, the corresponding alarm indication “ ” blinks in the display, along
with audible alarm. Meanwhile, the “reel in” movement of hoisting winch 1 and “reel out”
movement of derricking winch will be cut automatically, and the bypass key switch
Chapter 4
operation is effective.
2—Hoisting 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.
3—Hoisting 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.
4—Hoisting 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
5—Main boom 80° alarm
When the elevation angle of the main boom reaches 80°, and limit switch at the root of
main boom is closed, the corresponding alarm indication “ ” blinks in the display,
along with audible alarm. Meanwhile, the “reel in” movement of derricking winch will be
cut automatically, and the bypass key switch operation is ineffective.
4.10.6 Inspection of cable terminals and dust guards
Every dismantling of the basic machine and site transport requires the inspection for
whether the cable terminal is aligned and plugged tightly and whether the dust guard is
well covered.
4.10.7 Prevention of electrical parts or cables from catching fires
Fire of the electrical parts or cables can be prevented, and effective measures can be
taken to avoid such danger.
Precautions:
a) Inspect or exam the electrical devices of the crane regularly. Find out the cause for
faults like loose connection and cable heat, etc., and troubleshoot these devices
immediately.
b) Check all cables, connectors and terminals for looseness or damages (see if there
is any oxides formed on both poles of the terminal or battery), and rectify all
Chapter 4
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
Safety catch Bearing
Hook body
Fig. × 4 - 026 Hook
Chapter 4
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.
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.

Chapter 4
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 Oil passage Rolling bearing

nozzle
Fig. × 4 - 028 Schematic diagram for pulley lubrication
Each pulley has only one oil filling nozzle. Before the pulley lubrication, wipe the nozzle,
clean and inject the grease with grease gun until the fresh grease overflows from the
end face of bearing.
4.11.6 Inspection of the safety catch
The safety catch must be complete and undamaged so that it can limit the loose lifting
slings and other lifting devices on the hook.
Safety catch cannot bear the load. Therefore, lifting slings and other lifting
devices cannot be hung on the safety catch.
Chapter 4
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
Check the hook for deformation, local cold deformation and extrusion, crack, wear and
rust of clamping jaw. Lock the joint of hook nut.
Deformation: The hook must be replaced if the falcula has increased more than 10 % in
comparison with the original size “y”. The original size “y” is recorded on the hook.
Conduct measurement one by one.
Corrosion: Check the thread and shaft being operated for corrosion and wear.
Therefore, unscrew the hook nut on shaft.
If reprocessing is required to remove the corrosion, such process should not make the
diameter of the threaded core exceeds 5 %, otherwise the hook must be replaced.
(1). Do not use the hook with defects.
(2). Do not repair the hook by welding.
4.12 Maintenance of wire ropes
4.12.1 Cleaning of wire ropes
For dirty wire ropes, their external surface should be cleaned frequently. Especially, for
the wire ropes that are used in a corrosive environment or near chemical substances,
dirt on the surface should be removed in time.
Chapter 4
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 brush By cotton yarn By cotton yarn
Fig. × 4 - 030 Schematic diagram for wire rope lubricating oil application method
4.12.3 Inspection of wire ropes
The working life of a wire rope is different based on the operating condition of the
machine. Wire ropes for both lifting and derricking must be strictly inspected regularly to
find abrasion and damage in time.
Parts to be inspected:
a) Overall length of a wire rope;
b) The part which bends most frequently on a pulley or drum;
c) The parts which bend on pulleys or drums at the moment when load is lifted;
d) In the multi-layer winding system, the part where a wire rope contacts a drum
Chapter 4
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
Whether the wire rope should be replaced may be decided based on the following
factors. Refer to relevant Chinese National Standards (GB/T 5972) and ISO
standards (ISO 4309).
a) Fractured wire: In case more than 10% of the single wires (excluding filling
wires) of a wire rope within one lay length fracture, for the wire rope with
multilayer strands (typical multi strand structure), fractured wires mainly exist
inside, making such fracture “invisible”. In case lubrication at any local position
becomes dry or deteriorated, special attention should be paid;
b) Fractured line: In case fractured wires exist at or near the end of the rope,
even in a small number, it indicates that the stress at such position is great. If
the length of the rope permits, the position of fractured wires should be cut out
and re-installation should be performed properly;
c) Local aggregation of fractured wires: In case fractured lines cling together

and aggregate in the range of the rope length less than 6d (d: diameter of wire
rope) or exist almost in one strand, even though the number of fractured wires
is small;
d) Increase of fractured wires: Fractured wires would appear after a wire rope
has been used for a period of time, the number of fractured wires will increase
gradually, and the interval will be shorter and shorter.
e) Abrasion: Abrasion reduces the sectional area of a wire rope resulting in

Chapter 4
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:
04 - 38
Table × 4 - 008 Disposal of distortion of wire ropes

In case of d1≥4d/3, with the
length of a wire rope not
more than 25d, the wire rope
should be discarded as
Wave useless, where d is the
nominal diameter of the wire
rope; and d1 is the envelope
diameter after the wire rope
distorts.
Discard as useless
Cage distortion
immediately
Discard as useless
Strand extrusion
immediately
Single wire strand Discard as useless in case

extrusion distortion is severe
Multiple wire strands Discard as useless in case

extrusion distortion is severe
Chapter 4
In case the diameter of rope
The diameter of rope increases greatly at some
increases at some positions, the rope should be
positions discarded as useless without
delay
In case the diameter of rope

