FWX85 Operation Manual

FWX85M
Hydraulic Crawler Crane
Operation Manual
FUWA HEAVY INDUSTRY CO.,LTD.

Foreword
Thank you for purchasing FWX85M hydraulic crawler crane from FUWA Heavy Industry Co.,
Ltd, this product is developed, designed and accumulated with many years’ experience and
foreign advanced technology. You should read this manual carefully before to ensure safe
operation and improvement of working efficiency.
Warning
z If this manual is lost or damaged, please buy it from FUWA Heavy Industry Co.,
Ltd.
z In the event of sale, disposal or loan, the operation manual must accompany the
machine.
z Please refer to Parts Manual when buying spare parts of this machine.
z Please observe the local regulation when operating the machine.
z Please carefully check, operate and maintain the machine and keep safety first.
z Any damage occurred will not be guaranteed if operate in the crane is not
according to the instruction of this manual..
z Please comply with the conventional mechanical safety requirements in addition
to observe the safety requirement of this manual.
z If the crane need to reconstruct, contact us immediately.
Quality warranty
The quality assurance scope is clearly defined. The faults and damages recognized by us
will be free to repair during the warranty period.
Maintenance of parts
Please replace the parts periodically to avoid accidents happening due to key parts which
ensure the safety of the crane. Please refer to Parts Manual complied by us when selecting
the parts.
Ongoing development ensures the advanced technology and the high level of quality in our
machine. This may result in deviations between the instruction and your machine. Engine
and attachments refer to the Operation Manual by Parts manufacture. Please contact with
our company if there is any problem.
FUWA Heavy Industry Co.,Ltd

No.2 Shuangyang Road,Shuncheng District,
Fushun-Liaoning,China
P/C. 113126
Tel:+86-24-57649117/57642558
Fax:+86-24-57642766
Email:export@cnfuwa.com
www.cnfuwa.com
Contents
Chapter 1 Crane Instructions ............................................................................................1-1/12
1.1 General....................................................................................................................1-1/12
1.2 Serial No. of crane...................................................................................................1-3/12
1.3 Crane’s direction......................................................................................................1-3/12
1.4 Working environment and conditions of crane.........................................................1-4/12
1.5 Paste position and meanings of safety signs...........................................................1-6/12
Chapter 2 Safety...............................................................................................................2-1/53
2.1 Basic precautions ....................................................................................................2-1/53
2.1.1 Follow safety instructions .....................................................................................2-1/53
2.1.2 Wear protective items ...........................................................................................2-1/53
2.1.3 Protect against noise ............................................................................................2-2/53
2.1.4 Health requirements for the operators ..................................................................2-2/53
2.1.5 Responsibility and duty of the crew members ......................................................2-2/53
2.1.5.1 Operator’s responsibility ....................................................................................2-3/53
2.1.5.2 Signalman’s responsibility .................................................................................2-3/53
2.1.5.3 Responsibilities of all crew members.................................................................2-4/53
2.1.6 Emergency preparation ........................................................................................2-4/53
2.1.7 Requirements for working area.............................................................................2-4/53
2.1.8 Operate the crane in the correct position..............................................................2-5/53
2.1.9 Ground condition required for crane operation .....................................................2-6/53
2.1.10 Never dismantle the safety devices ....................................................................2-6/53
2.1.11 Assembling/dismantling the machine ..................................................................2-7/53
2.1.12 Opening/closing the cab door with care..............................................................2-7/53
2.1.13 Only operate the machine on the seat................................................................2-7/53
2.1.14 Only operators can stay on the working crane....................................................2-8/53
2.1.15 Do not use this crane to lift up person ................................................................2-8/53
2.1.16 Prevent tipping over accidents............................................................................2-8/53
2.1.17 Power lines .........................................................................................................2-9/53
2.1.18 Be cautious about electrification induced by high voltage radio waves ............2-10/53
2.1.19 Thunder and lightning hazard ........................................................................... 2-11/53
2.1.20 Precautions for operating on the windy days .................................................... 2-11/53
2.1.20.1 Precautions and treatments of wind ..............................................................2-13/53
2.1.20.2 Measuring method of wind speed..................................................................2-18/53
2.1.21 Precautions against earthquake .......................................................................2-19/53
2.1.22 Precautions when crane stop operating ...........................................................2-20/53
2.1.23 Precaution for swollen river/high tide in beach .................................................2-20/53
2.2 Preparation for safe operation ...............................................................................2-20/53
2.2.1 Ensure safety jobsite ..........................................................................................2-20/53
2.2.2 Check machine before operation........................................................................2-21/53
2.2.3 Adjust operator’s seat position............................................................................2-22/53
2.2.4 Inspection before starting engine........................................................................2-22/53
2.2.5 Warm-up operation .............................................................................................2-22/53
I
2.2.6 Inspection after starting engine...........................................................................2-23/53
2.2.7 Do not deactivate safety device functions ..........................................................2-23/53
2.3.Precautions for operation ......................................................................................2-23/53
2.3.1 Investigate jobsite environment ..........................................................................2-23/53
2.3.2 Avoid abrupt operation .......................................................................................2-24/53
2.3.3 Never attempt to leave operator’s seat...............................................................2-24/53
2.3.4 Operate the machine within working range ........................................................2-24/53
2.3.5 Prevent boom and jib from coming in contact with lifted load .............................2-25/53
2.3.6 Precautions when engine stop............................................................................2-25/53
2.3.7 Keep away from obstructions .............................................................................2-26/53
2.3.8 Pay attention to any abnormality in machine operational condition ....................2-26/53
2.3.9 Keep good visibility.............................................................................................2-26/53
2.3.10 Precautions for operation in cold weather season ............................................2-26/53
2.3.11 Precautions when combined operations ...........................................................2-27/53
2.3.12 Never use boom for pushing/pulling operation .................................................2-27/53
2.3.13 Do not relay safety devices...............................................................................2-28/53
2.3.14 Precautions for traveling ...................................................................................2-28/53
2.3.15 Precautions for traveling with load....................................................................2-30/53
2.3.16 Avoid injury from traveling in reverse or slewing operation...............................2-31/53
2.3.17 Precautions for slewing operation.....................................................................2-31/53
2.3.18 Never allow the lifted load to pass over a person .............................................2-32/53
2.3.19 Be cautious of sway of the unused hook ..........................................................2-32/53
2.3.20 Precautions for hoisting the boom ....................................................................2-32/53
2.3.21 Do not use a boom/jib longer than necessary...................................................2-34/53
2.3.22 Do not use both the front and rear drums at the same time .............................2-34/53
2.3.23 Do not lift more than one load...........................................................................2-35/53
2.3.24 Do not laterally pull or drag a load with the hook ..............................................2-35/53
2.3.25 Do not lift one load with two or more machines ................................................2-35/53
2.3.26 Know the lifting load weight beforehand ...........................................................2-36/53
2.3.27 Never overload operation .................................................................................2-36/53
2.3.28 Do not use the machine to extract loads ..........................................................2-37/53
2.3.29 Do not allow the lifted load to free-fall...............................................................2-37/53
2.3.30 Steady operation for free-fall ............................................................................2-37/53
2.3.31 Precautions for lifting the load off the ground ...................................................2-37/53
2.3.32 Hook overhoist prevention ................................................................................2-38/53
2.3.33 Lifting operation of a long-shape load...............................................................2-38/53
2.3.34 Precautions for extension in working radius .....................................................2-38/53
2.3.35 Select correct hook size and number of sling wire ropes..................................2-39/53
2.3.36 Be careful not to excessively pay out wire rope................................................2-39/53
2.3.37 Rectify irregular winding or twisting of wire rope...............................................2-39/53
2.3.38 Operate the machine safely if overloaded ........................................................2-40/53
2.3.39 Precautions for lifting ........................................................................................2-40/53
2.3.40 Precautions for operating it as clamshell bucket...............................................2-42/53
2.3.41 Lowering/Hoisting a load to/from the under ground level..................................2-44/53
II
2.3.42 Carefully pull out a buried object such as a pile................................................2-45/53
2.4 Precautions for preparation of operation and transportation..................................2-45/53
2.4.1 Setting machine..................................................................................................2-45/53
2.4.2 Keep away from machine when giving signals ...................................................2-45/53
2.4.3 Never jump on or off the machine.......................................................................2-46/53
2.4.4 Assemble/Disassemble machine in correct procedures .....................................2-46/53
2.4.5 Do not put your fingers and/or hands into pin holes when aligning pin hole
center………………………………………………………………………………………….2-46/53
2.4.6 Use safety belt when working at high locations ..................................................2-46/53
2.4.7 Carefully adjust the height crane boom ..............................................................2-47/53
2.4.8 Precautions for removing /installing counterweight.............................................2-47/53
2.4.9 Do not enter the inside of the boom/jib ...............................................................2-47/53
2.4.10 Prevent falling from the boom...........................................................................2-47/53
2.4.11 Jib holder of luffing jib .......................................................................................2-47/53
2.4.12 Precautions for lowering luffing jib ....................................................................2-47/53
2.4.13 Precautions for lowering boom .........................................................................2-48/53
2.4.14 Prevent pendant rope from falling.....................................................................2-48/53
2.4.15 Securely support luffing jib/boom/jib .................................................................2-48/53
2.4.16 Carefully drive out pins .....................................................................................2-49/53
2.4.17 Pay out wire rope in correct method .................................................................2-49/53
2.4.18 Wind wire rope in a regular alignment ..............................................................2-49/53
2.4.19 Install wire rope correctly ..................................................................................2-50/53
2.4.20 Before raising the boom, check if there is a part and/or tool remaining behind on
it………………………………………………………………………………………………..2-50/53
2.4.21 Ensure safety operation....................................................................................2-50/53
2.4.22 Loading/Unloading on trailer.............................................................................2-51/53
2.4.23 Avoid overloading trailer ...................................................................................2-51/53
2.4.24 Obey associated local regulations ....................................................................2-52/53
2.4.25 Investigate local traffic regulation .....................................................................2-52/53
2.4.26 Avoid letting the machine to come in contact or collide with obstructions.........2-52/53
2.4.27 Arrange a signal person ...................................................................................2-52/53
2.4.28 Check transportation route surfaces.................................................................2-53/53
2.4.29 Park machine safely .........................................................................................2-53/53
Chapter 3 Names and Functions of Parts.........................................................................3-1/50
3.1 Main parts of crane ..................................................................................................3-1/50
3.1.1 Composition of undercarriage.............................................................................3-3/50
3.1.2 Composition of superstructure..............................................................................3-4/50
3.1.3 Composition of counterweight ..............................................................................3-5/50
3.1.4 Composition of boom............................................................................................3-6/50
3.1.5 Composition of runner ..........................................................................................3-8/50
3.1.6 Fixed jib ................................................................................................................3-9/50
3.1.7Holding luffing jib .................................................................................................3-10/50
3.1.8 Mast device ........................................................................................................3-12/50
3.2 Positions and functions of operation parts .............................................................3-13/50
III
3.2.1 Cab parts ............................................................................................................3-13/50
3.2.2 Operating levers and pedals...............................................................................3-14/50
3.2.3 Operating console and display console ..............................................................3-20/50
3.2.4 Monitor system.................................................................................................3-33/50
3.2.5 Air-conditioner system ........................................................................................3-34/50
3.2.6 Overload release switch .....................................................................................3-37/50
3.3 Safety device .........................................................................................................3-39/50
3.3.1 Precautions for safety devices operation ............................................................3-39/50
3.3.2 Safety device operation ......................................................................................3-40/50
3.3.3 Annunciator and alarm light ................................................................................3-46/50
Chapter 4 Operation ...........................................................................................................4-1/17
4.1 Daily inspection .......................................................................................................4-1/17
4.2 Inspection before operating .....................................................................................4-1/17
4.2.1 Inspect pedal, hand grip, operating lever and switch............................................4-1/17
4.3 Connect the power ..................................................................................................4-1/17
4.4 Start engine .............................................................................................................4-2/17
4.4.1 Start engine ..........................................................................................................4-2/17
4.4.2 Preheat of engine...............................................................................................4-3/17
4.4.3 Use of auxiliary battery block................................................................................4-3/17
4.5 Inspection and operation after starting the engine...................................................4-4/17
4.5.1 Warm-up operation ...............................................................................................4-4/17
4.5.2 Inspection of engine parameter ............................................................................4-5/17
4.5.3 Inspection of engine’s sound and exhaust color ...................................................4-5/17
4.6 Inspection of moment limiter (overload protection device) (Fig 4.6) ........................4-5/17
4.7 Stop engine .............................................................................................................4-6/17
4.8 Hook hoisting/lowering operation.............................................................................4-7/17
4.9 Locking operation of derricking gear pawl ...............................................................4-8/17
4.10 Boom derricking hoisting/derricking lowering operation.........................................4-9/17
4.11 Slewing operation (including slewing lock, brake and float operation) ................. 4-11/17
4.11.1 Slewing brake operation ...................................................................................4-12/17
4.11.2 Slewing float operation......................................................................................4-13/17
4.11.3 Slewing locking operation .................................................................................4-13/17
4.11.4 Slewing operation .............................................................................................4-13/17
4.12 Traveling operation ..............................................................................................4-13/17
4.12.1 Traveling forward/backward..............................................................................4-15/17
4.12.2 Direction change during traveling .....................................................................4-15/17
4.12.3 Traveling direction change in original position ..................................................4-16/17
4.13 Wire remote control box operation.......................................................................4-16/17
Chapter 5 Assembling and Disassembling the Crane .....................................................5-1/93
5.1 Assembling ..............................................................................................................5-1/93
5.1.1 Preparation and precautions before assembling. .................................................5-1/93
5.1.2 Unloading the base machine from trailer (with track frame) .................................5-2/93
5.1.3 Drive the base machine off the trailer (without track frame)..................................5-4/93
5.1.4 Extension of track frame.......................................................................................5-6/93
IV
5.1.5 Installation of cab pedal ........................................................................................5-8/93
5.1.6 Installation of counterweight .................................................................................5-8/93
5.1.7 Installation of track carrier...................................................................................5-12/93
5.1.8 Counterweight’s self-assembling ........................................................................5-15/93
5.1.9 Configuration of boom/fixed jib and pendant rope ..............................................5-18/93
5.1.10 Installation of boom head..................................................................................5-24/93
5.1.11 Installation of boom insert .................................................................................5-28/93
5.1.12 Installation of fixed jib .......................................................................................5-32/93
5.1.13 Installation of runner .........................................................................................5-39/93
5.1.14 Installation of holding luffing jib .........................................................................5-41/93
5.1.15 Installation of hook and wire rope ......................................................................5-5393
5.1.16 Installation of rope socket .................................................................................5-61/93
5.1.17 Connection of boom cable ................................................................................5-62/93
5.2 Disassembling .......................................................................................................5-66/93
5.2.1 Preparation and precautions before disassembling............................................5-66/93
5.2.2 Disconnection of boom cable..............................................................................5-67/93
5.2.3 Disassembling the runner ...................................................................................5-69/93
5.2.4 Disassembling the fixed jib...............................................................................5-70/93
5.2.5 Disassembling the boom ....................................................................................5-74/93
5.2.6 Disassembling the luffing jib (take 24.7+18 as example) ....................................5-79/93
5.2.7 Disassembling the counterweight .......................................................................5-83/93
5.2.8 Retraction of track frame ....................................................................................5-86/93
5.2.9 Disassembling the cab pedal..............................................................................5-88/93
5.2.10 Drive the base machine onto trailer（with track frame）..................................5-88/93
5.2.11 Disassembling the self-assembly counterweight ..............................................5-90/93
5.2.12 Drive the base machine onto trailer (without track frame) ................................5-92/93
Chapter 6 Hoisting and Lowering the Boom ....................................................................6-1/32
6.1 Boom hoisting..........................................................................................................6-1/32
6.1.1 Boom hoisting.......................................................................................................6-1/32
6.1.2 Runner hoisting ....................................................................................................6-5/32
6.1.3 Fixed jib hoisting...................................................................................................6-9/32
6.1.4 Luffing jib working condition hoisting ..................................................................6-15/32
6.2 Boom lowering.......................................................................................................6-21/32
6.2.1 Boom lowering....................................................................................................6-21/32
6.2.2 Runner lowering .................................................................................................6-24/32
6.2.3 Fixed jib lowering................................................................................................6-26/32
6.2.4 Luffing jib working condition lowering .................................................................6-28/32
Chapter 7 Transportation ...................................................................................................7-1/12
7.1 Precautions when transporting on the road ..........................................................7-1/12
7.2 Crane transfer..........................................................................................................7-1/12
7.2.1 Attentions when transfer and transportation .........................................................7-1/12
7.2.2 Operation condition of crane disassembly............................................................7-6/12
7.3 Transportation weight and dimension ......................................................................7-7/12
7.3.1 Base machine.......................................................................................................7-7/12
V
7.3.2 Counterweight ......................................................................................................7-7/12
7.3.3 Boom ………………………………………………………………………………….. 7-8/12
7.3.4 Hook………………………………………………………………………………………7-9/12
Chapter8 Maintenance Instructions ...............................................................................8-1/59
8.1 Maintenance safety instructions ..............................................................................8-1/59
8.1.1 General…………………………………………………………………………………..8-1/59
8.1.2 Selection and qualification of maintainer ..............................................................8-1/59
8.1.3 Risks during maintenance ....................................................................................8-1/59
8.1.4 Precautions before lubrication and maintenance ................................................8-3/59
8.1.5 Fire prevention......................................................................................................8-4/59
8.1.6 Special notices for lubrication and maintenance...................................................8-5/59
8.1.7 Safety instruction for repair...................................................................................8-6/59
8.2 Periodic replacement of easy-damaged spare parts ...............................................8-6/59
8.2.1 Periodic replacement of easy-damaged spare parts.............................................8-6/59
8.2.2 Precautions for replacement of easy-damaged spare parts .................................8-8/59
8.3 Inspection and maintenance time table ...................................................................8-9/59
8.3.1 Daily inspection and maintenance time ................................................................8-9/59
8.3.2 Monthly inspection and maintenance time table ................................................. 8-11/59
8.3.3 Quarter inspection and maintenance time table .................................................8-14/59
8.3.4 Year inspection and maintenance time table ......................................................8-14/59
8.3.5Overhaul…………………………………………………………………………...……8-15/59
8.4 Mechanical inspection and maintenance time table ..............................................8-15/59
8.4.1 Mechanical inspection and maintenance time table ...........................................8-15/59
8.4.2 Grease maintenance ..........................................................................................8-20/59
8.4.3 Bolt inspection and fastening table .....................................................................8-21/59
8.4.4 Adjustment of track tension device .....................................................................8-22/59
8.4.5 Inspect and replace the wire rope.......................................................................8-23/59
8.4.6 Inspection of pulley block and lifting boom .........................................................8-25/59
8.4.7 Inspection and maintenance of hook ..................................................................8-26/59
8.4.8 Maintenance of fuel tank.....................................................................................8-27/59
8.5 Hydraulic inspection and maintenance ..................................................................8-27/59
8.5.1 Hydraulic inspection and maintenance time table...............................................8-27/59
8.5.2 Reducer inspection and maintenance ................................................................8-29/59
8.5.3 Hydraulic oil tank maintenance...........................................................................8-34/59
8.5.4 Hydraulic system oil temperature .......................................................................8-38/59
8.5.5 Hydraulic pump and motor maintenance ............................................................8-39/59
8.5.6 The tighten torque sheet for hydraulic piping......................................................8-40/59
8.5.7 Pressure test of hydraulic system.......................................................................8-41/59
8.5.8 Hydraulic faults inspection ..................................................................................8-45/59
8.6 Electric components maintenance.........................................................................8-47/59
8.6.1 Electric components maintenance time table .....................................................8-47/59
8.6.2 Battery maintenance...........................................................................................8-48/59
8.7 Notes for maintenance and inspection ..................................................................8-50/59
8.8 Inspection and maintenance at special working condition .....................................8-51/59
VI
8.8.1 Rain and snow operation ....................................................................................8-51/59
8.8.2 Seashore operation ............................................................................................8-51/59
8.8.3 Dusty environment..............................................................................................8-52/59
8.8.4 Stone environment..............................................................................................8-52/59
8.8.5 Rockfall site ……………………………………………………………………………8-52/59
8.8.6 Cold area .………………………………………………………………………………8-52/59
8.8.7 Other working environment ................................................................................8-52/59
8.9 Machine storage and use ......................................................................................8-52/59
8.9.1 Short term storage..............................................................................................8-52/59
8.9.2 Long term storage ..............................................................................................8-53/59
8.10 Painting repairing.................................................................................................8-55/59
8.10.1 Paint selection ..................................................................................................8-55/59
8.10.2 Paint confection ................................................................................................8-55/59
8.10.3 Requirements on surface treatment .................................................................8-55/59
8.10.4 Paint coating repair...........................................................................................8-56/59
Attachment 1 ...............................................................................................................8-57/59
Attachment 2 ...............................................................................................................8-58/59
Chapter 9 Technical Data………………………………………………………………………...9-1/25
9.1 Main technical data..................................................................................................9-1/25
9.2 Overall dimensions ..................................................................................................9-2/25
9.3 Hydraulic system diagram .......................................................................................9-3/25
9.3.1 Main winch free-fall (domestic) .............................................................................9-3/25
9.3.2 Non-free fall (domestic) ........................................................................................9-4/25
9.3.3 Double free-fall (Rexroth) .....................................................................................9-5/25
9.4 Electric system diagram and wiring diagram ...........................................................9-6/25
9.4.1 Mechanical engine electric diagram .....................................................................9-6/25
9.4.2 Electrical control engine .......................................................................................9-7/25
9.4.3 Controller…………………………….......................................................................9-8/25
9.4.4 Winch pawl, free-fall working principle..................................................................9-9/25
9.4.5 Slewing, traveling, cylinder .................................................................................9-10/25
9.4.6 Hirschmann moment limiter ................................................................................ 9-11/25
9.4.7Auxiliary equipments ...........................................................................................9-12/25
9.5 Load chart .............................................................................................................9-13/25
9.5.1 Notes for load chart ............................................................................................9-13/25
9.5.2 Boom load chart .................................................................................................9-14/25
9.5.3 Runner load chart ...............................................................................................9-15/25
9.5.4 Fixed jib load chart .............................................................................................9-16/25
9.5.5 Luffing jib load chart ...........................................................................................9-18/25
9.6 Working range .......................................................................................................9-22/25
Chapter 10 Appendix……………………………………………………………………………10-1/6
10.1.Freefall operation............................................................................................... …10-1/6
10.2 Hoisting pawl locking operation .............................................................................10-2/6
10.3 Maintenance of caliper brake ................................................................................10-3/6
10.3.1 Precautions.........................................................................................................10-4/6
VII
10.3.2 Installation ……………………………………………………………………………..10-4/6
10.3.3 Adjustment..........................................................................................................10-4/6
10.3.4 Maintenance .......................................................................................................10-4/6
10.3.5 Maintenance .......................................................................................................10-5/6
10.3.6 Fault analyses ....................................................................................................10-5/6
10.3.7 Overall and installation diagram as shown below: ..............................................10-6/6
VIII
Chapter 1 Crane Instructions
1.1 General
Thank you for purchasing 85T hydraulic crawler crane from FUWA Heavy Industry Co,Ltd,
which is the integration of our centuries’ manufacturing experiences and foreign
advanced technology. You should read this manual carefully before operation to ensure
safe operation and improvement of working efficiency.
z If this manual is lost or damaged, please order it from FUWA Heavy Industry Co.,Ltd.
z In the event of sale, disposal or loan, the operation manual must accompany with the
machine.
z When ordering the parts, please refers to “Parts Manual.”
z Please obey local regulations when using this machine.
z Operate, check and maintain carefully, keep safety first always.
z Any damages will be not guaranteed if you operate this crane without following the
manual.
z Please comply with the conventional mechanical safety regulations, besides the
safety operations in this manual.
z If the crane needs to reconstruct, contact us immediately.
z Quality Guarantee
The quality guarantee scope is clearly defined. Any damages or faults that recognized by
our company will be free to repair during the guarantee period.
z Maintenance of parts
Please replace the parts periodically to avoid accidents happening due to key parts which
ensure the safety of the crane. Please refer to Parts Manual compiled by us when
selecting the parts.
Due to ongoing development and advanced technology, there are differences between
this manual and our machines. Errors can also not be ruled out. Please understand that
1-1/12
no legal claims can be derived from the specifications, illustrations and descriptions
within these instructions.
FUWA Heavy Industry Co.,Ltd.
Add: No.2 ShuangYang Road, Shuncheng District, Fushun Liaoning, China
P.C. 113126
Tel: +86-24-57649117/57642558
Fax：+86-24-57642766
Email：export@cnfuwa.com
1-2/12
1.2 Serial No. of crane
The serial No. of crane is placed on the front of cab or front of superstructure
If any unclear, please tell us the serial No. of crane firstly.
1.3 Crane’s direction
“front, rear, left, right” in the crane refers to the direction when the driver is in the cab seat.
1-3/12
1.4 Working environment and conditions of crane
1. Working environment temperature is -20～+40℃, comparative humidity is less than 85%. It is
allowed to reach 100% when the time is short.
2. The machine can work normally under altitude 1000m.
3. Working wind speed: wind speed can’t be more than 13.8m/s (equal to Grade-6 wind) when
boom length is under 50m; wind speed can’t be more than 9.8ms (equal to Grade-5 wind) when
boom length is more than 50m. Stop working and drop the boom when wind pressure (wind
speed) is more than above.
4. Ground is firm and flat, ground inclination is ≦1%.
Working level is A1; working conditions:
Hoist: M5 Derricking: M2 Slew: M2 Travel: M1
In order to comprehend and master meaning of safety signs, danger figures and abide by safety
operation rules, the machine and its operation manual appear safety signs’ safety warnings, such
as “danger”, “warning”, “caution”, its meaning is as follows.
Icons symbol Meanings
Indicates an imminently hazardous situation which, if not
avoided , will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
5.Time limit of use
Working time limit of whole crane calculation, working condition on the assumption that as follow:
z Crane working is approximately same under the circumstance of big load, middle load and
small load.
z Hoist quantities is about 5-10 times every day.
1-4/12
z Average working time is 210 days every year.
In this case, proper maintenance work on the assumption that, use time limit can be more than
15 years.
Other spare parts design life is 20 years for structure parts, 10 years for mechanism spare parts.
Note: above data only for reference.
1-5/12
1.5 Paste position and meanings of safety signs
The safety signs, paste position and meanings are as shown below, and also take following
notes:
¾ Signs need to be clean, and to be put in marked position.
¾ Signs need to be washed with water or abstergent when dirty, do not use organics such as
petrol. If the grease cannot be cleaned, replace with the same ones.
¾ If signs are lost or damaged, please replace with the new ones.
Meanings Paste position
1. Read the operation manual carefully
2. Pay attention to locking safety devices.
3. Attention to electrical wire, to keep safe
distance.
Right console
1-6/12
Inside of cab door
4.Avoid finger injury when opening
or closing
the door.
5.Statement by the provisions of
operation to prevent tipping
machine
6.Please shut down the engine
and pull the key out before the
maintenance.
7. Ensure to lock the cylinder
device.(this sign is used for
telescopic crawler crane)
1-7/12
1-8/12
8.Keep away from boom section
when assemble or disassemble
the boom pins.
9. No standing under boom
10. Beware of falling off from high.
11. Be careful the high pressure
liquid.
12. Pay attention to hot surface.
13. Avoid finger injury when
opening or closing the door.
14. Do not make your hands into
extrusion area of spare parts in
case accidents happened.
1-9/12
15. Pay attention to the accident
caused by jack up.
16. Operate slowly.
1-10/12
17.Do not stand within the working
radius.
18. Please keep safe distance with
the crane in order to avoided
being extruded.
1-11/12
19. Please use hammer to break
the glass to run away in case the
door cannot be opened if there
happened fire.
20.Fire extinguisher position,
master the usage method.
21. Document box storage
position.
22. External drug bag storage
position.
1-12/12
Chapter 2 Safety
2.1 Basic precautions
2.1.1 Follow safety instructions:
¾ Thoroughly read and understand all safety instructions in

