Zoomlion ZCC1100H - Operation, Maintenance & Owners Manual

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ZOOMLION ZCC1100H - OPERATORS MANUAL - OWNERS MANUAL

- English Owners Manual / Operators Manual, to crawler crane Zoomlion ZCC1100H.


CONTENTS:

- To Users  I
- Safety Instructions. II
- Chapter 1 Safety
- Important instructions. 1-1
- Notes . 1-1
- Alarms and warnings 1-1
- Safety tips 1-2
- Safety precautions . 1-2
- Precautions for operator safety. 1-2
- Environmental safety . 1-2
- Personnel protective equipment (PPE) . 1-2
- Organizational safety measures . 1-3
- Personnel qualification, requirements and responsibilities  1-3
- Safety advice regarding specific operation phases . 1-4
- Special Hazards. 1-4
- Electrical power 1-4
- Gas, dust, steam, smoke and noise 1-5
- Welding or naked flames 1-5
- Hydraulic equipment. 1-5
- Chapter 2 Description of Crane
- 2.1 Product model . 2-1
- 2.1.1 Product name plate and its position 2-1
- 2.1.2 Engine type and its manufacturer . 2-2
- 2.1.3 Intended use of the crane. 2-2
- 2.1.4 Classification of the crane . 2-2
- 2.2 Terminology . 2-5
- 2.2.1 Crane modes . 2-5
- 2.2.2 Description of main components. 2-8
- 2.3 Product description 2-10
- 2.3.1 Crane working environment 2-10
- 2.3.2 Crawler travel gear. 2-10
- 2.3.3 Crane superstructure 2-10
- 2.3.4 Overall dimensions. 2-12
- 2.4 Technical data 2-13
- 2.4.1 Main technical parameter . 2-13
- 2.4.2 Specification of load hook and selection of rope reeving . 2-15
- 2.4.3 Performance of wire rope and winch. 2-15
- 2.4.4 Lifting height  2-18
- 2.4.5 Lifting capacity chart. 2-21
- 2.4.6 Lifting capacity in assembly mode  2-57
- Chapter 3 Safety Guidelines
- 3.1 Operational planning 3-1
- 3.1.1 Correct use of the crane. 3-2
- 3.1.2 Possible consequences resulting from improper use of the crane. 3-2
- 3.1.3 Responsibility of relevant personnel . 3-3
- 3.1.4 Work area  3-4
- 3.2 Safety technical notes 3-5
- 3.2.1 Safety instructions for crane operator . 3-5
- 3.2.2 The requirement for the crane operator during the whole operation  3-5
- 3.2.3 Safety instructions for the rigger . 3-6
- 3.2.4 Safety instructions for the signalman 3-7
- 3.2.5 Safety instructions for crane operating crew . 3-7
- 3.2.6 Electromagnetic influences. 3-8
- 3.2.7 Safety signs . 3-9
- 3.2.8 The potential dangers existing in crane operation. 3-17
- 3.2.9 Injuries due to hydraulic energy 3-18
- 3.2.10 Scald . 3-19
- 3.2.11 Risk of chemical burns 3-19
- 3.2.12 Risk of fire and explosion . 3-20
- 3.2.13 Risk of poisoning and asphyxiation. 3-22
- 3.2.14 Endangering the environment. 3-23
- 3.3 Slings  3-24
- 3.3.1 Hooks  3-24
- 3.3.2 Rigging introduction . 3-24
- 3.3.3 Slings introduction 3-25
- 3.3.4 Sling safety  3-25
- 3.3.5 Sling safety guide. 3-26
- 3.3.6 Taglines . 3-26
- 3.3.7 Load center of gravity. 3-27
- 3.4 Requirements for operating site . 3-28
- 3.4.1 Slopes and trenches. 3-28
- 3.4.2 Permissible ground pressure 3-29
- 3.4.3 Travel on level ground or slope without a load  3-30
- 3.4.4 Travel on level ground or slope with a load. 3-30
- 3.4.5 The requirements for crawler crane with attachments on uphill slopes  3-30
- 3.5 Operation weather . 3-32
- 3.5.1 Snow and ice . 3-32
- 3.5.2 Lightning Strikes. 3-32
- 3.6 Electrical safety 3-33
- 3.6.1 Safety regulations for auxiliary power supply (220V AC)  3-33
- 3.7 Underground cables. 3-34
- 3.7.1 In underground working, it is possible to damage: . 3-34
- 3.7.2 Safety precautions and protective measures when operating the equipment near underground cables. 3-34
- 3.7.3 Notes in connection with gas pipes. 3-35
- 3.7.4 The consequences of a gas pipe’s damage 3-35