The diameter of rope reduces greatly at some
reduces at some positions, the rope should be
positions discarded as useless without
delay
Part positions are Discard as useless in case

flattened the flattening is severe
Discard as useless in case

Twist
the flattening is severe
Discard as useless
Bending
immediately
04 - 39
Damages caused by
Discard as useless in case
the action of heating
of any color change
or electric arc
4.13 Maintenance of air conditioning equipment
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
Chapter 4
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 Schematic diagram for whether refrigerant injection is

appropriate
04 - 40
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
Inspection items Content Time
Inspect the looseness and damage conditions of pipelines and pipe
Piping joint joints, and whether oil dirt exists on pipe joints. Oil dirt indicates Weekly
microscale leakage, and repair should be conducted.
Inspect whether dust and muddiness exist on the cooling fin, and
Condenser Weekly
high pressure water should be utilized for washing if necessary
Evaporator Inspect whether cleaning dirt exists and utilize compressed air to
Once a quarter
cooling fin blow off it
Once two
Compressor Inspect the oil level of compressor and replace refrigerant oil
quarters
Pressure of high
& low pressure Check the pressure of high & low pressure ends Once a quarter
ends
Chapter 4
Electrical
Inspect, and adjust if necessary Once a quarter
components
Inspect the operation condition of blower, charge lubricating oil and Once three
Blower
no abnormal sound should exist on components during operation quarters
Inspect whether bolts of assembly parts are loose, and if any,
Assembly parts Once a quarter
fasten them.
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
4.14.1 Grades of lubricating grease
Table × 4 - 010 ZL-2 and ZG-3 lubricating grease recommended by our company
Parameters
Dropping Working Moisture,
Type Appearance point penetration (%)
(°C) (1/10mm) Max.
ZL-2 lubricating Smooth ointment with color from
175 265~295 ——
grease light yellow to brown
ZG-3 lubricating Uniform ointment with color from
90 220~250 2.5
grease light to dark brown
4.14.2 Injection method
Daubing or injection by oil gun.
Fig. × 4 - 031 Schematic diagram of lubricating grease injection

Chapter 4
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
Oil filling interval (hour) Remarks
S/N Oil filling position
10/day 50/week 200/month 500/quarter
Ratchet latching Lubricating grease,
1 ●
mechanism daub
Lubricating grease,
2 Slewing ring ●
daub
Lubricating grease, oil
3 Winch bearing ●
gun injection
4 Track carrier roller ● GL-5 85W/90
5 Track roller ● GL-5 85W/90
6 Driven sprocket ● GL-5 85W/90
04 - 42
Every week or 25
hours
Every week or 25
hours
Every day or 5
hours
Every quarter or 500

hours
Chapter 4
Fig. × 4 - 032 Super and lower structures lubricating grease injection
4.14.3.2 Boom
Table × 4 - 012 Boom system lubricating grease injection

Oil filling interval (hour) Remarks
S/N Oil filling position
10/day 50/week 200/month
Main boom pivot section pin
1 ●
spindle
A-frame movable pulley pin
2 ●
spindle
Main boom tilting-back support
3 ●
pin spindle
Hinge joint position of derricking
4 ●
anchoring rod and A-frame shaft
Main winch, auxiliary winch and Based on service
5
derricking wire rope conditions
6 Derricking pulley and pin spindle ●
7 Auxiliary hook shaft and bearing ●
8 Main hook shaft and bearing ●
9 Boom pulley and pin spindle ●
04 - 43
Each month or 200 hours

Chapter 4
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
tolerance
Chapter 4
Length of boom section ≤3,000 3,000 – 6,000 >6,000
Local straightness
2 per meter
tolerance
Overall length
3 4 6
straightness tolerance
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 Minimum Chord member
Ruler Ruler
Fig. × 4 - 034 Chord member local straightness test schematic diagram
04 - 45
u Overall length straightness of chord member
As shown in the figure, arrange a φ0.49 - 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.
Turn the boom by 90°, and repeat the above test for the same chord member.
Chord Wire rope

Maximum
member
Minimum
Fig. × 4 - 035 Chord member overall length straightness test schematic diagram
Chapter 4
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
4.15.2 Inspection of lower structure parts
Chapter 4
Fig. × 4 - 037 Crawler frame inspection schematic diagram
04 - 47
Fig. × 4 - 038 Crawler frame lug Fig. × 4 - 039 Slewing ring bottom
inspection schematic diagram inspection schematic diagram
4.15.3 Boom inspection
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;

Chapter 4
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
Fig. × 4 - 040 Main boom welding line inspection schematic diagram
Chapter 4
Fig. × 4 - 041 Fixed jib welding line inspection schematic diagram
04 - 49
4.15.4 Anchoring rod inspection
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.
Chapter 4
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.
e) Inspect the plastic deformation of anchoring rod
Inspect whether the anchoring rod possesses twist, and in case of any twist, the
Chapter 4
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
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
No. Troubles Causes Solutions