this manual and safety signs affixed to the machine to ensure
proper and safe machine operation.
¾ Always maintain the safety signs clean. In case safety sign
or this manual becomes damaged or missing, immediately order
a replacement from your nearest FUWA dealer. Reinstall the
safety sign in its original position. Store the manual in the
specified place to make it available as needed.
¾ Allow only trained, qualified, and authorized personnel to
operate the machine.
¾ Learn the correct and safe operation, and service of
the machine.
¾ Always keep your machine in proper working condition. Be sure to operate the machine within
the specifications range.
¾ Never apply unauthorized modifications to the machine. A reduction in safety, function,
and/or short life-time of the machine may result and the warranty will be void.
¾ Descriptions indicated with mark cover safety instructions that need to be
observed. Also, pay close attentions to safety other than that which is described in this
manual.
2.1.2 Wear protective items
¾ Do not wear loose and slack clothes, scarves, and keep
free ends of shirts and coats fastened.
¾ Don’t wear bracelet, finger rings, ear rings or other
¾ jewelry to prevent entangling into running parts of machine.

¾ Wear personal protective items.
¾ Periodical clean and maintenance.
¾ Replace the damaged protective items immediately.
¾ Protective items including: safety hat, safety shoes,
safety glasses, dustproof mask, heavy gloves and seat belt, etc.
¾ Do not wear clothes with grease on it, to prevent it from catching fire.
2-1/53
2.1.3 Protect against noise
Loud ambient noise can cause impairment or loss of hearing.
¾ Wear earmuffs or ear plugs in case prolonged
exposure to loud noise is unavoidable when engaging
in works such as when servicing the engine.
2.1.4 Health requirements for the operators
¾ The operator must be healthy physically and mentally
¾ and meet various requirements of health.
¾ The operator must be alert, physically fit, and free
from the influences of alcohol, drugs, or medications that
might affect his eyesight, hearing, reactions, and judgments.
¾ The operator should know first aid procedures and can operate fire extinguisher.
2.1.5 Responsibility and duty of the crew members
If job coordination with personnel concerned is omitted or insufficient,
occurrence of unexpected accidents may result. Be sure to coordinate
the following points beforehand.
¾ Appoint a conductor at the jobsite and unify the order.
¾ Appoint a signal person, and coordinate the signs to be
used in the jobsite.
¾ Appoint a responsible person in lifting work and coordinate the lifting method.
¾ Confirm the locations of other co-workers.
¾ Confirm the installation position of crane and ground conditions. Reinforce the ground
strength as needed.
¾ Confirm the load weight and lifting capacity of crane.
¾ Confirm safety rules regarding prohibited practices or precautions have been publicized.
¾ Provide fences or ropes around limit area.
2-2/53
2.1.5.1 Operator’s responsibility
The operator is the best safety feature in any crane. Safety must always be the operator’s most
important concern. He must refuse to operate when he knows it is unsafe and consult his
supervisor when safety is in doubt.
¾ During operation the operator should focus on the work and keep careful watch of the signal
man, don’t chat during work.
¾ The operator should fully master the working principle of working attachment and familiar
with its structure and the function and usage of safety devices. The operator should also
master the operation, maintenance and repair skills.
¾ The operator must understand how to use the Load Chart of the crane and know that his
machine can safely lift each load before attempting to lift it.
¾ The operator must never lift a load without knowing the length of the boom, the weight of the
load, and the load radius or boom angle.
¾ Never attempt to operate the crane at conditions exceeding those shown on the Load Chart.
Such operation can cause tipping or structural failure of crane which can result in damage,
injury and even death.
¾ The operator must be sure that there are no unnecessary people, equipment and material
stay within the work area. The work area should be properly barricaded.
¾ The operator should not leave the driver’s cabin with the load being hung in the air.
¾ When an operator’s vision is restricted or when operating in hazardous places such as near
electrical power lines or around people, such operation must be done under the directions of
a signal man. Because the operator is not always in the best position to judge distances and
can not see all parts of the jobsite. A signal man must be used at all times. Operators must
understand standard crane signals and take signals only from designated signalman.
2.1.5.2 Signalman’s responsibility