- 3.7.5 Measures adopted if a gas pipe is damaged and the gas escapes, or a leak is suspected 3-36
- 3.7.6 Measures adopted in the event of a gas fire . 3-36
- 3.7.7 Notes in connection with underground electric cables. 3-37
- 3.7.8 The consequences of damaging an underground cable 3-37
- 3.7.9 The measures taken when the machine damages an underground cable . 3-37
- 3.8 Checking safety measures. 3-39
- 3.8.1 Daily inspection of the crane. 3-39
- 3.8.2 Safety checking before crane operation 3-39
- 3.9 Crane operation with a load . 3-40
- 3.9.1 Counterweight 3-40
- 3.9.2 Crane operation . 3-41
- 3.10 Hand signals for controlling crane operations . 3-53
- Chapter 4 Crane operation
- 4.1 Operating and control instruments 4-1
- 4.1.1 Operator’s cab, overview 4-1
- 4.1.2 Operating console 4-3
- 4.1.3 Control lever. 4-4
- 4.1.4 Left control panel 4-7
- 4.1.5 Right control panel . 4-8
- 4.1.6 Control panel on the roof of operator’s cab. 4-9
- 4.2 Instruction for digital display system. 4-12
- 4.2.1 Load moment limiter. 4-12
- 4.2.2 Electrical system 4-13
- 4.3 Startup of the crane . 4-19
- 4.3.1 Adjustment of crane operator’s seat . 4-19
- 4.3.2 Checks before startup  4-21
- 4.3.3 Turn on power supply. 4-22
- 4.3.4 Operation of air conditioning in operator’s cab 4-24
- 4.3.5 Horn. 4-24
- 4.3.6 Start of engine 4-25
- 4.4 Safety device. 4-27
- 4.4.1 Emergency stop button  4-27
- 4.4.2 Battery master switch. 4-28
- 4.4.3 Flashing light 4-29
- 4.4.4 Load moment limiter. 4-29
- 4.4.5 Boom angle indicator . 4-31
- 4.4.6 Derricking limiter  4-32
- 4.4.7 Lowering limiter 4-33
- 4.4.8 Hoisting limiter . 4-34
- 4.4.9 Anemometer  4-35
- 4.4.10 Crane inclinometer . 4-35
- 4.4.11 Checklist of safety device . 4-36
- 4.5 Crane operation. 4-40
- 4.5.1 Preparation for operation 4-40
- 4.5.2 Inspection during operation  4-40
- 4.5.3 Valid area of control lever. 4-41
- 4.5.4 Setting of work mode . 4-42
- 4.5.5 Operation of travel gear 4-42
- 4.5.6 Operation of crane winches 4-46
- 4.5.7 Operation of slewing mechanism 4-51
- 4.5.8 Auxiliary remote control box . 4-55
- 4.6 Rope reeving. 4-57
- 4.6.1 Hoisting rope guidance and reeving . 4-57
- 4.6.2 Derricking rope reeving  4-61
- 4.6.3 Fixation of rope end point. 4-63
- Chapter 5 Assembly and Dismantling
- 5.1 Safety-technical notes 5-1
- 5.1.1 Notes on assembly. 5-1
- 5.1.2 Checking safety measures . 5-1
- 5.1.3 Checking wire rope, load hook, rope pulley and anchoring rod 5-3
- 5.2 Assembly of basic machine 5-5
- 5.2.1 Unloading of basic machine 5-5
- 5.2.2 Self-assembly and dismantling of crawler carrier (optional). 5-10
- 5.2.3 Extending and retracting of crawler carrier 5-16
- 5.2.4 Assembly of central counterweight . 5-22
- 5.2.5 Self-assembly and dismantling of counterweight. 5-26
- 5.2.6 Fixation of mounting cylinder 5-32
- 5.3 Available boom configurations 5-34
- 5.4 Boom configuration 5-37
- 5.4.1 Main boom (S-1)  5-37
- 5.4.2 Main boom with fixed jib (SF-1)  5-50
- 5.5 Assembly and dismantling of main boom . 5-59
- 5.5.1 Preparations for assembly 5-59
- 5.5.2 Assembly of main boom. 5-59
- 5.5.3 Electrical connection to main boom  5-66
- 5.5.4 Erecting main boom . 5-68
- 5.5.5 Lowering and dismantling main boom. 5-70
- 5.6 Assembly and dismantling of main boom with fixed jib 5-71
- 5.6.1 Preparation for assembly 5-71
- 5.6.2 Assembly of fixed jib. 5-71
- 5.6.3 Electrical connection to fixed jib 5-76
- 5.6.4 Erecting main boom with fixed jib . 5-78
- 5.7 Assembly and dismantling of tip boom . 5-81
- 5.8 Transport weights and dimensions of main components. 5-82
- 5.9 Transport means and safety precautions for transport  5-85
- 5.9.1 Safety precautions for transport 5-85
- 5.9.2 Other requirements  5-85