When crane is 1. The crawler tensions on
traveling in straight both sides are different from 1. Adjust the crawler tension.
1 each other.
line, it deviates to one
side. 2. The crawler is slack. 2. Adjust the crawler tension.
1. The crawler is tight. 1. Adjust the crawler tension.
The traveling
2 2. Fill up the ground to make
resistance is large. 2. The ground is soft.
it solid and flat.
1. The crawler is slack. 1. Adjust the crawler tension.
3 The crawler slips.
2. The track pad is worn. 2. Change the track pad.
The track roller is mounted Unscrew the bolt, pad a
The track roller leaks
unevenly, thus leading to the 1mm-thick iron plate under
4 oil or it does not
deformation of sealing ring of the track roller, and then
rotate.
track roller. tighten the bolt.
1. The crawler is slack. 1. Tighten the crawler.
The drive sprocket is
5 meshed with track 2. The drive sprocket is
2. Grind and correct the top
pad irregularly meshed with track pad
edge of drive sprocket.
improperly.
5.2 Troubleshooting of power system

X
X
Chapter 5
The following table shows the troubles of power system and their solutions.
X
X Table × 5-002
X
X No. Troubles Causes Solutions
1. The battery is charged
1. Charge the battery.
insufficiently.
The starting motor 2. The wire connected to 2. Tighten the wire of terminal
1 does not rotate or it starting motor has come on the motor. Weld a new
rotates weakly. loose. terminal if necessary.
3. The solenoid switch of 3. Make a check by special
starting motor fails. personnel.
1. The fuel tank is empty. 1. Add oil.
2. Change the filter cartridge
The engine can not 2. The fuel filter is clogged.
of fuel coarse filter.
start up, or the engine 3. The fuel pipe, coarse filter 3. Clean the fuel pipe, coarse
2
stops suddenly after it or filtering screen is clogged. filter or filtering screen.
starts. 4. Check the sealing
4. The fuel supply system or
elements of fuel supply
fuel filter leaks oil.
system or fuel filter.
05 - 1

5. Check the sealing
elements. Clean the fuel
5. The fuel has not
coarse filter. Change the fuel
cold-resisting property.
filter. Use the fuel suitable for
cold climate.
The fuel loop leaks oil or the Check the fuel loop for leaks.
The engine starts
3 pressure of fuel loop is too Make pressure test by
difficultly.
low. qualified repair plant.
The fuel loop leaks oil, or the
Check the fuel loop for leaks.
The engine stops pressure of fuel loop is lower,
4 Make pressure test by
suddenly. or the oil pump drive is
qualified repair plant.
invalid.
Check the fuel supply system
The engine outputs The fuel supply system is
5 for oil leaks, and consult the
weakly. clogged or leaks oil.
Change the fuel temperature
The fuel consumption The fuel temperature is too
6 sensor, and consult the
is severe. high.
1. There is leakage at the 1. Check and repair the
outside of engine. leaking points.
2. The engine oil is 2. Change engine oil and oil
The engine oil
unqualified or it is dirty. filter.
7 consumption is
3. Check the sealing
severe.
3. The oil seal of turbocharger elements of turbocharger,
leaks. and repair oil seal by a
special person.
1. Check the tension of
1. The conveying belt is conveying belt. And change
slack. the driven sprocket if
The charge indicator necessary.
8 light lights up when
2. The conveying belt is worn. 2. Change the conveying belt.
the engine is running. X
3. Check the generator or X
3. The generator or voltage
voltage stabilizer, and consult
Chapter 5
stabilizer fails. X
the qualified repair plant. X
1. The antifreeze coolant X
1. Change the sensor.
temperature sensor fails. X
2. The antifreeze coolant is
insufficient or the cooling 2. Add antifreeze coolant,
system does not discharge and discharge air completely.
air completely.
3. The conveying belt is
3. Change the conveying belt.
damaged.
The temperature of 4. The outside and inside of
9
engine is too high. radiator are dirty or the
4. Clean the radiator or
radiator is blocked by lime
remove the lime deposit.
deposit.
5. Check the thermostat, and

change it if necessary.
5. The thermostat fails. Consult the qualified repair
plant.
05 - 2

1. Consult the qualified repair
1. The injector fails.
plant.
The engine emits the
10 2. The exhaust turbocharger 2. Make a visual check, and
black smoke.
or air intake pipe fails, or the consult the qualified repair
air filter is not clean. plant about the problem.
The oil level in the engine is
Set proper oil level, and
The engine emits the too high, and thus the engine
11 check oil level by qualified
blue smoke. oil flows into combustion
repair plant.
chamber.
There is leakage at the
cylinder head or the Use compressed pressure to
The engine emits the cylinder-head gasket, thus test the cylinder, and consult
12
white smoke. making antifreeze coolant the qualified repair plant
enter into combustion about the problem.
chamber.
Consult the qualified repair
13 Knocking of engine Burning failure
plant.
1. Repair the leaking points.
1. There is leakage in air
And change the sealing
intake pipe and exhaust pipe.
elements if necessary.
2. The turbine or air
Abnormal sound is compressor is scraped with
14
made. the cover, or the object enters 2. Change the exhaust
into turbine or air turbocharger by a qualified
compressor, or the bearing repair plant.
gets stuck into the rotary
components.
1. Check the engine, oil
1. Some components may pipeline and radiator for
leak antifreeze coolant. leaks. Repair the leaking
The consumption of points by special person.
X 15 antifreeze coolant is 2. The temperature of engine
X severe. is too high, and the
Chapter 5
2. Eliminate the failure by
X temperature of antifreeze
special person.
X coolant is higher than the
X normal temperature.
X 1. Detect the signal output
The temperature of 1. The temperature sensor from the temperature sensor,
antifreeze coolant is fails. and change the sensor if
16
lower than the normal necessary.
temperature.
2. The thermostat fails. 2. Repair it by special person.
05 - 3
5.3 Troubleshooting of hydraulic system
The following table shows the troubles of hydraulic system and their solutions.
Table × 5-003