¾ Assists the operator to work safely and efficiently.
¾ Signal man must understand clearly each hoisting
work so that he can safely coordinate each job
with operator and other crew members.
¾ Signal man must stand at a position where he can be
2-3/53
clearly seen and where he can safely observe the entire operation.
¾ Standard crane signals must be used unless other methods of signaling such as interphone.
2.1.5.3 Responsibilities of all crew members

¾ Any unsafe condition or practice must be corrected or reported to the job supervisor.
¾ Everyone who works around the crane, including riggers, must obey all warning signs and
watch out for his own safety and the safety of others.
¾ Crew members setting up machines or handling loads are expected to know proper machine
erection and rigging procedures.
¾ Watch for hazards during operations and alert the operator and signalmen of dangers such
as power lines, the unexpected presence of people, other equipment or unstable ground
conditions.
2.1.6 Emergency preparation
Set up emergency procedures and guidelines to cope
with fires and accidents. Learn in advance how to use a
fire extinguisher and first aid kit, and be informed where
they are located.
2.1.7 Requirements for working area
People other than the crew members should not stay
in the working area when the crane lifts heavy objects.
To prevent people from unexpectedly entering in the
working area, first barricade this area and take measures to
prevent entering. Ensure only the necessary people and
equipment is in the working area before operation.
People can be crushed by the rear (counterweight) of the machine if there is not enough
room for it to swing. Ensure when crane work, people will not be crushed between
counterweight and buildings.
2-4/53
2.1.8 Operate the crane in the correct position
If operate the crane in the wrong position or an unauthorized
crane modification, and it may result in personal injury, crane
damage or tipping over. Always operate the crane
in the correct position which conforms to the specifications.
Never attempt to modify the crane without receiving the
authorization from FUWA. In case any crane modifications
required, please contact the local FUWA dealer.
Check points related to the position of machine operation:
¾ Counterweight weight
¾ A-frame height
¾ Composition of boom, fixed jib, luffing jib and pedant rope
¾ With of extended track
¾ Position of wire rope reeving (before hoisting boom)
¾ Check winding method of wire rope (after hoisting boom)
2-5/53
2.1.9 Ground condition required for crane operation
Weight of the crane and the load may cause ground sink or collapse, which can cause the
crane collapse, then accidents may happen.
¾ Working ground should be flat, firm and have enough carrying capacity, or the crane
may collapse.
¾ Matting plate may be used based on the ground condition to keep crane in level position
during operation. Ground inclination is ≦5/1000.
¾ Avoid soft or unstable ground, sand, and areas with high water contents or partially
frozen ground.
¾ When machine are working near trenches, the trenches should be shored or sloped to
prevent cave-ins and slides.
2.1.10 Never dismantle the safety devices
Dismantle or incorrect operation of the safety device may result in personal injury or death. Do
not dismantle the safety devices. Understand correct operation methods of all safety devices and
always maintain them so that they can operate correctly. Check all guards and covers for
incorrect installation, missing parts, or any damage. Repair or service the machine if problem is
found.
Safety devices: overload prevention device, hook overhoist prevention device, winch overhoist
prevention device, boom limit device, fixed jib limit device, luffing jib limit device, alarm, brake and
drum pawl, etc. Details refer to Chapter 3.
2-6/53
2.1.11 Assembling/dismantling the machine
Always use handrails and steps when assembling/dismantling
the machine. Never jump on /off the machine, or falling
accidents. When assembling/dismantling the machine,
face the machine and keep a three-point contact with the
handrail and steps. Never take any control hand grips
as hand holds. When assembling/dismantling,
be cautions the handrails and steps, it may be slippery and wet sometimes. If the oil is found,
please clean it at once.
Sometimes it is very slippery, so take care when getting on or off the crane.
2.1.12 Opening/closing the cab door with care
When opening/closing the cab door, and the door is pushed
forward. Be careful not to trip on the steps.
2.1.13 Only operate the machine on the seat
Do not start the engine in a position other than the
driver’s cab. This may result in accidents.
Be sure always start and run the engine on driver’s seat.
Only start the engine on the driver’s seat.
2-7/53
2.1.14 Only operators can stay on the working crane
If other persons stay on the crane, he will obstruct
the view of operator, which will result in mis-operation,
moreover he himself may be shaken off from the
crane or crushed by obstacles.
z Don’t let other persons get in the crane during operation.
2.1.15 Do not use this crane to lift up person
It is not allowed to lift up people with hook.
If necessary, please abide by following requirements:
¾ Special hitchhiking equipment set for lifting tools
¾ Hitchhiking personnel’s seat belt must be fastened.
¾ Drive must be utilized for drop when dropping.
¾ (No fast free fall)
¾ Never exceed rated load.
2.1.16 Prevent tipping over accidents
Subsidence or collapse of the ground due to machine
weight or vibration may cause the machine to tip
over or to fall, possibly resulting in personal injury
or death. Operate and/or travel the machine only
on solid level ground strong enough to support the
machine. Investigate the landform, geological condition,
strength of bridges and structures in advance. Before operating the machine on soft ground,
slopes or terrains where underground embedding exists, sufficiently reinforce and level such
ground with steel planks of required size and strength.
The following typical grounds to be reinforced:
¾ Inclined surface ground
¾ Areas close to a cliff, road shoulder, deep ditch, or hole
¾ Temporary asphalt or thin thickness concrete pavement
2-8/53
¾ Fill-up ground
¾ Swampy ground immediately after rain fall
¾ Frozen ground
2.1.17 Power lines

Electrical shocks may occur when the hoisted load comes into contact with a live power line.
The following actions should be taken：
¾ Obey local regulation, keep safety distance with the power lines.
¾ If the required safe distance cannot be secured, please contact the local authorities before
commence operation.
¾ Keep the personnel at a safe distance from the crane or the hoisted load.
¾ All personnel should wear insulated rubber shoes.
¾ Use only a professional signaler for such work.
¾ When operating the machine, the distance between machine or hoisted load and power line
cannot be less than safety distance.
¾ It can estimate the voltage according to insulator Qty. those used. But the accurate voltage
must be acquired by local power administration bureau.
¾ If working around high voltage power line inevitably, be sure to use proper electrical shock
protective equipment. Contact the electric utility for installation and removal of the electrical
shock protective equipment.
Safety Distance for Crane Working near High Voltage

For operation around high voltage supply wire:
Voltage；KV（Grade） Min. clearance, feet（m）
V﹤ 50 10 (3.5)
15 (4.60)
50＜V≤200
20 (6.10)
200＜V≤350
25 (7.62)
350＜V≤500
35 (10.67)
500＜V≤750
45 (13.72)
750＜V≤1000
2-9/53
For transit without load, boom or mast lowering:
Voltage: KV（Grade） Min. clearance, feet（m）

4 (1.22)
V≤0.75
6 (1.83)
0.75＜V≤50
10 (3.05)
50＜V≤345
16 (4.87)
345＜V≤750
20 (6.10)
750＜V≤1000
Note: please increase clearance under fog, soot, rainy weather.

Treatment after electric shock
Please take following measures if electric shock happens：
z Contact the respective local authorities.
z Operate the crane to leave the site.
z Keep personnel away from the crane and load.
z Keep the operator in the cab, use a wooden ladder
if possible to evacuate the operator and make sure the
operator does not the touch the crane when he land
on the ground at the same time.
z If a metal ladder has to be used, mat the ground with dry wooden plank, evacuate the
operator onto the metal ladder and then onto the wooden plank without any contact with the
ground.
Inspection after electric shock：
Check all crane parts before operation; if any abnormal performance is found, please contact us
for repair.
2.1.18 Be cautious about electrification induced by high voltage radio waves
When the machine is operated in the vicinity of a radio or
TV transmitting station, the hook and/or wire rope may
become electrified, possibly causing co-worker(s) to be
electrically shocked, or the safety devices to malfunction.
Be sure to ground the hook to discharge electricity before
starting lifting work.
2-10/53
2.1.19 Thunder and lightning hazard
Thunder may result in crane damage and even personal serious injury.
Precaution measures：
¾ Stop operating, put the load and boom on the ground.
¾ Brake or lock the hoisting and slewing mechanism, and shut down the engine.
¾ Cut the power of moment limiter and limit switch
¾ Inform all the personnel away from the crane.
If it is suspected that the crane has been hit by thunder
or lightning, take the below mentioned procedures
before starting the crane.
¾ Check for damage parts and ropes.
¾ Check all electrical system and self load indicator.
¾ Check that every running parts are working properly.
2.1.20 Precautions for operating on the windy days
This crane should be operated under maximum wind speed limit, otherwise will result in
turnover of crane.
What we talk about wind speed is instantaneous wind speed.
If the instantaneous wind speed exceeds 10m/s, and the crane should stop operating.
2-11/53
The following dangers will be caused if operating under strong wind:
¾ Wind load will cause the crane overturn, and damages the boom.
¾ The longer the boom, the higher the load position, and the bigger load facing wind surface will
become.
¾ Wind load varies proportionately with the size of object, hoisting height and the length of
boom.
¾ When the boom lift up to maximum angle and hook is empty, then if there is strong wind front,
the boom is liable to tilt backward and cause damage.
Precaution measures:
¾ Before operation, the operator must know that daily weather forecast and actual wind speed.
If the wind exceeds the safety limits, cease operation to prevent serious damage.
¾ The anemometer installed boom or luffing head is used for measuring wind speed.
¾ If the crane is without anemometer, the instant wind speed can be calculated according to
weather forecast.
¾ When the crane is operating on the ground, maximum wind speed is not more than 9.8m/s.
¾ Please operate the crawler crane under allowable wind speed:
¾ Beware of dangerous strong high wind.
¾ When hoisting the bigger expandedness surface load, please reduce the load weight.
¾ Please move the load carefully and slowly.
Wind speed may vary widely based on different terrain and altitudes, rural area and
2-12/53
suburbs area. Different precaution measures should be carried out. In case the actual wind
speed exceeds the maximum allowable wind speed, stop the crane and lower the load onto
the ground.
Inspection after wind:
¾ Check every part of crane for any abnormity before operating, if not, start to work normally.
2.1.20.1 Precautions and treatments of wind
Boom and fixed jib:

1. When the wind speed is below 10m/s, be careful when lifting the object according to working
condition, and stop working according to the specific condition.
2. Please stop working when the wind speed is 10~15m/s, and take the following measures:
①Counterweight faces the wind.
②Boom angle is 60°.
③Hoist the hook till the over-hoist stop device
begins to move.
④Lock slewing brake and slewing locking pin.
⑤Put all the control joysticks to Neutral position.
⑥Put pilot pressure switch to Cut off position.
⑦Put main, aux. drum and derricking drum
pawls switches to Locking position, and other
control switches to Neutral position.
⑧Shut down the engine.
3．Please stop working when the wind speed is
15～30m/s, and take following measures:
① Put the hook on the ground.
② Lower the lifting boom on the ground.
③ Lock the slewing brake and slewing locking pin.
④ Put all the joysticks to Neural position.
⑤Put pilot pressure switch to Cut off position.
⑥Put main, aux. drum and derricking drum pawls
switches to Locking position, and other control
switches to Neutral position
⑦Shut down the engine
2-13/53
z When the boom is too late to be lowered on the ground, and take the emergency measures:
① The counterweight faces the wind.
② Boom angle is 60°.
③ Hang the anchor weight to the hook, and make the
wire rope tighten.
¾ Please refer to the anchor weight table and
prepare it in advance.
¾ The anchor weight cannot leave the ground
when the wire rope is tighten.
4 Lock the slewing brake and slewing locking pin.
○
⑤ Put all the joysticks to Neural position.
⑥ Put the pilot enable hand grip to Locking position.
⑦ Put main, aux. drum and derricking drum pawls
switches to Locking position, and other control
switches to Neutral position.
⑧ Shut down the engine.
Wind
Wind
4．Wind speed exceeds 30m/s(hurricane)

If the typhoon forecast wind speed 30m/s, and the following measures will be taken in advance:
①Lower the hook on the ground.
②Lower the luffing jib on the ground.
③Lock the slewing brake and slewing locking pin.
4 Put all the joysticks to Neural position.
○
⑤ Put the pilot enable hand grip to Locking position.
2-14/53
⑥ Put main, aux. drum and derricking drum pawls switches to Locking position, and other
control switches to Neutral position.
⑦ Shut down the engine.
Luffing jib working condition:
1.When the wind speed is 10～15m/s, stop working
and take the following measures:
① Counterweight faces the wind.

② The angle of the luffing boom angle is 90°.
③ The angle of the luffing jib is 50°.
④ Hoist the hook till the over-hoist stop device begins to move. Luffing jib 50°
⑤ Lock the swing brake and swing locking pin.

⑥ Put all control levers in neutral position.
⑦ Put pilot pressure general switch in switch-off position.
⑧ Put the switch of main/aux. drum and derricking drum pawl
in locking position, and other control switches in neutral position.
⑨ Shut down the engine.
Luffing boom 90°

2.When the wind speed is 15～30m/s, stop working and take the
following measures:
Lower the tower frame on the ground:
○
1 Fix the luffing jib on the luffing boom by
the anti-fall device.
○
2 Put the hook on the ground.
○
3 Put the luffing jib on the ground.
○
4 Lock the swing brake and swing locking pin.
○
5 Put all control levers in neutral position.
○
6 Put pilot pressure general switch in switch-off position.
2-15/53
○
7 Put the switch of main/aux. drum and derricking drum pawl in locking position, and other
control switches in neutral position.

Take the following urgent measures 1 when the tower has no time to be put on the ground.
① Counterweight faces the wind.

② Fix the luffing jib on the luffing boom.
③ Lower the hook on the ground.
④ Make the luffing boom is 70°.
⑤ Lock the swing brake and swing lockpin. Put it to neutral
position.
⑥ Put pilot pressure main switch in switch-off position.

Luffing boom 70°
⑦ Put the switch of main/aux. drum and derricking drum pawl in locking position, and other
control switches in neutral position.
hook
Take the following urgent measures 1 when the tower has no time to be put on the ground.
①Counterweight faces the wind.
②The angle of the luffing boom is 90°
③The angle of the luffing jib is 50°.
④The hook is mounted with anchor weight, make the wire rope tight.
z Something about the anchor weight refers to the anchor weight
chart, make preparations in advance.
Angle 50
z The anchor weight cannot leave from the ground when the wire
rope is tight.
⑤Lock the swing brake and swing locking pin.
⑥Put all control levers in neutral position.
⑦Put pilot pressure general switch in switch-off position.
⑧Put the switch of main/aux. drum and derricking drum pawl in
locking position, and other control switches in neutral position. Anchor
⑨Shut down the engine. Angle 90 weight
2-16/53
3. When the wind speed exceeds 30m/s, take the following measures
in advance:
①Fix the luffing jib to luffing boom correctly.
②Put the hook on the ground.

③ Put the luffing boom on the ground.
④ Lock the swing brake and swing locking pin.
⑤ Lock the swing brake and swing lockpin. Put it to neutral position.
⑥Put pilot pressure main switch in switch-off position.

⑦Put the switch of main/aux. drum and derricking drum pawl
in locking position, and other control switches in neutral position.
Lufing boom
Anchor weight
Model Anchor weight
Working Boom Fixed jib/luffing jib/holding luffing jib

condition (lower to the ground )
55t 1t above 5t above
2-17/53
2.1.20.2 Measuring method of wind speed
Estimation table for wind power and wind speed
Wind force Approx. speed Description (on land)
of wind 10m
above the
ground
Grade Notes （m/s）

Calm 0-0.2 Calm; smoke rises vertically
0
Light air 0.3-1.5 Direction of wind shown by drifting of smoke but not
1
by wind vanes
Light 1.6-3.3 Wind felt on the face; leaves rustle; ordinary vane
2
breeze moved by wind
Gentle 3.4-5.5 Leases and small twigs in constant motion; wind
3
breeze extends light flag
Moderate 5.5—7.8 Raises dust and loose paper; twigs and small
4
breeze branches are moved
Fresh 8.0-10.7 Small trees in leaf begin to sway ; crested wavelets
5
breeze form on inland waters
Strong 10.8-13.8 Large branches in motion; telegraph wires whistle;
6
breeze umbrellas used with difficulty
Moderate 13.9-17.1 Whole trees in motion.
7
gale
Moderate 13.9-17.1 Whole trees in motion.
8
gale
Strong 20.8-24.4 Slight structural damages occurs(chimney pots and
9
gale slates removed)
Whole gale 24.5-28.4 Trees uprooted; considerable structural damage
10
occurs
Storm 28.5-32.6 Widespread storm damage (very rarely experience)
11
Hurricane 32.7and above Devastation occurs
12
2-18/53
2.1.21 Precautions against earthquake
Once the earthquake happens during the crane is working, please stop operating, and follow the
below actions:
¾ Lower the load on the ground and lower the boom as near to the ground as possible.
¾ Brake and lock the hoist and swing systems, shut down the engine, shut off the switches of
the moment limiter and other limiting devices.
¾ Evacuate all people from the site.
After earthquake, check all parts before starting operation:

¾ Any damaged parts.
¾ All actions working correctly.
¾ All equipments functioning well.
Intensity Speed Descriptions
Grade Notes (cm/s2)
1 Slight 0.8～2.5 Felt by people who are still or very sensitive.
2 Weak 2.5～8 Many people can feel. Partitions may slightly rattle.
3 Rather 8～25 Houses shake, partitions rattling. Also, water in a
strong washbasin ripples.
4 Strong 25～80 Houses shake violently. Unstable furniture falls. Also,
people who are walking can feel.
5 Very 80～250 Wall cracks. Tall structures may fall.
strong
6 Disastrous 250～400 Many houses (less than 30% of all houses) collapse.
Landslides and cracks in on the ground. Many people
cannot stand.
7 Ruinous More than Many houses (more than 30 % of all houses) collapse.
400 Landslides and cracks on the ground, and dislocations.
2-19/53
2.1.22 Precautions when crane stop operating
After operation, it is dangerous that the operator leaves the crane without any safety measures.
Take following measures before leaving the seat:
Park the crane on the firm and level ground, don’t park the crane near collapsed bank or
low-lying ground.
¾ Lower the load on the ground, and lower the boom if necessary.
¾ Lock the traveling, slewing and other brakes.
¾ Execute stop brake
¾ Shut off the power.
¾ Pull the engine key out.
¾ Lock all the doors and windows
¾ During crane storage, when it is estimated there is strong winch, and refer to 2.1.20, take
corresponding measures.
2.1.23 Precaution for swollen river/high tide in beach
In case the machine is operated on river bed or near a beach, the machine may unexpectedly be
submerged. Pay attention to sudden increases in water level.
2.2 Preparation for safe operation
2.2.1 Ensure safety jobsite
Unless job site safety is ensured, personal
accidents may result. Inspect the job site as to
the layout of the land and geological conditions,
location of machine operation, layout of traveling
passages, whether any obstructions or obstacles
are present or not, weight of loads to be lifted,
and crane performance before operation.
Then, employ the best operation method to ensure
safety. In case operation is required to be made
on a public road, appoint the signal person and
set up barriers to ensure safety of other traffic.
2-20/53
2.2.2 Check machine before operation
If not check carefully before operation, and unexpected accidents may happen.
Check each part of machine, if any abnormal points are found, and repair them immediately,
inspection items shown as below:
¾ Safety device: overload prevention device, winch overhoist prevention
¾ device, hook overhoist prevention device, boom limit device, etc.
¾ All alarm buzzers and all locking devices.
¾ Operation control: control lever, pedal and all switches.
¾ Brake device: drum brake, slewing brake.
¾ Wire rope: hook hoisting wire rope, boom derricking wire rope, pendant rope and rope
sections.
¾ Hoist tools: hook
¾ Sling tools: sling belt, sling chain, shackle.
Keep operator’s feet, hands, surrounding environments and
Passage clean and in good order
If the handrails, steps, levers, pedals, floors,
and/or passages become contaminated with foreign
matter such as oil, mud, water, and/or snow, or if parts
and/or tools are scattered at random on the machine,
sliding or stumbling, and falling off the machine may
result. Completely remove the adhered foreign matter such as oil from the machine. Do not use
the footings and/or passages as a storing place of parts and/or tools.
Clean the vicinity around the engine
Accumulation of dead leaves and/or paper dirt, or oily spots around the engine may cause fires.
Be sure to remove these fire hazards before operation.
Ensure visibility
Poor visibility may disturb safe operation, possibly creating an unexpected accident. Always keep
the windowpanes, lights, and mirrors clean. Adjust the mirror to the correct position and check
that the head lights, and work lights operate correctly to ensure good visibility. Repair the
damaged or abnormal equipment if any.
2-21/53
Clean caution plates
If any caution plate affixed on the machine is difficult for the operator or the co-workers to read,
the precautions described on it may not be properly understood, possibly creating a hazardous
situation.
¾ Keep all caution plates clean.
¾ In case any caution plates become missing or damaged, install an identical new one in the
same location.
2.2.3 Adjust operator’s seat position
If the operator’s seat is not adjusted in the correct position,
unexpected accidents may result due to mis-operation.
Adjust the operator’s seat position so that all pedals and levers
can be correctly operated.
2.2.4 Inspection before starting engine
Starting the engine without checking the position of the control levers and pedals, or safety
around the machine may introduce personal injury and/or death. Before starting the engine,
check the following points, and sound the horn to alert the personnel around the machine.
¾ Positions of the control levers, pedals, and switches.
¾ Presence of any obstructions or personnel inside, outside, or under the machine.
¾ Presence of any parts kept removed from the machine.
¾ Attachment of a “Do not Operate” tag or notification.
2.2.5 Warm-up operation
Neglecting warm up operation may reduce operational output, shorten the service life, or cause
any number of malfunctions of the machine, possibly resulting in an unexpected accident. Be
sure to perform warm up operation until the engine and hydraulic oil temperature sufficiently
increases.
2-22/53
2.2.6 Inspection after starting engine
Neglecting machine check after starting the engine may delay detection of any failure in
instruments, components and/or devices, possibly resulting in an unexpected accident.
¾ After starting the engine, check that all monitor panels and instruments display correctly.
¾ After performing warm up operation, check the safety around the machine.
¾ Operate the machine with no loads to check that all controls and safety devices operate
correctly.
¾ If any abnormality is found, immediately repair it.
¾ Check the machine in a wide and safe place with no bystanders or obstructions being
present.
2.2.7 Do not deactivate safety device functions
If the machine is operated with the safety device functions deactivated, personnel injury and/or death
may result. Be sure to operate the machine with all safety devices such as the overload prevention
device, and overhoist prevention device activated correctly. If any abnormality is found in a safety
device, immediately repair it.
Safety Devices: Overload prevention device, Hook overhoist prevention device, boom limit device and
all buzzers, locking devices. As for safety devices refer to Chapter 3.
2.3.Precautions for operation
2.3.1 Investigate jobsite environment
Operating the machine without paying attention to the
circumstances surrounding the machine may cause
an unexpected accident. Before operating the machine,
check the machine operating position, passage locations,
presence of obstructions, and other machine locations
in the job site. Always beware of changes in the circumstance surrounding the machine during
operation.
2-23/53
2.3.2 Avoid abrupt operation
Abrupt operation may cause the machine and/or lifted
load to become unstable, possibly resulting in tipping
over of the machine. Avoid abrupt operations such as
sudden start, stop, or acceleration of actuators.
2.3.3 Never attempt to leave operator’s seat
Do not leave the operator’s seat without lowering
the lifted load to the ground and stopping the engine.
Failure to do so may create a hazardous situation.
Always take the following measures before leaving
the operator’s seat.
¾ Lower the lifted load to the ground.
¾ Return all control levers to neutral.
¾ Apply all brakes and engage all locks.
¾ Move the pilot control shut-off lever forward to OFF or neutral.
¾ Engage drum locking, and turn all the switches OFF or neutral.
¾ Stop the engine and remove the key.
¾ Lock the cab door.
2.3.4 Operate the machine within working range
Rated Rated
range range
Boom working range Jib working range
2-24/53
Boom working condition:
If the machine is operated outside the working range relative to the installed boom length, the
machine output performance will exceed the allowable specification, tipping over of the machine
or damage to the machine may result, introducing personal injury and/or death. Always check the
boom length, working radius, and lifting load value while referring to the rated load table, and be
sure to operate the machine within the specifications shown in the rated load table.
Jib, luffing jib working condition:
If the machine is operated outside the working range relative to the installed jib length, the
machine output performance will exceed the allowable specification, tipping over of the machine
or damage of the machine may result, introducing personal injury and/or death. Always
check the luffing jib height, jib length, luffing jib angle, working radius, and lifting load value while
referring to the rated load table, and be sure to operate the machine within the specifications
shown in the rated load table.
2.3.5 Prevent boom and jib from coming in contact with lifted load
If the boom, fixed jib, or luffing jib come in contact
with the lifted load, falling of the lifted load or
damage to the tower or jib may result, possibly
causing unexpected personal injury or death.
Be cautious not to allow the boom, fixed jib, or luffing
jib to come in contact with the lifted load. In case the boom,
fixed jib, or luffing jib is damaged due to contact with
the lifted load, immediately stop operation. Lower the
lifted load to the ground. Contact your nearest FUWA
dealer for repair of the damaged part.
2.3.6 Precautions when engine stop
¾ If the engine stops during operation, the lifted load may fall, possibly resulting in personal
injury or death.
¾ If the engine stops, immediately apply the drum brake and return the drum control lever to
neutral.
2-25/53
2.3.7 Keep away from obstructions
If the machine and/or lifted load come in contact with an
obstruction, personal injury or death may result due to
breakage of the machine and /or the obstruction, or
falling of the lifted load. Be alert for obstructions in the
surroundings or overhead of the machine. In case wire
rope or the lifted load becomes entangled with an
obstruction, unfasten the entangled wire rope or lifted load
from the obstruction without forcibly hoisting the lifted load.
2.3.8 Pay attention to any abnormality in machine operational condition
If the machine is kept operated under any abnormal operational condition, an unexpected
accident may result. If any abnormality in sound, vibration, smell, and/or indication/display of the
instruments, or leakage of fuel, oil, and/or water is found, immediately stop operation of the
machine. After parking the machine in a safety place, check and repair the cause of the problem.
2.3.9 Keep good visibility
If the machine is operated with poor visibility, sufficient
recognition of footings, people and obstructions nearby
the machine may be difficult, possibly resulting in personal
injury or death. When operating the machine in a
dark place, turn the head lights and work lights ON. Use
additional illumination as needed so that the machine
and the overall operation in the job site can be clearly
viewed. In case visibility is poor due to rain, snow, or fog,
stop operation until good visibility is resumed.
2.3.10 Precautions for operation in cold weather season
During cold weather season, perform sufficient warm up operation to prevent the lifted load from
falling, or the machine collision during travel operation due to malfunctions of the machine
systems. Then, obey the following instructions:
¾ Check that the safety devices, drums, and brakes function normally. Remove snow, then
2-26/53
defrost or dry as needed.
¾ Before beginning regular operation, slowly operate the machine under a light duty conditions
until lubricants are sufficiently circulated.
¾ After operation is finished, take necessary measure so that the crawlers and/or the lifted load
do not freeze to the ground, or mud does not freeze the tracks.
2.3.11 Precautions when combined operations
Sway of the lifted load due to sudden changes in speed or mis-operation in combined operations
may result in personal injury or death.
¾ Be sure to smoothly operate the machine and avoid sudden changes in speed.
¾ Do not attempt to perform combined operation before becoming
accustomed to operation of the machine.
¾ Some combined operation speeds may become
slower than the speed of each actuator single operation.
¾ When changing operation mode from combine
operation to single operation, some operation speeds
may become faster.
2.3.12 Never use boom for pushing/pulling operation
¾ Pulling/pushing operation with the boom may cause the boom to become damaged, possibly
resulting in personal injury or death.
¾ Whenever moving a heavy load, use a crane or hoist such as a fork lift. Never attempt to use
the boom in applications other than those of crane front attachment.
2-27/53
2.3.13 Do not relay safety devices
This machine is equipped with safety devices such as the moment limiter, boom overhoist
prevention device, and hook overhoist prevention device. However, these devices cannot
discover malfunctions due to faulty assembly or adjustment, predict the collapse of the ground on
which the machine is standing, or compensate for the effect of wind. Be noted that the ability of
safety devices is not almighty. Thoroughly read and understand this Operation Manual before
operating the machine to prevent accidents from occurring in advance.
2.3.14 Precautions for traveling
Ensure safety in surroundings