The engine runs
normally, however, no The shutoff valve of oil
1 Open the shutoff valve.
pilot pressure is suction pipe is not opened.
generated.
The engine runs 1. There is leakage of pilot 1. Determine the leaking
normally, however, system. point.
2
the pilot pressure is 2. The pressure release valve 2. Check and adjust the
too low. fails. overflow pressure.
1. Check and repair the main
1. The hydraulic pump fails. pump, and change it if
necessary. ※
2. The pressure release valve 2. Check pressure release
fails. valve. ※
3. Check and adjust the
3. The main overflow valve of
overflow pressure of main
The engine runs main valve malfunctions.
overflow valve.
normally, however, no
4. The valve or oil pipeline is 4. Clean the oil pipeline or
crane movements are
3 blocked. valve.
performed after
moving the control 5. The circuit is out of order. 5. Change the circuit.
lever.
6. The control lever fails. 6. Change control lever.
7. An amount of air enters 7. Run the engine without
into the pipeline after load for 5 minutes to
maintenance. discharge the air.
8. The shutoff valve on X
8. Check the shutoff valve
hydraulic oil tank is not X
and open it.
Chapter 5
opened. X
1. The shutoff valve of oil X
1. Open the shutoff valve.
suction pipe is not opened. X
2. Check and adjust the X
2. The slewing valve
overflow pressure of slewing
malfunctions.
valve.
3. Check and repair the
3. The slewing pump fails. slewing pump, or change it if
No slewing necessary. ※
4 movements are 4. Check if the pressure is
4. The slewing brake is not
performed. output from slewing brake
actuated.
solenoid valve. ※
5. The fuse of controller fails. 5. Change the fuse.
6. Check if the brake is
6. The circuit is out of order. electrified. And change the
circuit if necessary.
7. The slewing control lever
7. Change the control lever.
fails.
05 - 4

1. There is leakage at the
motor, or change it if
inside of slewing motor.
The slewing necessary.
5 movements are 2. The crane is overloaded. 2. Reduce the load. ※
performed weakly. 3. The valves and oil pipeline
3. Clean the oil pipeline and
of slewing hydraulic system
valves.
are blocked.
1. The traveling resistance is 1. Reduce the traveling
large. speed.
2. The central revolving joint 2. Clean the central revolving
or oil pipeline of travel gear joint or oil pipeline of travel
hydraulic system is blocked. gear hydraulic system.
No traveling 3. Check and repair the
3. The traveling motor leaks
movements are motor, or change it if
oil.
performed or the necessary. ※
6
traveling movements 4. Check and repair the main
are carried out 4. The hydraulic pump fails. pump, or change it if
weakly. necessary. ※
5. The fitting of travel gear
5. Tighten the fitting with
hydraulic system is not
special wrench. ※
screwed tightly.
7. Change the travel gear
7 The travel gear pedal fails.
pedal.
1. Check and repair the pump
1. The pump or motor leaks
or motor, or change them if
The speed of oil.
necessary.
7 actuating assembly is 2. The oil pipeline is blocked. 2. Clean the oil pipeline.
low.
3. The pilot pressure is not 3. Detect the pilot pressure.
enough. ※
X 1. Check and repair the main
X 1. The hydraulic pump fails. pump, or change it if
Chapter 5
X necessary.
X 2. The oil pipeline is blocked. 2. Clean the oil pipeline.
X No movements are
X performed by hoisting 3. The crane is overloaded. 3. Adjust the load.
winch 1 (or 2), or the 5. The hoisting winch 1 (or 2) 5. Change the control lever.
8 movements of control lever fails. ※
hoisting winch 1 (or 2) 6. The brake cylinder is not 6. Detect the starting
are carried out actuated. pressure of brake cylinder.
weakly. 7. The quick-release coupling 7. Screw the quick-release
is not screwed tightly. coupling tightly.
8. The pressure of overflow 8. Detect the pressure of
valve on main valve is too overflow valve. Reset the
low. pressure if necessary.
1. The oil viscosity is too low. 1. Change hydraulic oil.
The hydraulic system 2. The oil temperature is too 2. Preheat the hydraulic
9 low. system.
makes the noise.
3. The back pressure of oil 3. Modify the hydraulic
return pipe is too high. pipeline.
05 - 5

1. The radiator or oil pipeline 1. Clean the radiator or oil
is blocked. pipeline.
2. The radiator is damaged. 2. Change the radiator.
3. The brand of hydraulic oil
3. Change the hydraulic oil.
The oil temperature is is wrong.
10 4. The hydraulic oil 4. Change the hydraulic oil.
too high.
deteriorates. ※
5. The oil in the hydraulic oil
5. Add oil to specific value.
tank is insufficient.
6. The solenoid valve of
6. Change the solenoid valve.
cooler fails.
1. There is an amount of air in
1. Discharge the air.
hydraulic system.
2. Adjust the pipe clamp and
2. The pipe clamp is loose.
fix the pipeline.
The hydraulic pipeline
11 3. The overflow valve or
vibrates fiercely. 3. Clean the valve. ※
safety valve is blocked.
4. The pump, motor or valve
pump, motor or valve, or
fail.
change them if necessary.
1. The pipe fitting is not
1. Tighten the fitting.
The pipe fitting leaks screwed tightly.
12
oil. 2. The sealing element is 2. Change the sealing
damaged. element.
1. The hose does not match
1. Change the hose.
the applied pressure.
2. The hose is aging and
13 The hose bursts. 2. Change the hose.
scratched.
3. The fitting of hose is
3. Clean the hose and fitting.
blocked.
1. Change the oil seal of X
1. The reducer leaks gear oil. X
reducer.
Chapter 5
The connectors of 2. Detect the pressure of oil X

hydraulic pump and drain hole of pump and X
14 X
hydraulic motor leak 2. The hydraulic pump and motor. If it exceeds 3bar,
modify the oil drainage X
oil. hydraulic motor leak oil.
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
5.4 Troubleshooting of electrical system
5.4.1 Troubleshooting of cab electrics
Table × 5-004

1. The wiper switch is
1. Change the wiper switch.
damaged.
2. Check and repair the wiper
The wiper does not
1 2. The wiper motor fails. motor. Or change it if
work.
necessary.
3. The drive device of wiper 3. Check and repair the drive
gets stuck or damaged. device of wiper.
1. Check and repair the fan
1. The fan motor fails. motor. Or change it if
The electric fan does
2 necessary.
not work.
1. The circuit is out of order.
circuit.
1. The safety fuse is broken. 1. Change the fuse.
2. The resistance wire blows
2. Change the wire.
The cigarette lighter out.
3 3. The circuit connection is 3. Check and repair the
does not work.
incorrect. circuit.
4. Check or change the
4. Poor contact of switch.
switch.
CD player does not 1. The circuit is out of order.
4 circuit.
work.
2. The CD player is damaged. 2. Change the CD player.
X The interior light of circuit.
5
X cab fails. 2. The interior light is
Chapter 5
X
2. Change the interior light.
damaged.
X 1. Check and repair the
X 1. The circuit is out of order.
circuit.
X Nothing is shown in 2. The relevant video camera 2. Change the relevant video
6
the LCD of monitor. is damaged. camera.
3. The LCD is damaged. 3. Change the LCD.

The rocker switch is circuit.
7
not in functional work. 2. The rocker switch is
2. Change the rocker switch.
damaged.
The switch on 1. Check and repair the
8 dashboard is not in circuit.
functional work. 2. The switch is damaged. 2. Change the switch.
The control lever is circuit.
9
not in functional work. 2. The control lever is
2. Change the control lever.
damaged.
05 - 7

The horn switch on 1. The circuit is out of order.
circuit.
10 control lever can not
2. The horn switch is
work normally. 2. Change the horn switch.
damaged.
circuit.
The buzzer can not
11 2. The buzzer is damaged. 2. Change the buzzer.
sound.
3. No signal is output from the 3. Consult the after-sale
control program. service man.
circuit.
2. The screen is damaged. 2. Change the screen.
12 The main screen fails.
3. Check and repair the circuit
3. The communication to PLC
or consult the after-sale
fails.
service man.
5.4.2 Troubleshooting of slewing table electrics
Table × 5-005

The battery master The battery master switch is Change the battery master
1
switch fails. damaged. switch.
The rotational speed circuit.
2
sensor fails. 2. The rotational speed 2. Change the rotational
sensor is damaged. speed sensor.
The pressure sensor circuit.
3
fails. 2. The pressure sensor is 2. Change the pressure X
damaged. sensor. X
Chapter 5
1. Check and repair the X

The inclination sensor circuit. X
4
fails. 2. The inclination sensor is 2. Change the inclination X
damaged. sensor. X
circuit.
The traveling alarm
2. The traveling alarm is 2. Change the traveling
5 does not sound the
damaged. alarm.
alarm.
3. The controller can not 3. Consult the after-sale
output the signal. service man.
The electric horn can circuit.
6
not sound. 2. The electric horn is
2. Change the electric horn.
damaged.
1. The circuit is out of order. circuit.
LED acoustic control
7
light fails.
2. LED acoustic control light 2. Change LED acoustic
is damaged. control light.
05 - 8

circuit.
The slewing alarm
2. The slewing alarm is 2. Change the slewing
8 does not sound the
damaged. sensor.
alarm.
3. The controller can not 3. Consult the after-sale
output the signal. service man.
The lowering limit circuit.
9
switch fails. 2. The lowering limit switch is 2. Change the lowering limit
damaged. switch.
No fuel level is circuit.
10
shown. 2. The fuel level sensor is 2. Change the fuel level
damaged. sensor.
The shutoff valve limit circuit.
11
switch fails. 2. The limit switch is
2. Change the limit switch.
damaged.
The main boom angle 1. The circuit is out of order.
circuit.
12
(80°) limit switch fails. 2. The limit switch is
damaged.
The slewing limit circuit.
13
switch fails. 2. The limit switch is
damaged.
The engine oil circuit.
14
pressure sensor fails. 2. The engine oil pressure
2. Change the sensor.
sensor is damaged.
X The water 1. The circuit is out of order.
circuit.
X 15 temperature sensor
Chapter 5
2. The water temperature
X fails. 2. Change the sensor.
sensor is damaged.
X
X The working 1. The circuit is out of order.
X
circuit.
16 floodlights do not light
2. The working floodlights are 2. Change the working
up.
damaged. floodlights.
05 - 9
5.4.3 Troubleshooting of boom electrics
Table × 5-006