Pay attention to safety in the vicinity of the machine while traveling.
¾ Confirm the operation direction of the travel lever in relation to the machine travel direction
before operating the travel lever.
¾ Do not approach precipices or weak road shoulders. If collapsed, tipping over of the machine
may result.
Check the position of the undercarriage in relation to the operator’s position
If the machine is driven without checking which direction the undercarriage is positioned, the
machine may be driven in an unexpected direction, possibly resulting in personal injury or death.
2-28/53
Be sure to check the position of the undercarriage in relation to the operator’s position.
¾ If the travel motors are located in front of the cab, the machine will move in reverse direction
when travel levers are operated to the front.
¾ Normally, drive the machine with the travel motors located at the rear.
Precautions for the boom angle and hook position
If the machine is driven with the boom held in an excessively
small or excessively large angle, or with the hook held at
a low position, the boom may be damaged, or the boom
and the hook may be moved severely by accelerated
reaction force of impact loads in travel operation,
possibly resulting in personal injury or death. Be sure to raise the boom to about 60°and hoist
the hook up to a position close to the overhoist prevention device before traveling the machine.
Be cautious about ground conditions
If the machine is driven without paying attention to the ground conditions, the machine may tip
over or fall, possibly resulting in serious injury or death due to hard contact or crushing. Always
be cautious about the ground conditions while traveling. Observe the following points:
¾ Far away from cliff edge or soft road.
¾ When traveling, select level and firm ground.
¾ Know about ground strength, if the strength is not enough to support the machine, and
reinforce it with steel plate.
¾ For rain, snow or cold weather, the crane traveling on the slippery ground, and the
anti-slippery measures must be taken.
Precautions for crossing river
Crossing a river without paying attention may cause the machine to become immersed or tip over,
possibly resulting in personal injury or death. When crossing a river is unavoidable, drive the
machine carefully after checking the river bottom, water flow strength, and the depth of water.
¾ Do not allow the machine to enter water deeper than the lower face of the main frame.
Precautions for traveling on slopes
Do not travel on the slope to avoid overturn. If the crane is traveling on the slope inevitably, and it
2-29/53
can use lifting boom to adjust the crane’s center of gravity.
Take following points when traveling the machine.
¾ Never attempt to travel with a load suspended.
¾ Slowly and carefully travel the machine.
¾ Travel the machine on a solid level surface.
¾ When traveling on the upsweep, uneven ground and narrow space, appoint a signal man,
and lock the slewing during traveling.
2.3.15 Precautions for traveling with load
Traveling with a load lifted will cause the load to slewing
and increase impact reaction force, possibly resulting in
personal injury or death due to damage and/or tipping
over of the machine. Use another safer method to
transport the load. In case traveling the machine with a
load lifted is unavoidable, be sure to follow the instructions described below.
¾ Appoint a signal man beforehand. Always travel the machine following all instructions from
the signal man.
¾ Travel the machine on level ground. Avoid traveling on soft or uneven surface ground.
¾ Hold the lifted load at the lowest possible position to prevent the lifted load from swaying as
much as possible.
¾ Travel the machine so that the hoist wire rope does not sway more than 3　 if the lifted load
is swung.
¾ Drive the machine at a slow speed to reduce machine vibration.
¾ Position the lifted load in front of the track while traveling forward.
¾ While traveling, never operate any other controls such as the hoist, slewing, or boom
derricking
¾ Never lift a load heavier than the rated load.
¾ Engage the slewing lock and apply the slewing brake.
¾ When traveling under power lines, keep the boom tip sufficiently away from the power lines.
¾ Always lower the load on the ground before changing travel direction. Pay out the hoist rope
2-30/53
by the length necessary to loosen the rope tension so that the machine can change direction
without being restricted by grounding the load.
2.3.16 Avoid injury from traveling in reverse or slewing operation
Visibility may be obstructed during slewing and/or reverse travel operation, possibly creating
serious injury or death to anyone in close vicinity of the machine by hitting, pinching, or running
over. Strictly follow the instructions below.
¾ Appoint a signal person beforehand. Always operate the machine following all instructions
from the signal person.
¾ Check that no bystanders are present around the machine.
¾ Use the horn to alert bystanders not to enter the vicinity of the machine.
2.3.17 Precautions for slewing operation
Prevent the lifted load from swaying
Sudden start/stop or fast speed slewing operation may cause the lifted load to sway, possibly
resulting in damage to the machine, tipping over of the machine, and/or personal injury or death
due to falling of the lifted load.
¾ Slowly operate the slewing system
(starting, operating, and stopping)
so that the lifted load does not sway.
2-31/53
Avoid using the slewing function to push/pull a load
¾ Do not push /pull a load using the slewing function. Failure to do so may cause personal
injury or death due to damage to the machine and/or tipping over of the machine.
Precautions for unexpected swinging
¾ Unexpected slewing drift due to inclination of the
machine or wind force may occur,
possibly resulting in personal injury or death.
¾ Always apply the slewing brake when slewing operation is not required.
2.3.18 Never allow the lifted load to pass over a person
¾ Accidental falling loads may result in serious injury or death.
¾ Never move a lifted load over a person’s head.
¾ Do not allow any person to enter below the lifted load.
2.3.19 Be cautious of sway of the unused hook
When the machine is operated with the jib attached, the unused hook may sway during slewing
or boom hoist operation, possibly causing unexpected accidents if the swung hook comes in
contact with the boom or obstructions around the machine.
¾ Hoist the unused hook up to a point close to the height where the overhoist prevention
device becomes activated.
2.3.20 Precautions for hoisting the boom
Correctly hoist or lower the luffing jib/boom
When hoisting the tower/boom or lowering the luffing jib/boom to the ground, always face the
luffing jib/boom toward the correct direction relative to the undercarriage, and place pads on the
ground to support the tower/boom tip. Failure to do so may cause personal injury or death due to
damage to the machine and/or tipping over of the machine.
2-32/53
Do not pull, raise, or lift a load off the ground by hoisting the boom or luffing jib.
¾ Failure to follow the instructions below may result in personal injury or death due to damage
to the machine or tipping over of the machine caused by overloading or sway of the lifted load.
Luffing jib working condition:
¾ Never pull, raise, or lift a load off the ground by hoisting the luffing jib.
Boom working condition：
¾ Never pull, raise, or lift a load off the ground by hoisting the boom.
Avoid abrupt hoist operation

¾ Avoid abrupt tower jib/boom hoist operation. Failure to do so may reduce stability of the
machine and the lifted load, possibly resulting in personal injury or death.
2-33/53
Carefully operate the jib at a position close to the upper limit angle
If the jib is carelessly hoisted up to the position close to the upper limit angle,
the jib may be moved backward by reaction force, or the lifted load may
come in contact with the jib, possibly resulting in personal injury or death
due to damage to the machine or tipping over of the machine. When the jib
is hoisted up to a position near the upper limit angle, reduce the hoisting
speed so that the jib is not hoisted beyond the upper limit angle. When
lowering the load with the jib held at a position near the upper limit
angle, slightly lower the jib from the upper limit angle position.
Then, slowly lower the load in the power lowering mode.
Carefully operate the boom at a position close to the upper limit angle
If the boom is carelessly hoisted up to a position close to the upper limit
angle, the boom may be moved backward by reaction force, or the
lifted load may come in contact with the boom, possibly resulting in
personal injury or death due to damage to the machine or tipping over of
the machine. When the boom is hoisted up to a position near the upper
limit angle, reduce the hoisting speed so that the boom is not hoisted
beyond the upper limit angle. When lowering the load with the boom
hoisted at a position near the upper limiter angle, slightly lower the jib from the upper limit angle
position. Then, slowly lower the load in the lower lowering mode.
2.3.21 Do not use a boom/jib longer than necessary
Luffing jib working condition
¾ If jib longer than necessary is used, the balance of the lifted load will be reduced, possibly
resulting in personal serious injury.
2.3.22 Do not use both the front and rear drums at the same time
If two separate loads, or one load is lifted with the main and auxiliary hooks at the same time, the
over load prevention device does not operate correctly, possibly resulting in personal injury or
death due to damage to the machine or tipping over of the machine. Use only either the front or
the rear drum only in crane operation.
2-34/53
2.3.23 Do not lift more than one load
If more than one load is lifted at the same time, it is difficult for the
operator to equally pay attention to all of the lifted load conditions.
Beside that, one lifting tool may come in contact with other lifted load,
possibly creating an unexpected accident. Never lift more than one
load at the same time.
2.3.24 Do not laterally pull or drag a load with the hook
Pulling or dragging a load with the hook laterally may cause personal
injury or death due to damage to the machine or tipping over
of the machine.
¾ Move the machine as close to the load position as
possible and lift the load vertically.
2.3.25 Do not lift one load with two or more machines
The use of two or more machine to lift one heavy or unwieldy load may result in personal injury or
death due to damage to the machine or tipping over of the machine. Avoid using two or more
machine to lift one load. In case using two or more machine to lift one heavy or unwieldy load is
unavoidable, strictly follow the instructions below.
¾ Set the machines on solid level ground.
¾ Use identical models with sufficient lifting capacity.
Luffing jib working condition
¾ Use the tower height, jib length, tower angle, and working radius identical to the respective
machine.
General crane working condition
¾ Use the boom length and working radius identical to the respective machine.
¾ Operator on the respective machine must follow the direct directions from the job
coordinator.
¾ The job coordinator must coordinate lifting procedures with both machine operators in
advance.
¾ Operate all machines at the same time.
2-35/53
¾ Operate both machines at slow speed.
¾ Operate each machine with single operator, never travel either machine.
¾ Lift the load vertically.
¾ Carefully operate the machine, make the two machines hoist the load at the same time.
¾ Always keep the load in a horizontal position.
2.3.26 Know the lifting load weight beforehand
Lifting unknown weight loads may introduce an
overloading condition, possibly resulting in personal
injury or death due to damage to the machine, tipping
over of the machine, or falling of the load. Be sure to
check the lifting load weight beforehand.
2.3.27 Never overload operation
Overloading the machine may cause the machine
to break or tip over, possibly introducing personal
injury or death. Do not lift a load which will exceed
the gross rated load. When lifting a load in water, avoid
abruptly lifting the load out of water or pulling the load
laterally to relieve the negative pressure developed under the load bottom.
The load weight in water is reduced due to buoyancy. As soon as the load is lifted out of water,
the load weight becomes heavier as the buoyancy dissipates and water weight contained in the
load is applied. Slowly lift the load so that water can be drained as much as possible.
2-36/53
2.3.28 Do not use the machine to extract loads
Do not use the machine to extract buried or driven-in
objects in the ground, or to hoist a load when wire rope
or the lifted load is entangled in an obstruction without
removing the obstruction. Failure to do so may cause the
machine to break or tip over, possibly introducing
personal injury or death. Never attempt to lift the object
driven in the ground, or buried in mud or soil. In case the wire rope or the lifted load is entangled
in any obstructions such as a tree, or steel structure, hoist the load only after removing or
detaching the obstruction.
2.3.29 Do not allow the lifted load to free-fall
Free fall of a heavy load by operating the brake pedal may
induce mis-operation, possibly resulting in personal injury
or death due to the load falling. Use free fall operation mode
only when lowering the hook with no load. When the lifted
load is to be lowered, always select the auto-brake mode
to lower the load in the power lowering mode.
2.3.30 Steady operation for free-fall
Delayed braking operation when free fall, may cause the hook to fall, possibly resulting in
personal injury or death. Do not remove your foot from the brake pedal during free fall operation
so that the brake can be quickly applied whenever needed.
2.3.31 Precautions for lifting the load off the ground

Hoisting 2nd
If the load is carelessly lifted off the ground, Start hoisting
brake hoisting
falling of the lifted load or tipping over of the
machine may result, possibly introducing personal
injury or death. After lifting the load off the ground
by several centimeters, stop lifting the load.
Then, check the brake function, slinging
condition, and machine stability for any abnormality.
2-37/53
2.3.32 Hook overhoist prevention
If the hook is overhoisted, the hook and the lifted load may come in contact with the boom or the
jib, possibly resulting in personal injury or death due to damage to the boom or jib, or falling of the
lifted load. Always pay attention to the position of the lifted load so that the hook is not
overhoisted.
¾ Depending on the jib angle or the size of the lifted load, the lifted load may come in contact
with the jib creating a hazardous condition if the hook is overhoisted before the overhoist
prevention device is activated.
2.3.33 Lifting operation of a long-shape load
Keep stability of a long-shape lifted load is very
difficult. Loss of balance may result in personal injury or
death. Attach tag-lines to both ends of the lifted load to
maintain the load stability.
¾ Be careful not to get dump with the lifted load.
2.3.34 Precautions for extension in working radius
As the lifted load is lowered, the working radius increases. Depending on the circumstances, the
machine may become overloaded. Then, if the machine tips over, personal injury or death may
result.
¾ Set the working radius or gross rated load with an appropriate allowances in advance so that
even if the working radius is increased, the machine will not tip over.
¾ When the load is lifted off the ground, the working radius will increase due to the stretch of
the hoist and pedant ropes. As the load becomes heavier, the working radius will further
increase.
2-38/53
2.3.35 Select correct hook size and number of sling wire ropes
¾ Select the proper hook size and number of sling wire ropes
matching the lifted load weight and the tower and jib lengths.
¾ Failure to do so may result in personal injury or death due to
breakage of wire rope.
2.3.36 Be careful not to excessively pay out wire rope
If wire rope is excessively paid out of the drum, the rope
may be disconnected from the drum or the rope
may be broken, possibly introducing personal injury
or death due to falling of the lifted load or hook.
Be sure that at least 3 turns of the rope remains around the drum when paying out the rope.
2.3.37 Rectify irregular winding or twisting of wire rope

If irregular winding or twisting of wire rope is not rectified, the wire rope
May be broken, possibly resulting in personal injury due to falling of the
lifted load, rotation of the hook, or unthreading of wire rope from the
sheave. In case irregular wire rope winding occurs, rewind the wire
rope correctly. If wire rope is twisted, rectify the twisting before
operating the machine.
2-39/53
2.3.38 Operate the machine safely if overloaded
¾ Lower the lifted load by lowering the hook if an overload
situation occurs to the machine.
¾ Quick operation of the jib under an overloading condition
may make the situation worse by causing the lifted
load to sway, possibly resulting in personal injury
or death due to tipping over of the machine.
2.3.39 Precautions for lifting
Do not use improper lifting tools
¾ Using improper lifting tools may cause the breakage or damage
of the lifting tools, possibly resulting in personal injury or death.
¾ Be sure to use proper size and strength of the intact sling
wire rope, lifting chains, and shackles.
Set lifting angle between sling wire ropes as small as possible

¾ Set the lifting angle between sling wire ropes to smaller
than 60 degrees.
¾ The larger the lifting angle between sling wire ropes is
set, the more the force is applied to each sling wire rope so that breakage or skid of the wire
rope may result, possibly resulting in personal injury or death due to falling of the lifted load.
Position the hook just above the center of the lifted load
¾ Sling a load with the hook positioned just above the center of the lifted load weight.
¾ If a load is lifted without aligning the hook position with the center of the lifted load weight,
tipping over or falling of the lifted load may result, possibly introducing personal injury.
2-40/53
Use soft material pads
¾ When slinging sharp edges or slippery sections of
a load, use soft material pads between the slinging ropes and the
load to prevent the slinging rope from breaking, or coming off the
load, possibly resulting in personal injury or death.
Do not lift a load with one sling rope
¾ Do not lift a load with one sling rope. Failure to do so
may cause the lifted load to automatically rotate,
possibly introducing an unexpected accident.
Do not allow anyone to enter below the lifted load
¾ Do not allow anyone to enter below the lifted load.
Should the lifted load fall, personal injury or death may result.
Use a latch to prevent wire rope from coming off the hook
¾ If the latch is not used, or the latch does not function properly, the sling rope may come off
the hook so that the lifted load may fall, possibly resulting in personal injury or death.
¾ Be sure to use the hook latch when a load.
¾ Check that the latch functions correctly in advance.
2-41/53
Arrange a signal person
¾ Arrange a signal person when slinging a load. Then, always
operate the machine according to the signal direction.
¾ If no signal person is used, or the signal person’s direction
is neglected during slinging a load, occurrence of an
unexpected accident may result.
2.3.40 Precautions for operating it as clamshell bucket
Check locations of underground gas lines, waterlines, and cables beforehand
¾ Clearly locate all underground utilities such as gas lines,
water lines, and cables before digging.
¾ Accidental severing of underground gas lines, water lines,
or cables may result in personal injury or death.