The solar lamp can
1 The solar lamp is damaged. Change the solar lamp.
not light up.
The wind speed is not circuit.
2
shown. 2. The anemometer is
2. Change the anemometer.
damaged.
The warning icon 1. The circuit of boom is out 1. Check and repair the
“Hoisting limit for of order. circuit.
3
H1/H2” flash 2. The hoisting limit switch is 2. Change the hoisting limit
irregularly. damaged. switch.
5.4.4 Troubleshooting of load moment limiter
Table × 5-007

1. The safety fuse is broken.
The screen of load safety fuse.
1 moment limiter 2. The circuit is not connected 2. Check and repair the
becomes black. well. circuit.
3. The screen is damaged. 3. Change the screen.
1. The parameter is set
1. Readjust the parameter.
wrong.
2. The selected operating 2. Readjust the operating
The data shown in the mode is wrong. mode.
2 3. The circuit is not properly
screen is not correct. 3. Check and repair the circuit
connected to the interface of X
and interface of sensor.
sensor. X
Chapter 5
4. The sensor is damaged. 4. Change the sensor. X

X
1. No data is downloaded. 1. Download the data again. X
X
2. The main board of load 2. Change the load moment
No data is shown in moment limiter is damaged. limiter.
3 3. The communication
the screen. 3. Check the connecting
between central unit of load
cable from central unit to
moment limiter and screen
screen.
fails.
05 - 10
5.5 Troubleshooting of air conditioning system
The following table shows the troubles of air conditioning system and their solutions.

1. The temperature control
1. Change the temperature
switch is damaged, or the
control switch, or push the
cooling/heating rocker switch
cooling/heating rocker switch
is not pushed to “heating”
to “heating” position.
position.
The system can not 2. The hot-water valve of air
1
generate the hot air. conditioning system is not 2. Open the hot-water valve.
opened.
3. The water temperature of 3. Increase the rotational
engine is too low. speed of engine.
4. Wire connection is wrong. 4. Connect the earth wire.
1. The air compressor is 1. Change the air
damaged. compressor.
2. The air compressor belt
2. Change or adjust the belt.
slips.
3. The condenser 3. Change the high-pressure
high-pressure pipe leaks gas. pipe.
4. Connect the switch or
The system can not 4. The switch is cut off. adjust the pressure of
2
generate the cold air. system.
5. The condenser is
condenser fan. Change it if
damaged.
necessary.
6. The temperature controller 6. Change the temperature
is damaged. controller.
7. The refrigerant is
X 7. Add refrigerant
insufficient.
X
Chapter 5
X
X
X
X
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:
X
X Table × 6-001
Chapter 6
X
X Ambient
X temperature
X - 45℃ - 35℃ - 25℃ - 15℃ 0℃ 15℃ 25℃ 35℃ 45℃
Brand of
lubricating oil
5W-40
10W-30
15W-40
06 - 1
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 -45℃ -30℃ -15℃ -5℃ 0℃ 5℃ 10℃ 20℃ 30℃ 40℃ 50℃
Brand of oil
5#
0#
-10 #
-20 #
-35 #
-50 #
The engine only uses vehicle diesel oil, which must comply with National Standard
GB19147-2009.
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. X
Do not add any special fuel additive into vehicle diesel oil. If a fuel additive is added, your X
Chapter 6
X
warranty will be limited. X
X
The fuel tank capacity is 300L. X
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
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.
Table × 6-004
X
X Hydraulic Oil Physical & Chemical Character Variation
Chapter 6
X Inspected item Limitation Value

X L-HS L-HV L-HM
X Kinematic viscosity
X ±10% ±10% ±10% - 15%
(40℃) (mm2/s)
Acid value addition
0.3 0.3 0.3
(mgKOH/g)
Moisture (%) 0.1 0.1 0.1
Flash point (°C) -76 -76 -76
Solid grain pollution
20/16 20/16 20/16
grade
06 - 3
Recommended brand of hydraulic oil used in different ambient temperature
Table × 6-005
The lowest The lowest The lowest The highest
Ambient temperature temperature working temperature Hydraulic oil
temperature for cold start for cold start temperature of hydraulic brand
(without load) (with load) with load oil
-40℃ -35℃ -15℃ 50℃ SH 0358-95
Below -30℃ 10# aviation
-35℃ -22℃ -5℃ 60℃ hydraulic oil
GB11118.1-94
low condensed
Above -30℃ -28℃ -15℃ 0℃ 70℃
hydraulic oil
L-HV32
Between GB11118.1-94
low condensed
-20℃ and -20℃ -10℃ 5℃ * 80-85℃
hydraulic oil
40℃ L-HM46
GB11118.1-94
low condensed
Above 40℃ -5℃ -3℃ 20℃ ** 100℃
hydraulic oil
L-HM68
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.
4. If you find any special working conditions which are not listed in the above table,
please consult the related departments of our company.
X
X
Chapter 6
X
1. Check and measure oil temperature of system at any time! X
X
2. The suitable temperature range for hydraulic system in working condition is X
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
6.6 Lubricating grease
In order to keep crane in good working condition, all machinery parts should be supplied
with specified grease periodically.
Table × 6-006 Recommended lubricating greases

Drop Work wimble
Moisture (%) no
Type Appearance point degree
more than
(℃) (1/10mm)
ZL-2 Smooth inunctum with
lubricating the color from pale 175 265 - 295 ——
grease yellow to brown
ZG-3 Equal inunctum with the
lubricating color from pale yellow to 90 220 - 250 2.5
grease brown
X
X
Chapter 6
X
X
X
X
06 - 5
for Crawler Crane
Chapter 7 Appendix
7.1 Tightening torque of threaded parts
Table ×7-001 Tightening torque (N.m) of threaded parts (8.8-12.9 grade)
Performance grade 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
M8×1 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
M10×1 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
M12×1.5 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
M14×1.5 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
M16×1.5 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
M18×1.5 127 - 152 171 - 205 210 - 247 247 - 291 331 - 397 457 - 541 541 - 641
Specification of bolt
M20 160 - 192 216 - 258 264 - 312 312 - 366 417 - 500 576 - 683 683 - 808
M20×1.5 178 - 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
M20×1.5 239 - 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
M24×2 301 - 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
M27×2 437 - 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
M30×2 608 - 728 820 - 982 1005 - 1203 1164 - 1393 1587 - 1900 2196 - 2629 2566 - 3072
Chapter 7
M36 961 - 1150 1295 - 1550 1587 - 1900 1838 - 2200 2506 - 3000 3466 - 4150 4051 - 4850
M36×3 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
M42×3 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
M48×3 2513 - 3008 3387 - 4055 4152 - 4970 4807 - 5755 6556 - 7848 9069 - 10857 10598 - 12688
07 - 1
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
1/8″ 1/4″ 1/4″ 3/8″ 1/2″ 1/2″ 3/4″ 1″ 11/4″ 11/2″
thread
Specification
Metric M10× M12× M14× M16× M18× M22× M26× M33× M42× M48×
of pipe orifice
taper
thread 1 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2
Specification of oil pipe
φ6 φ8 φ10 φ12 φ15 φ18 φ22 φ28 φ35 φ42
(mm)
Pipe
thread 18 35 35 70 90 90 180 310 450 540
Tightening (light)
torque Metric
(N.m) taper
18 25 45 55 70 125 180 310 450 540
thread
(light)
Table × 7-003 Tightening torque of thread parts at pipe orifices (applicable to heavy pipe
fittings)
Pipe
1/4″ 1/4″ 3/8″ 3/8″ 1/2″ 1/2″ 3/4″ 1″ 11/4″ 11/2″
thread
Specification
Metric M12× M14× M16× M18× M20× M22× M27× M33× M42× M48×
of pipe orifice
taper
thread 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2
Specification of oil pipe
φ6 φ8 φ10 φ12 φ14 φ16 φ20 φ25 φ30 φ38
(mm)
Pipe
thread 55 55 80 80 115 115 180 310 450 540
Tightening (heavy)
torque Metric
(N.m) taper
35 55 70 90 125 135 180 310 450 540
thread
(heavy)
Chapter 7
07 - 2
7.3 Attached tools for maintenance
Table ×7-004 Attached tools for maintenance
Names of the
No. ID code Specification QTY.
tools
1 1019900187 Pressure gauge SPG063-00060-01-S-M04 1
2 1019900189 Pressure gauge SPG063-00400-01-S-M04 1
Pressure testing
3 1140102826 SMK20-M14X1.5-PC 1
joint
4 1140207054 Testing hose P20-PM14-3-1500 1
Pressure testing
5 1140102828 SMK20-G1/4-PC 1
joint
6 00663009100001010 Square timber 12
7 1991100032 Tool box assy. GJX70-91-0 1
Flexible belt with
8 1090100043 ST009 2T-8000 2
two ends fastening
Pressure testing
9 1140102830 SMK20-10L-PK 2
joint
10 1102900001 Screw jack QL5 2
Chapter 7
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 Crane manufacturer: Serial Number: Serial Number of user:
Company: Inspected by: Recorded by: Date:
1. Inspection category: Power system

Components Inspection
Result Remarks
inspected intervals
Check rotational speed,
water temperature, oil
Engine
pressure and relevant
warning icons etc.
Engine mounting Check the bolts for tight fit
fastening bolts and and the housing for oil
engine housing leakage
Fan blade and belt
Antifreeze coolant
level
Engine oil level
Check it for deformation and
Radiator core
water leaks
Wind drag of air filter
Air intake pipe
Check it for deformation and
Intercooler core
wind leaks
Check it for oil leaks and
Fuel pipeline
Chapter 7
damage
Check if there is water in the
Fuel pre-filter
filter.
Check if there is sediment
and water in the tank.
Fuel tank
Check the tank for
corrosion.
07 - 4
2. Inspection category: winch reducer

Inspection
Components inspected Result Remarks
intervals
Check if the load falls
Status of load down uncontrollable
after engine stops.
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
Bearing of reducer
lubricating condition
of bearing.
Lowering limiter
Check them for oil
Reducer and motor
leaks
Mounting screw (or bolts)
3. Inspection category: slewing mechanism
Inspection
intervals
Sound made by slewing
reducer and slewing ring
when they are running
Gear oil level
Brake
Slewing reducer Check it for oil leaks
Chapter 7
Slewing motor Check it for oil leaks

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
4. Inspection category: travel gear