¾ Arrange a signal person and follow all direction from the
signal person when operating a clamshell bucket.
¾ If the bucket is difficult to see from the operator’s seat,
the bucket may come in contact with sheetings,
possibly introducing occurrence of an unexpected accident.
Do not hit the ground with the bucket
¾ Do not use the bucket in lieu of a hammer to loosen
the ground. The bucket may rebound so that
an unexpected accident may result.
2-42/53
Do not excessively tension the bucket holding rope
¾ If the bucket holding rope is excessively tensioned while
lifting the bucket, and bucket may be opened,
causing the bucket oad to fall, which may lead to
personal injury or death.
¾ Whenever lifting the bucket, be sure to close the bucket by
winging up the bucket open/close wire rope.
Do not allow the bucket to sway
If the swing operation is made at fast speed or is quickly
stopped, the bucket may sway so that tipping over of the
machine, damage to the machine, or falling of the bucket
load may introduce personal injury or death. Always
perform slewing operation slowly to prevent the bucket from swaying.
Never move the bucket over the truck operator’s cab or a person’s head
¾ If the bucket load falls, personal injury or death may result.
Never move the bucket over the truck operator’s
cab or a person’s head.
Avoid irregular winding of wire rope
¾ Wire rope may be broken due to irregular winding of
wire rope, possibly resulting in personal injury or death
if the bucket or a load falls. Beware not to excessively
loosen wire rope during excavation with the bucket.
2-43/53
Lower the bucket on the ground after operation
¾ Lower the bucket on the ground with the teeth opened
after operation.
¾ If the bucket is kept lifted above the ground,
or if the bucket is lowered on the ground with the
teeth closed, falling or overturning of the bucket
may cause personal injury or death.
2.3.41 Lowering/Hoisting a load to/from the under ground level

Pay attention to the wire rope length
¾ If the wire rope length is not sufficient, the rope may be
pulled out of the drum, or may be cut off, possibly
causing personal injury or death due to falling of the lifted
load and/or hook.
¾ Select the machine equipped with long
wire rope enough to meet the working conditions.
¾ When the hook is lowered to the lowest position, minimum 3 turns of wire rope must remain
around the drum.
¾ Arrange a signal person and follow the signal person’s direction. If it is impossible for the
operator to see how underground work, such as when slinging, from the operator’s seat,
occurrence of an unexpected accident may result.
2-44/53
2.3.42 Carefully pull out a buried object such as a pile
¾ If a buried object such as a pile is forcibly pulled out,
overturning or damage to the machine may result,
possibly introducing personal injury or death. When
pulling out a buried object such as a pile, avoid abruptly
pulling it out.
¾ In case pulling it out is difficult, use other equipment such as a vibration hammer to assist the
work.
2.4 Precautions for preparation of operation and transportation
2.4.1 Setting machine
If the machine is operated in an inclined position, personal injury or death may result. Check that
the ground strength is strong enough to support the machine in advance. In case the ground is
not strong enough, reinforce the ground using steel planks having sufficient strength and place
the machine on the horizontal surface.
2.4.2 Keep away from machine when giving signals
¾ Keep away from machine when giving signals.
Stepping in the disassembling/ assembling work site of
the machine will increase possibility of entanglement with
the machine, resulting in personal injury or death.
2-45/53
2.4.3 Never jump on or off the machine
Jumping on or off the machine may introduce personal
injury or death due to falling from the machine. Be sure
to use the handrails, steps, or a footstool when mounting
or dismounting the machine.
¾ Never jump on or off the machine.
2.4.4 Assemble/Disassemble machine in correct procedures

¾ Incorrect assembling/disassembling procedures of the
machine may introduce personal injury or death.
¾ Always follow the correct assembling/disassembling
and/or removal/installation procedures.
2.4.5 Do not put your fingers and/or hands into pin holes when aligning pin hole center
When aligning the pin hole center, do not put your fingers
and/or hands into pin holes. If the hole position becomes
misaligned when your fingers and/or hands are inside
the pin hole, personal injury or death may result. Align
the pin hole center by visual inspection or with a tool
such as a screw driver.
¾ Keep your fingers and/or hands away from the pin holes.
2.4.6 Use safety belt when working at high locations
Working at a high location is very hazardous, possibly
resulting in personal injury or death due to falling. Use
safety belt when working at high locations.
2-46/53
2.4.7 Carefully adjust the height crane boom
When the boom derricking lowering, and load will lower,
and possibly resulting in personal injury.
Please take following instructions:
¾ Do not allow anyone to enter the area under or
inside the boom.
2.4.8 Precautions for removing /installing counterweight
When removing or installing the counterweight, the machine may overturn or the counterweight
may fall, possibly resulting in personal injury or death. Please take following instructions.
¾ Place the machine on the firm and solid ground.
¾ Do not allow anyone to enter the area under the counterweight.
¾ Extend the A-frame.
¾ Extend the track frame.
2.4.9 Do not enter the inside of the boom/jib
Do not enter the inside or the area under the boom, or jib when assembling /disassembling
/removing/installing them.
¾ If the boom, or jib falls, personal injury or death may result.
2.4.10 Prevent falling from the boom
¾ When working on the boom//jib, ensure the footings. Falling from the top of the boom/jib may
result in personal injury or death.
2.4.11 Jib holder of luffing jib
When without the protection of auxiliary crane, and use jib holder, fix the luffing jib and boom, to
avoid accidents or personal injury due to jib’s free rotation.
Luffing jib Boom
Luffing working condition
2-47/53
2.4.12 Precautions for lowering luffing jib
¾ When lowering the luffing jib to the ground,
take care not to pinch the hook hoist rope between the
luffing jib tip and the ground.
¾ If the wire rope is broken, an unexpected
accident may result.

Luffing working condition
2.4.13 Precautions for lowering boom
¾ When lowering the boom to the ground,
take care not to pinch the hook hoist rope
between the boom tip and the ground.
¾ If the wire rope is broken, an unexpected

Boom working condition
accident may result.
2.4.14 Prevent pendant rope from falling
When installing and dismantling the boom, to prevent
pendant rope falling from the boom. Once the pedant rope
falling down from boom, and it may causing accidents.
2.4.15 Securely support luffing jib/boom/jib
If the luffing jib/boom/jib connection pins are removed
without properly supporting the tower/boom such
as when replacing or disassembling the tower/boom/jib,
the luffing jib/boom/jib may fall, possibly causing
personal injury or death. Before removing the connection pins,
securely support the entire length of the luffing jib/boom/jib with an assistant crane or racks
having sufficient strength.
2-48/53
2.4.16 Carefully drive out pins
¾ When driving out the luffing jib/boom/jib connection pins,
the pins may fly out, possibly introducing an unexpected
accident.
¾ Pay attention to the movement of the pins and
avoid standing in front of the pin connections.
2.4.17 Pay out wire rope in correct method
¾ Pay out wire rope while rotating a wood frame or coil. If
wire rope is paid out following an incorrect method,
deformations, kinks, warping, or untwisting of wire rope
may result, possibly introducing an unexpected accident.
2.4.18 Wind wire rope in a regular alignment
When winding wire rope around the drum, never allow
wire rope to become twisted or loosely wound. Failure to
do so may cause the premature damage or kinking of
wire rope, possibly introducing an unexpected accident.
Strictly observe the following instructions. No twist
¾ Do not allow the wire rope twisted.
¾ Securely wind the wire rope in 1st layer on the drum. Apply tension force equivalent to2~3%
of rope breaking load to the rope while winding the wire rope around the drum.
¾ Wind the wire rope in a regular alignment around the drum.
2-49/53
2.4.19 Install wire rope correctly
If the wire rope end is incorrectly installed in the drum or socket, wire rope may come off, possibly
introducing an unexpected accident. Observe the following points to correctly install the rope
ends.
¾ Use the sizes of sockets, wedges, and wire clips proper to the diameter of wire rope to be
installed.
¾ Install wire rope in to the drum and socket in the correct direction.
¾ Install the wire clips in the correct direction.
Wrong
Correct
2.4.20 Before raising the boom, check if there is a part and/or tool remaining behind on it
After installing the boom attachment to the base machine, check that no parts or tools are
remaining behind on the boom before raising the boom. If the boom is raised with any part and/or
tool remaining behind on it, falling of the part and/or tool may cause personal injury or death.
2.4.21 Ensure safety operation
Before operating the machine, recheck that all safety measures are taken. Failure to do so may
cause personal injury. Recheck the following points:
¾ Check if the purposes and processes of work to be performed are fully understood.
¾ Check if the signals to be used are fully understood.
¾ Check if safety around the machine is ensured.
¾ Check if the machine inspections have been completely and thoroughly conducted.
2-50/53
2.4.22 Loading/Unloading on trailer
I f the machine is loaded or unloaded on a trailer following
incorrect methods, or if the machine is not sufficiently
secured to the trailer, overturn of the trailer, and tipping
over, falling, and collision of the machine may result,
possibly causing personal injury or death.
When loading/unloading the machine, strictly follow the instructions below:
¾ Load/unload the machine on a firm level surface.
¾ Select a trailer with specifications matching the machine weight to be transported.
¾ Apply the trailer parking brake. Wedge all trailer wheels.
¾ Remove the counterweight from the machine.
¾ Remove or store all projections from the machine.
¾ In case the machine is required to slewing on the trailer, securely support the trailer flatbed
with jacks or blocks beforehand.
¾ Apply the slewing lock, slewing brake, drum locks and drum brakes.
¾ Close and lock all cab doors.
¾ Secure the machine with wire rope and chains to the trailer bed so that the machine does not
move during transportation.
¾ Use soft material pads at the sharp edged corners between the machine and wire rope or
chains to prevent the machine, wire rope and/or chains from being damaged.
2.4.23 Avoid overloading trailer
Overloading may cause the trailer to overturn or collide, possibly resulting in personal injury or
death. Before transporting the machine, disassemble the machine into subassembly units so that
each unit matches the correct transportation weight and dimensions. Then, select a trailer with
specifications matching the correct transportation weight and dimensions.
2-51/53
2.4.24 Obey associated local regulations
If the machine is transported on public roads without
obeying the associated local regulations such as the
requirements of transportation or the arrangement of a
pilot car, the trailer may overturn or collide, possibly
resulting in personal injury or death. Investigate the traffic conditions up to the objective point
beforehand, and transport the machine in a method conforming to the associated local
regulations.
2.4.25 Investigate local traffic regulation
There may be local traffic restrictions in width, height
and weight. neglecting such restrictions may introduce
an unexpected accident. Investigate local traffic
regulations beforehand to transport the machine on
public roads. Select the safety routes.
2.4.26 Avoid letting the machine to come in contact or collide with obstructions
Contact or collision of the machine with obstructions
during transportation may cause personal injury or death.
Before going through a tunnel or under the electric train
overhead wires, overpasses, or girder bridges,
investigate the height and width of them. Maintain proper
clearances from their borders when passing
through them.
2.4.27 Arrange a signal person
Arrange a signal person when passing through tight
areas or going into an unclear passage. Be sure to follow
the signal person’s directions while checking safety
along the path. If the trailer is driven without checking
safety, contact or collision with a person or building may
result, possibly causing personal injury or death.
2-52/53
2.4.28 Check transportation route surfaces
Driving on a rough terrain may cause the trailer to skid or to steer seriously, possibly resulting in
personal injury or death. When driving on snow covered roads, frozen roads, rough terrain, or
slopes, always drive the trailer at slow speed while ensuring safety. Check the transportation
route surfaces beforehand, and take necessary measures such as putting on tire chains.
2.4.29 Park machine safely
Leaving the machine in such spots as possibility of falling stones or ground collapse is expected,
or in a low ground where flooding may occur, or parking the machine on a slope may cause an
unexpected accident.
If parking the machine on a slope or public load is unavoidable, take the following measures.
When parking the machine on a slope, face the machine parallel to the slope direction. Wedge
both crawlers to prevent the machine from running away.
When parking the machine on a public road, select a parking area so that traffic of other vehicles
and pedestrians are not disturbed. Clearly discriminate the parking area using caution signs such
as flags, barriers, or flashing signals.
2-53/53
Chapter 3 Names and Functions of Parts
3.1 Main parts of crane
Fig 3.1
3-1/50
Table 3.1
No. No. No.
1 Undercarriage
2 Superstructure
3 Main hoist device (Hoist 1)
4 Derricking gear
5 Cab
6 Counterweight
7 Mast device
13 Boom
14 Runner
15 Jib
17 Aux.hoist device (Hoist 2)
20 Holding luffing jib
23 Electric system
3-2/50
3.1.1 Composition of undercarriage
Fig 3.1.1
1．Undercarriage Table 3.1.1
No. Name Remark
1.1 Left track frame
1.2 Right track frame
1.3 Track carrier
1.4 Upper roller
1.16 Guide wheel assy.
1.5 Drive unit
1.6 Track roller assy.
1.8 Track take-up
1.9 Chassis
1.1 Extension device
1.11 Fixed frame
1.14 Outrigger assy. A
1.15 Outrigger assy. B
3-3/50
3.1.2 Composition of superstructure
Fig 3.1.2
2.Superstructure Table 3.1.2
No. Name Remark
2.1 Superstructure welding parts
2.3 Backstop base
2.4 Slewing bearing
2.5 Rope anti-fall roller assy.
3-4/50
3.1.3 Composition of counterweight
Fig 3.1.3
6.Counterweight Table 3.1.3
No. Name Remark
6.1 Counterweight block
6.2 Tighten device
6.3 Linking frame C
6.4 Counterweight tray
6.5 Small counterweight block
6.6 Linking frame D
6.7 Additional counterweight
3-5/50
3.1.4 Composition of boom
Fig 3.1.4
3-6/50
13.Boom Table 3.1.4
No. Name Remark
13.1 Boom foot
13.2 Boom 3m section
13.5 Boom head
13.0.1 Wire rope 35W×7×φ26×220m
13.0.2 Wire rope 35W×7×φ26×200m
13.6 Backstop rod
13.2.1 3m pendant rope
13.5.10 6.9m pendant rope
3-7/50
3.1.5 Composition of runner
Fig 3.1.5
14.Runner Table 3.1.5
No. Name Remark
14.1 Lower bracket
14.2 Stay bar
3-8/50
3.1.6 Fixed jib
Fig 3.1.6
15.Fixed jib Table 3.1.6
No. Name Remark
15.1 Jib foot
15.2 Jib insert
15.3 Jib head
15.4 Jib strut
15.4.1 Strut body
Front pendant rope linking
15.4.2
frame
Rear pendant rope linking
15.4.3
frame
15.5 Jib pendant rope 1
15.0.1 Stay bar
3-9/50
3.1.7Holding luffing jib
Fig 3.1.7
3-10/50
20.Holding luffing jib Table 3.1.7
No. Name Remark

20.2 Travelling block
20.3 Boom head strut
20.4 Luffing jib strut
20.5 Balance device
20.6 Luffing jib head
20.7 Luffing jib 3m section
20.8 Luffing jib foot
20.9 Luffing jib backstop
20.1 Boom head
20.12 Limit device
20.13 Boom backstop
3-11/50
3.1.8 Mast device
Fig 3.1.8
7．Mast device Table 3.1.8
No. Name Remark
7.1 Mast balance frame
7.2 Upper pulley block
7.3 Lower pulley block
3-12/50
3.2 Positions and functions of operation parts
3.2.1 Cab parts
For operation details, refer to chapter 4 Operation
Fig 3.2.1
3-13/50
Table 3.2.1
No. Name Remark
18.1 Side top operating console
18.2 Indoor light
18.3 Engine operating lamp
18.4 Loudspeaker
18.5 Fire extinguisher
18.6 Documents box
18.7 Seat
18.8 Storage box
18.9 A/C evaporator
18.10 Right operating console
18.11 Left operating console
18.12 Pilot enable hand grip
18.13 Throttle pedal
18.14 Main winch free-fall pedal See attachment
18.15 Right traveling pedal
18.16 Left traveling pedal
18.17 Aux.winch free-fall pedal See attachment
18.18 Sundries box
18.19 Wiper jug
18.20 Left traveling operating lever
Right traveling operating
18.21
lever
18.22 Front display panel
18.23 Front wiper
18.24 Rearview mirror
18.25 Sunproof curtain
18.26 Front lighting
18.27 Monitor display screen
18.28 Top wiper
3.2.2 Operating levers and pedals

3.2.2.1 Pilot enable hand grip
¾ Pilot enable hand grip is a safety device, to prevent the machine mis-operation.
¾ When the pilot hand grip is on locking position, during assembling or dismantling the
machine, it cannot be unintentionally operated even if the operator comes in contact with the
control lever.
3-14/50
¾ Pilot enable hand grip to locking position, and close all brakes. It is forbidden to pull
the hand grip to (Fig 3.2.2.1) B enable position, to prevent mis-operation.
¾ Before moving the pilot enable hand grip to start position, be sure to check that all
control levers, pedals are in neutral. Failure to do so may cause the machine to
suddenly move, possibly resulting in personal injury or death.
¾ Before leaving the machine, be sure to stop the engine and move the enable hand grip
to the LOCK position.
¾ After the work is complete or when transporting the machine, be sure to move enable
hand grip to the LOCK position.
1.Locking position: Hoist (1,2), boom derricking, track extension, slewing and traveling functions
cannot be used;
2.Enable position: Hoist (1,2), boom derricking, track extension, slewing and traveling functions
can be used;
Fig 3.2.2.1
Table 3.2.2.1
No. Name Remark
A Locking position
B Enable position
3-15/50
3.2.2.2 Operating grip
1.Left operating grip
Fig 3.2.2.2a
Table 3.2.2.2a
No. Name Remark
A Aux.winch hoist
B Aux.winch lower
C Slewing leftward
D Slewing rightward
18.11.1 Left operating grip
18.11.1.1 Slewing brake start button
18.11.1.2 Slewing brake close button
3-16/50
2. Right operating grip
Fig 3.2.2.2b
Table 3.2.2.2b
No. Name Remark
A Aux. winch hoist

B Aux. winch lower
C Main winch hoist
D Main winch lower
E Self-assembly Shift with aux.winch hoist
F Self-assembly Shift with aux.winch lower
18.10.1 Right operating grip

18.10.1.1 Confluence button
18.10.1.2 Electrical horn button
3-17/50
3.2.2.3 Traveling operating levers and pedals
Fig 3.2.2.3
Table 3.2.2.3
No. Name Remark
Left traveling operating lever and pedal
18.20 Left traveling operating lever series-action during operating
Left traveling operating lever and pedal