Inspection
intervals
Check the convex
Track pad teeth of track pad for
wear
Pin spindles of track pad Check them for cracks
Check the slot of drive
Drive sprocket
sprocket for wear
Check it for oil leaks
Track roller
and cracks
Tension of crawler
Traveling reducer Check it for oil leaks
5. Inspection category: hydraulic system
Inspection
intervals
Oil level in the hydraulic oil
tank
Check if there is
Hydraulic oil tank
sediment in the tank.
Change the filter
Oil return filter
cartridge
Check them for oil
Pipelines and pipe fittings
leaks and damage
Check if the filter is
Air filter
clogged.
Oil cooler
and damage.
Hydraulic motor and pump
Valves in the hydraulic Check them for oil
system leaks
Energy accumulator
Chapter 7
and damage
07 - 6
6. Inspection category: electrical system

Inspection
intervals
Check if the value shown is
correct and the warning icon
Load moment limiter flashes when irregular condition
occurs.
Hoisting limit switch Check it for functional work
Lowering limit switch Check it for functional work
Tilting-back limit switch Check it for functional work
Shutoff valve limit switch Check it for functional work
Angle limit switch Check it for functional work
Check if the wind speed is
Wind speed sensor shown or the sensor is
damaged.
Check if the inclination
Inclination sensor shown is correct or the
sensor is damaged.
Check if the pressure
Pressure sensor shown is correct or the
sensor is damaged.
Check the clearness of
Monitoring system image, and the video for
damage
Check if the plug and
Connector on the boom socket are connected
and slewing table tightly, or they are
damaged.
Check if the oil level is
Oil level sensor shown or the sensor is
damaged.
Chapter 7
7. Inspection category: load hook and pulley

Inspection
intervals
Check the lubricating
Pulley
condition of pulley
Check the sealing seat of
Pulley spindle spindle and its roll
resistance
Check the sealing seat of
Hook shaft
shaft and its roll resistance
Check it for cracks and
Load hook
wear
07 - 7
8. Inspection category: wire rope

Inspection
intervals
Check rope end point,
Wire rope for hoisting
number of wire breaks and
winch 1
strand breaks
Wire rope for hoisting
number of wire breaks and
winch 2
strand breaks
Derricking rope number of wire breaks and
strand breaks
Rope thimble and rope Check them for cracks and
lock deformation
9. Inspection category: safety equipment
Inspection
intervals
Check the spring for
Main boom tilting-back functional work and the
support tilting-back support for
deformation and corrosion.
Front tilting-back support functional work and the
of fixed jib tilting-back support for
Rear tilting-back support functional work and the
of fixed jib tilting-back support for
Mounting spindle of
Check it for tight fit
tilting-back support
10. Inspection category: Boom, jib and other load-bearing parts
Inspection
intervals
Chapter 7
Check the attachment

points on the boom, and
Main boom check the boom for
deformation, corrosion and
cracks.
points on the jib, and check
Fixed jib
the boom for deformation,
corrosion and cracks.
Check the attachment points on
FA-frame, and check the boom
FA-frame for deformation, corrosion and
cracks.
07 - 8
Inspection
intervals
points on A-frame, and
A-frame check the boom for
deformation, corrosion and
cracks.
Check the lubricating
Rope pulley on A-frame
condition of rope pulley
Main boom anchoring Check it for deformation,
rods corrosion and cracks.
Fixed jib front anchoring Check it for deformation,
Fixed jib rear anchoring Check it for deformation,
Chapter 7
07 - 9

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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)

Unauthorized person is not allowed to dismantle or adjust the hydraulic elements

The following symbols appear in this manual:

Indicate an imminent threat or danger, which could lead to

Indicate a danger, which could lead to serious injury of one or more

Indicate a potential danger, which could lead to slight or minor injury of

Indicate a danger which could lead to severe damage to the machine

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

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

Special information ....................................................................................................................II

Chapter 1 About this manual ............................................................................................. 01-1

1.1 General ......................................................................................................................... 01-1

Chapter 2 Safety instructions ............................................................................................. 02-1

2.1 Safety guidelines .......................................................................................................... 02-1

Chapter 3 Description of the crane .................................................................................... 03-1

3.1 Description of main components .................................................................................. 03-1

Chapter 4 Maintenance and service ................................................................................... 04-1

4.1 General ......................................................................................................................... 04-1

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

Chapter 5 Troubleshooting ................................................................................................. 05-1

5.1 Troubleshooting of mechanical drive ............................................................................ 05-1

Chapter 6 Application of oil................................................................................................. 06-1

6.1 Antifreeze coolant ......................................................................................................... 06-1

Chapter 7 Appendix ............................................................................................................. 07-1

7.1 Tightening torque of threaded parts.............................................................................. 07-1

stipulated in this manual, especially the information about ,

1.2 Product identification

Fig. × 1-001 Position of name plate

1.3 Illustration and symbols

― Position of working mechanism to be operated

1.4 Hazard indicator

Indicate an imminent threat or danger, which could lead to life-threatening

2.1 Safety guidelines

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

j) Depressurize all pipelines or containers before demounting the fittings or

2.2 Environmental protection disposal

Dispose harmful substances according to the following regulations:

d) The pollutant must be gathered together and preserved according to different

Chapter 3 Description of the crane

3.1 Description of main components

Main boom anchoring rods

Wire rope for hoisting winch 1

Main load hook

Fig. × 3-001 Overview of crawler crane

Operator’s Slewing mechanism

Hydraulic oil Engine system

Right crawler carrier

Main boom derricking

Fig. × 3-002 Overview of crane undercarriage

3.2 Hydraulic system

3.2.1 Hydraulic system diagram

Traveling motor (L) Reducer

Hoisting winch 1 Reducer

Traveling motor (R) Reducer

Derricking motor Reducer

Slewing motor Reducer