18.16 Left traveling pedal series-action during operating
Right traveling operating lever and pedal

18.21 Right traveling operating lever series-action during operating
Right traveling operating lever and pedal

18.15 Right traveling pedal series-action during operating
A Traveling forward
B Traveling backward
C Traveling forward
D Traveling backward
3-18/50
3.2.2.4 Free-fall pedal
See attachment
3.2.2.5 Electrical pedal throttle
Fig 3.2.2.5.
Table 3.2.2.5
No. Name Remark
18.13 Electrical throttle pedal
A Throttle increase direction
B Throttle decrease direction
3.2.2.6 Electrical knob throttle
Fig 3.2.2.6
Table 3.2.2.6
No. Name Remark
18.10.4 Electrical knob throttle
A Throttle decrease direction
B Throttle increase direction
3-19/50
3.2.3 Operating console and display console
3.2.3.1 Left operating console
Fig 3.2.3.1a
Table 3.2.3.1a
No. Name Remark
18.11.2 Emergency stop button
18.11.3 Limit release switch
18.11.4 Idle speed adjustment switch
18.11.5 Standby
18.11.6 Working condition selection switch
18.11.7 Standby
18.11.8 Standby
18.11.9 Standby
18.11.10 Standby
18.11.11 Fault diagnosis switch
18.11.12 Aux.hoist/self-assembly shift switch
3-20/50
1. Emergency stop button
¾ When the crane needs emergency stop, press the emergency stop button (18.11.2) and lock
it, then engine stops immediately, the crane loses the power.
¾ When the crane needs to resume working, rotate the emergency stop button (18.11.2)
clockwise, and the engine can start normally.
Fig 3.2.3.1b
Table 3.2.3.1b
No. Name Remark
18.11.2 Emergency stop button
A Urgency stop
B Release resume
2. Limit release switch

¾ Press the limit release switch (18.11.3), and lamp is ON, except moment overload and boom
upper limit switch limit, and other limits can be released. Loosen the switch, and resume
original working status.
¾ The limit release switch (18.11.3) is used under special conditions, (such as crane
dismantling or working condition change), it is not recommended to use under
normal working conditions.
Fig 3.2.3.1c
3-21/50
3. Engine idle speed adjustment switch
¾ Press the switch to , the lamp is ON, and the engine Rev. is increased as certain
step；
¾ Press the switch to , the lamp is ON, and engine Rev. is decreased as certain step;
Fig 3.2.3.1d
4．H2/W working condition selection switch
¾ Press the switch to H2, and lamp is ON, aux. hoist device is operating under boom
working condition;
¾ Press the switch to W, and lamp is ON, luffing jib derricking device is operating under
luffing jib working condition;
Fig 3.2.3.1e
5．Engine fault diagnosis switch
¾ Press the switch to , and lamp is ON, the engine is fault diagnosising, and the stop
lamp flashes the fault code as certain frequency.
Fig 3.2.3.1f
6．Aux.hoist/self-assembly shift switch (3-digit self-lock switch)

¾ When aux.hoisting, press the switch to , the lamp is ON, and push the hand grip to
have aux. hoisting.
¾ When self-assembling, press the switch to , 作 the lamp is ON, and push the hand
grip to have self-assembling.
3-22/50
¾ It no need both above, and put the switch in the middle.
Fig 3.2.3.1g
3.2.3.2 Right operating console
Fig 3.2.3.2a
Table 3.2.3.2a
No. Name Remark
18.10.2 Power key switch
18.10.3 Start key switch
18.10.4 Throttle knob
18.10.5 Slewing lock switch
18.10.6 Traveling high low speed switch
18.10.7 Aux.hoist pawl switch
18.10.8 28 pump high pressure switch
18.10.9 Standby
18.10.10 Standby
18.10.11 Main derricking pawl switch
18.10.12 Main hoist pawl switch
18.10.13 Slewing float switch
18.10.14 Standby
3-23/50
1. Power key switch
¾ Rotate the switch rightward: connect the whole crane power; switch to neutral; cut off the
whole crane power.
Fig 3.2.3.2b
2．Start key switch
¾ Rotate the switch rightward: engine start (reset to neutral position automatically)
¾ Switch to neutral: engine working position
¾ Rotate the switch leftward: engine stop (locking).
Fig 3.2.3.2c
3. Throttle knob
Refer to 3.2.2.6 throttle knob.
4. Slewing lock switch
¾ Press the switch to , and lamp is ON, turn the slewing lock device on.
Fig 3.2.3.2d
Notes: the slewing lock only mechanically lock to 4 points, cannot lock to whole slewing area.
When the crane finishes operation, transportation or stop on the inclined ground, set the locking
device to fix the superstructure slewing.
3-24/50
5.Traveling high/low speed switch
¾ Press the switch to , and lamp isON, under traveling high speed status;
¾ Press the swicth to , under traveling low speed status;
Fig 3.2.3.2e
6. Aux.hoist pawl switch
¾ Press the switch to , the lamp is ON, aux. winch pawl disengages, and the
aux.winch can be operated;
¾ Uplift the switch, the lamp is OFF, aux. winch pawl drum is locked, and aux. winch
cannot be operated;
Note: this switch controls the aux. winch pawl, when it no need drum operation, switch to LOCK
position and lock the drum, to prevent the drum operation under outer force.
¾ Before crane working, the pawls must be disengaged, or may damage the drum.
Fig 3.2.3.2f
7．28pump high pressure switch
¾ Press the switch to , lamp is ON, and all cylinders can be operated;
¾ Or the pump is under off-load status.
Note: this switch is only used when assembling/dismantling the crane, and uplift the switch
when normal working.
Fig 3.2.3.2g
3-25/50
8. Main derricking pawl switch
¾ Press the switch to , the lamp is ON, and the main derricking pawls are
disengaged, main derricking can be operated;
¾ After uplifting the switch, lamp is OFF, and main derricking pawl locks the drum, main
derricking cannot be operated;
Note: this switch controls the main derricking pawl, when it no need the drum operation, switch to
LOCK and lock the drum, to prevent drum operation under outer force.
¾ Before the crane is working, and pawls must be disengaged, or may damage the drum.
Fig 3.2.3.2h
9. Main hoist pawl switch
¾ Press the switch to , the lamp is ON, and main winch pawl is disengaged, main
winch can be operated;
¾ After uplifting the switch, the lamp is OFF, and main winch pawl will lock the drum, main
winch cannot be operate.
Note: this switch controls the main winch pawl, when it no need the drum operation, switch to
LOCK and lock the drum, to prevent drum operation under outer force.
¾ Before the crane is working, and pawls must be disengaged, or may damage the drum.
Fig 3.2.3.2i
3-26/50
10. Slewing float switch
¾ Press the switch to , the lamp is ON, and crane is under slewing float status;
contrarily, exit the slewing float status.
Fig 3.2.3.2j
3.2.3.3 Front display console

1.Parameter display
Fig 3.2.3.3a
Table 3.2.3.3a
No. Name Remark
18.22 IC6600 Parameter display of moment limiter system Imported moment limiter
2. Integration lamp
3-27/50
Fig 3.2.3.3b
Table 3.2.3.3b
No. Name Remark
18.22.2.1 Power light(green)

Connect the whole crane’s power, and lamp is ON.
18.22.2.2 Charging light (white) engine sends out normal voltage, and lamp is ON.
18.22.2.3 Preheat lamp（green） The lamp is ON, means the engine is preheating
18.22.2.4 Start wait light (green) The lamp is ON, means the engine is preheating
when the lamp is ON, indicating the engine happens
18.22.2.5 Fault diagnosis light(yellow) general fault, to prompt the driver repair the engine in
short time
when the lamp is ON, indicating the engine happens
18.22.2.6 Stop light（red） serious fault and needs to stop; when the lamp flashes,
used for reading engine fault code
main hook or aux.hook is hoisted to max. limit, and lamp
18.22.2.7 Hook overhoist lamp（red）
is ON.
18.22.2.8 Luffing jib upper limit light（red） When luffing jib is hoisted to limit angle, and lamp is ON.
18.22.2.9 Boom upper limit light (red) When boom is hoisted to limit angle, and lamp is ON.
18.22.2.10 When the light is ON, means the crane’s
Traveling reverse light (white)
superstructure/undercarriage is under reverse status.
when slewing brake starts, and lamp is dark, slewing can
be operated; slewing brake closes, and lamp is ON, the
18.22.2.11 Slewing brake light（green）
slewing operation is limited.
18.22.2.12 Vacancy (white)
3-28/50
3．Display panel
Fig 3.2.3.3c
Table 3.3.3c
No. Name Remark
18.22.3 Free-fall caution light Refer to attachment—free-fall operation
18.22.4 Electrical injection engine diagnosis connection,
Diagnosis connection
used for computer testing
18.22.5 If main winch disc brake is abrasion, and this
Main winch disc brake abrasion lamp
lamp is ON.
18.22.6 If aux. winch disc brake is abrasion, and this
Aux. winch disc brake abrasion lamp
lamp is ON.
18.22.7 Main winch free-fall switch Refer to attachment—free-fall operation
18.22.8 Aux.winch free-fall switch Refer to attachment—free-fall operation
3.2.3.4 Side top operating console
Fig 3.2.3.4a
3-29/50
Table 3.2.3.4a
No. Name Remark
18.1.1 Multi-functional annunciator
18.1.2 Cab auxiliary function switch
18.1.3 A/C panel
18.1.4 New Wind speed control board
1. Multi-functional annunciator
Fig 3.2.3.4b
Instructions for multi-functional annunciator:
¾ Connect the power, panel red power lamp (18.1.1.1) is ON, press the “ON/OFF” power
switch (5), and power lamp (18.1.1.1) is darken, at the same time, the annunciator
enters into standby mode, press it again to enter into working mode.
¾ Alarm system: press the “alarm” switch (18.1.1.5), and the loudspeaker on the top of
cab alarm. Press it again to stop alarm system.
¾ Tone selection: press the “tone” key to select (18.1.1.4), and A,B,E will alarm circularly,
the customers can select suitable tone according to requirements.
¾ Volume adjustment: increase and decrease volume by “∨”(decrease)
(18.1.1.6)and“∧”(increase18.1.1.7), increase and decrease the alarm volume by “∨”
and “∧”; when the megaphone function is ON, increase and decrease the megaphone
volume by “∨” and“∧”.
¾ Megaphone function (18.1.1.8): when the mike is ON/OFF, and megaphone function
can be realized, the sound can be sent out via the loudspeaker at top of cab.
2. Cab auxiliary function switch
¾ The front window wiper switch, press the switch, the front window wiper starts to work, there
are two positions, slow speed mode and quick speed mode.
3-30/50
Fig 3.2.3.4c
¾ The top window wiper switch, press the switch, the top window wiper starts to work, there are
two positions, slow speed mode and quick speed mode.
Fig 3.2.3.4d
¾ Front window sprinkler switch, press the switch, and front window sprinkler starts to work,
loose it then reset stop.
Fig 3.2.3.4e
¾ Top window sprinkler switch, press the switch, and top window sprinkler starts to work, loose
it then reset stop.
图 3.2.3.4f
¾ Cab front light switch, press the switch to turn cab front light on, supply the lighting to site,
which is front of base machine.
3-31/50
Fig 3.2.3.4g
Fig 3.2.3.4h
¾ Winch lighting switch, press the switch to turn the winch lighting on, to check the wire rope
winding status on the winch clearly.
Fig 3.2.3.4i
Fig 3.2.3.4j
3-32/50
3. Air conditioner panel
Refer to 3.2.5.2
4. New wind speed control panel
Refer to 3.2.5.3
3.2.4 Monitor system
3.2.4.1Composition of monitor system
The monitor system is composed of HD video display, has the function of audio output, two
monitor cameras, one with night view function and monitoring the winch working status, the other
is used for rearview camera; one power reverse box, installation position as shown below:
Fig 3.2.4.1
Table 3.2.4.1
No. Name Remark
18.27 Monitor display screen
18.27.1 Monitor display reverse box
13.2 Monitor camera (winch camera)
13.2.1 Monitor camera (rearview camera)
3.2.4.2 The operation of monitor display

(1)DAY/NIGHT (18.27.2)：Select day/night mode by this key
(2)MENU-key(18.27.3)：
¾ Color adjustment: press “MENU” to select “COLOR”, press “+” “-” to adjust color.
¾ Lightness adjustment: press “MENU” key to select “LIGHTNESS”, press “+” “-” to adjust
lightness.
¾ Contrast adjustment: press “MENU” key to select “CONTRAST”, press “+” “-” to adjust
contrast.
3-33/50
¾ Volume adjustment: press “MENU” key to select “VOLUME”, press “+” “-” to adjust volume.
(3)-key(18.27.4)：Decrease-key during adjustment.
(4)+ key(18.27.5)：Increase-key during adjustment.
(5)MIR/NOR (18.27.6)：Press this key to select MIR/NOR
(6)CAMS elect/ (18.27.7) :Power switch and select menu key

(7)Power lamp (18.27.8)
(8)Audio output port(18.27.9)
Fig 3.2.4.2
3.2.5 Air-conditioner system
Details refer to Operation Manual of Air-conditioner.
It is not allowed to operate under following conditions:

¾ The place may be with flammable gas or heavy smoke (such as fuel, cinder,
sawdust, wheat buttress, etc.)
¾ In the closed space (such as garage), which will be easily poisoning.
¾ During oiling.
3.2.5.1 Parts names
3-34/50
Fig 3.2.5.1
Table 3.2.5.1
No. Name Remark
18.1.3 A/C panel
18.1.4 New wind speed control panel
18.9.1 Rear airflow ventilation port
18.9 A/C evaporator
18.9.2 Front airflow ventilation port
3.2.5.2 Functions of air-conditioner panel function
Fig 3.2.5.2
3-35/50
Table 3.2.5.2
No. Name Remark
Power is turned on after pressing the power switch, the LCD
18.1.3.1 power switch backlight will light. and then press the power switch,
disconnect the power, the backlight off.
18.1.3.1.2
Press refrigeration button and system enters the cooling
Refrigeration mode and cancel the other mode, the screen display
button
refrigeration icon and temperature digital is shown in
the screen.
18.1.3.1.3 Defrosting key and system enters the core defrost mode, the
Defrost button
screen displays the defrost icon .
18.1.3.1.4 Heating button. Press heating key and system enters the
heating mode, the screen displays the icon and temperature
Heating button
values of the heating .

18.1.3.1.5 New wind button. In the cooling or heating mode, the new
wind key on the control panel, outside loop icon light is
displayed on the screen, system enters the outside loop
mode state to get a new air in the cab. New wind button. In
New wind button
the cooling or heating mode, the new wind key on the
control panel, outside loop icon light is displayed on the
screen, system enters the outside loop mode state to get a
new air in the cab.
18.1.3.6 Light button All nightlight will be on after pressing this button.
18.1.3.7
.press to increase temperature, press to
18.1.3.8
reduce temperature.
Temperature
Setup Long time to press or 3s system to
enter refrigeration state. Press any button
for exit（except for wind speed button, nightlight button and
temperature setting button）
18.1.3.9
18.1.3.10 press to increase wind speed,
Wind speed
Setup
Press to reduce wind speed. There are three gears
in the wind speed. (L, M, H).
3-36/50
18.1.3.11 Outside loop icon
18.1.3.12 Inside loop icon
18.1.3.13 Temperature setup
value
18.1.3.14 Refrigerate icon
18.1.3.15 Heating icon
18.1.3.16 Wind speed icon
3.2.5.3 New wind speed control panel
Fig 3.2.5.3
Under refrigeration or heating mode, press the New wind key on the A/C panel to have indoor air
cycle, adjust the new wind speed knob (18.1.4.1) to change the new wind supply in certain time.
The wind speed set up as low speed (18.1.4.2), middle speed (18.1.4.3) and high speed
(18.1.4.4)
3.2.6 Overload release switch
The overload release switch (23.3.1) of crane stays in the sliding electric control cabinet, only
used when dismantling the crane boom during lowering boom, to constrainedly allow the
derricking lowering operation and hook hoisting operation when moment limiter overload stops.
It is forbidden to use overload release switch to release the moment limiter overload
during crane normal working, if release it constrainedly, and will cause crane overturn,
damage, or personal accidents. We will not be responsible for that.
3-37/50
Fig 3.2.6a
Table 3.2.6a
No. Name Remark
23.3 Sliding electric control cabinet
23.3.1 Moment overload release switch
¾ Turn the moment overload switch (23.3.1) right once time (loose it then reset to neutral
position), to make the crane enter into release overload status, and it cannot stop
derricking lower operation and hook hoisting operation when moment limiter is overload.
¾ Turn moment overload release switch (23.3.1) left once time (loose it then reset to
neutral position) or give the electricity to crane again, to make the crane exit the release
overload status, resume the auto-stop derricking lower operation and hook hoisting
operation when moment limiter is overload.
Fig 3.2.6b
3-38/50
Table 3.2.6b
No. Name Remark
23.3.1 Moment overload release
A Right turn to moment overload release position Loose it to neutral
B Left turn to moment overload not release position Loose it to neutral
3.3 Safety device

3.3.1 Precautions for safety devices operation
This crane is equipped with all kinds of safety devices, which are very important to ensure safe
operation.
¾ Always check that safety devices operate correctly and be sure to use them during
operation.
¾ The safety devices are auxiliary devices to ensure safe operation. Even though the
safety device functions are normal, tipping-over of the machine may occur due to
collapse of the ground, wind, incorrect adjustment of the safety devices, and/or lateral
pull of a lifting load. Be more careful during operation.
¾ Wrong operation, intentional deactivation, and insufficient check and/or maintenance
of the safety devices may cause serious accidents.
¾ Observe the gradienter before operation, to make its job within safe level angle.
¾ If the safety devices are malfunction, and repair them immediately, then it can be
used.
¾ Stop operating when heavy wind, earthquake or thunder weather. To prevent electric
shock and high frequency electric wave during operating.
Precautions for safety devices operation.
The following safety devices are provided on this machine:
¾ Hook overhoist prevention device
¾ Boom overhoist prevention device
¾ Hook overhoist prevention device
¾ Moment limiter (overload limit device)
¾ To always correctly operate the safety devices, check them a regular intervals according to
the instructions described in this Operator’s Manual.
¾ Never attempt to modify the safety devices.
¾ In case a safety device does not operate correctly, stop the machine and contact your
nearest FUWA dealer for repairs.
¾ Don’t operate the machine with the safety devices deactivated. If intentionally deactivated,
3-39/50
the machine may be overloaded or the hook or the boom may be overhoisted without
noticing, resulting in a serious accident such as machine breakdown or tipping over.
¾ Observe the following points to accurately operate the moment limiter.
¾ Install the hook and wire rope correctly, refer to chapter 5-1.15
¾ The maximum load ratings are designated depending on the length of the boom and the jib to be
used. Be sure to use the number of wire rope falls and the hook size corresponding to the
maximum load rating.
3.3.2 Safety device operation
3.3.2.1 Hook overhoist prevention device
¾ The hook overhoist prevention device is mainly used to prevent the crane damage
caused by hook hoisted too high, so ensure to operate under safety, it is important
device.
¾ Always check that this device operates correctly and use this device during operation.
If this device fails, immediately repair it. Operate the machine only after repairing the
failure. Never attempt to modify this device. If failed or any abnormality occurs,
contact your nearest FUWA dealer.
¾ When the hook overhoist prevention device during assembling or dismantling the
boom (that is boom angle is 10°or much less)
¾ Do not adjust the distance between hook height limit switch and hammer, for it has
been adjusted to 1.5~1.7m before shipping the machine from factory.
When the hook is hoisted to limit height, and support the hammer, then height limit switch limits,
hook overhoist lamp is ON, at the same time, controller stops hook hoisting, and load light’s red
light is ON with continuous alarm. At this time, only operate hook lowering and derricking gear
operation.
3-40/50
Fig 3.3.2.1
Table 3.3.2.1
No. Name Remark
23.4 Main hook height limit switch
23.5 Aux.hook height limit switch
3.3.2.2 Boom overhoist prevention device
¾ The boom overhoist prevention device is mainly used to prevent the crane
damage caused by derricking gear hoisted too high, so ensure to operate under
safety, it is important device.
¾ Always check that this device operates correctly and use this device during
operation. If this device fails, immediately repair it. Operate the machine only after
repairing the failure. Never attempt to modify this device. If failed or any
abnormality occurs, contact your nearest FUWA dealer.
¾ The boom overhoist prevention device has been set before shipping the machine
from factory, limit switch and boom touches rear limit, and do not adjust the
position of limit switch or limit switch installation bracket.
Boom working condition, when the boom is hoisted to exceed the max. angle, which is limited by
moment limiter, and boom touches the limit switch to make it limit, boom light is ON, , boom lamp
is ON, at the same time, controller stops hook hoisting and derricking hoisting, and load light’s
red light is ON with continuous alarm. At this time, only operate hook lowering and derricking gear
lowering.
3-41/50
Luffing jib working condition, when the boom is hoisted to exceed 90°, and boom touches the limit
switch to make it limit, boom light is ON, at the same time, controller stops hook hoisting and
derricking hoisting, and load light’s red light is ON with continuous alarm. At this time, only
operate hook lowering and derricking gear lowering.
Fig 3.3.2.2
Table 3.3.2.2
No. Name Remark
23.6.1 Boom upper limit switch under boom working condition
23.6.2 Boom upper limit switch under luffing jib working condition
3.3.2.3 Hook overhoist prevention device
¾ The hook overhoist prevention device under crane hook is lowering, always keep wire
rope layers winding on the hoisting winch is above safety lower limit (3 layers), to
ensure wire rope is locked on the hoisting winch safe and reliable, so make sure the
crane is operating under safety, it is very important device.
¾ Always check that this device operates correctly and use this device during operation.
If this device fails, immediately repair it. Operate the machine only after repairing the
failure. Never attempt to modify this device. If failed or any abnormality occurs,
contact your nearest FUWA dealer.
¾ Before shipping the crane from factory, hook lowering depth limit device has been
adjusted, when hook lowers to 3 layers wire rope winding on the hoisting winch, the
proximity switch has tested to hook lowering depth limit device’s moveable iron block
shift to limit, do not adjust the position of proximity switch or limit device.
3-42/50
¾ when main hook or aux.hook lowers to 3 layers wire rope winding on the winch, the
proximity switch has tested to hook overhoist prevention device’s moveable iron
block shift to limit, at the same time, controller stops main hook lowering or aux. hook
lowering, and load light’s red light is ON with continuous alarm. At this time, only
operate hook hoisting and derricking gear operation.
Fig 3.3.2.3
Table 3.3.2.3
No. Name Remark
23.7 Main winch overhoist prevention proximity switch
23.7.1 Main winch overhoist prevention active iron block
23.8 Aux. winch overhoist prevention proximity switch
23.8.1 Aux. winch overhoist prevention active iron block
3.3.2.4 Moment limiter

The moment limiter is auxiliary device to ensure safe operation, when crane happens overload
conditions, which may cause the crane or personal accidents, giving the alarm to crane operator,
and corresponding actions output signal to limit the crane towards to dangerous direction.
¾ The moment limiter only protects the overload moment within crane boom
uprightness plane, cannot protect inclined lifting, wind power, inclined ground or
railway, or traveling wheel out of rail, and other conditions those will cause crane
overturn. Therefore, do not relay only to the safety devices. You must assume
responsibility for safety operation.
¾ Only be calibrated and setup correctly, the moment limiter can supply safety
3-43/50
protection to crane and supply the operators with available information. To prevent
causing personal injuries, please make sure working conditions reevings and limit
parameter of moment limiter is correct before operating crane.
¾ If the moment limiter happens failure of works abnormally during operation, please
operator stops operating and contact our after-sales. For the badness results caused
by operating crane under moment limiter failure or cannot work, and our company
does not take any responsibility.
¾ Installation position of moment limiter’s parts
Fig 3.3.2.4a
3-44/50
Fig 3.3.2.4b
Table 3.3.2.4
No. Name Remark
23.9 Wind speed sensor
23.10 Force sensor
23.11 Moment limiter computer
23.12 Angle sensor
23.13 Boom foot junction box
18.22 IC6600 Parameter display of moment limiter system
2.Parameter display of moment limiter

The moment limiter is calculated according to sensor’s data and crane’s parameter, display
below data in real-time:
¾ Working condition code display
¾ Reevings display
¾ Jib length
¾ Jib angle
¾ Boom length
¾ Height
¾ Boom angle
¾ Radius
¾ Fault code
¾ Moment percentage
¾ Rated weight
¾ Actual weight
¾ Level angle
¾ Pilot pressure
¾ Wind speed value
¾ Fuel level
¾ Engine Rev.
3-45/50
¾ Engine oil pressure
¾ Engine coolant temperature
¾ Working time
3. Control and caution function of moment limiter
When the actual load is less than 90% of rated load, the screen shows load proportional bar in
green color, and no warning alarm from the safe load indicator.
When the actual load exceeds 90% of rated load while is less than 100% of rated load, the
screen shows yellow color and an intermittent warning alarm sounds.
When the actual load exceeds 100% of rated load while less than 105% of rated load, the
monitor screen shows red color and the safe load indicator gives continuous warning alarm, and
output control signal.
When the actual load exceeds 105% of rated load, the monitor screen shows red color and gives
out a continuous warning alarm, at the same time the safe load indicator put out control signal to
stop the hoisting action of hooks and lowering action of derricking gear.
4. Operation and setup of moment limiter
Please refer to Operation Manual of Moment Limiter.
3.3.3 Annunciator and alarm light
3.3.3.1 Position and function of annunciator and alarm light
This crane is equipped with kinds of annunciators and alarm lights to make surrounding
personnel to know about crane’s current operating status, operating actions and load status, etc.
to ensure crane’s safety operation and prevent the surrounding personnel and things from
damages, make sure the annunciators and alarm lights working normally before operating the
crane.
Main annunciators and alarm lights are shown as below:
(1) Load light (display crane’s load)
(2) Turning light (only use when crane left/right slewing, the turning light flashes to alarm
surrounding personnel)
(3) Height light (install on the boom head, to indicate the highest position of crane)
(4) Loudspeaker (send the indications from operator to surrounding personnel near crane)
(5) Engine operating lamp (after engine starts and flashes, used for showing working status of
engine)
(6) Test device (after testing crane’s traveling and slewing), then send to annunciator and turning
light)
(7) Annunciator (when the crane is traveling or slewing left/right, the annunciator gives out alarm
to surrounding people)
3-46/50
Fig 3.3.3.1a
Fig 3.3.3.1b
Table 3.3.3.1
No. Name Remark
23.14 Load light
23.15 Turning light
23.16 Height light
23.17 Green light
23.18 Test device
23.19 Loudspeaker
18.3 Engine operation lamp
3-47/50
3.3.3.2 Alarm of load light
¾ When operating the crane normally, the load light takes three colors (red, yellow, green)
lamp’s lighten status and with/without continuous, intermitted alarm to indicate the crane
current load status and limit conditions. When the crane with electric moment limiter system
operation, and load light has one color light on according to crane’s operation status, as
shown below:
¾ Green light: means the actual load is less than 90% of rated load,
¾ Yellow light is ON and an intermittent warning alarm sounds: means the actual load exceeds
90% of rated load while is less than 100% of rated load.
¾ Red light is ON and gives out a continuous warning alarm: means the actual load exceeds
100% of rated load or crane happens below limits:
Fig 3.3.3.2
Table 3.3.3.2
No. Name Remark
23.14 Load light
23.14.1 Red light
23.14.2 Yellow light
23.14.3 Green light
3-48/50
3.3.3.3 Alarm of traveling and slewing action
¾ When the operator operates the crane to slew leftward, slew rightward, the test device
(23.18) can test the slewing signal and send it to annunciator (13.17) and left right turning
light (23.15.1, 23.15.2), then annunciator (23.17) sends alarm and left right turning light flash
is ON, to caution the surrounding personnel that the crane is under slewing operation.
Fig 3.3.3.3
Fig 3.3.3.3b
3-49/50
3.3.3.4 Height light
When the crane needs to work at night, please turn solar height light (23.16) on, which is installed
on the boom head or fixed jib head, then solar height light (23.16) will flash automatically at night,
to indicate the highest position of crane.
Fig 3.3.3.4
3-50/50
Chapter 4 Operation
4.1 Daily inspection
Inspect the machine as chapter 8 before operating.
4.2 Inspection before operating
4.2.1 Inspect pedal, hand grip, operating lever and switch
4.2.1.1 Inspect the position of pedal

Check right traveling pedal (18.15) and joystick (18.21), left traveling pedal (18.16) and
operating lever (18.20), throttle pedal (18.13.1) and knob throttle (18.10.4) on the initial
position not bearing outer force.
4.2.1.2 Inspect the position of hand grip
Left operating grip (18.11.1), right operating grip (18.10.1) should be on the neutral position.
4.2.1.3 Inspect the position of joystick
¾ The pilot enable hand grip (18.12) stays on locking position;
4.2.1.4 Inspect the position of switch on the operating panel
¾ The emergency button (18.11.2) should stay on UPLIFT status;
¾ Main derricking pawl switch (18.10.11) should be on OFF status.
¾ Slewing locking switch (18.10.5) should be on OFF status
¾ Aux. hoisting pawl switch (18.10.7) should be on OFF status
¾ Main hoisting pawl switch (18.10.12) should be on OFF status
¾ Slewing float switch (18.10.13) should be on OFF status.

4.3 Connect the power
Turn the power switch (18.10.2) right to CONNECT, and power lamp is ON (18.22.2.1), then
parameter display (18.22) with electricity operation.
Fig 4.3
4-1/17
4.4 Start engine
Only confirm that no person within crane, after the horn sounds, and it can start
engine.
4.4.1 Start engine
1. Check the pilot locking lever (18.12) on the locking position;
2. Adjust throttle knob (18.10.4) to low speed;
3. Rotate the start key switch (18.10.3) from stop position to working position, and engine
with electricity enter into start status.
As shown in Fig 4.4.1, start wait light (18.22.2.4), fault diagnosis light (18.22.4.5), stop
light (18.22.2.6) will be on for 2s then will be off, it is the procedure for electric
injection fuel engine self-check, to indicate the lamp working normally and engine
circuitry with no failure.
4. Press the horn button (18.10.1.2) of right hand grip, to alarm surrounding people away
from the crane.
5. Rotate the start key switch (18.10.3) from working position to start position, and engine
starts.
The time for engine starting, please do not exceed 10s. if the engine does not start,
return the start key switch (4) to stop position, after waiting 30s, start it again. In case,
which will cause the start motor damage and battery loss electricity fast.
6. When the engine starts, loose the start key switch (18.10.3), and automatically return to
working position; at this time, the generator works, and charging lamp (18.22.2.2) is ON.
Fig 4.4.1
4-2/17
4.4.2 Preheat of engine
When starting engine under cold weather, and please start the preheat device of engine.
Before starting the engine, the pre-heater of electronic fuel injection engine will test if needs
to start or not automatically; when turns the start key switch (18.10.3) from START to
WORKING, to observe start-wait lamp (18.22.2.4) is ON or not, if it is ON, and means the
engine is preheating, it cannot start. When the (18.22.2.4) is off, after pre-heater stops
working, and it can start the engine.
Fig 4.4.2
4.4.3 Use of auxiliary battery block
¾ The battery may happen a kind of volatile gas. So the battery must be far away from the
fire and spark. When the electrolyte level is lower than the regulated value, please don’t
use or charge it continuously, in case causing the battery exploded. Park the crane and
other equipments with battery on the dry soil or surface of concrete. Never connect the
anode wiring end to cathode wiring end, in case it will be short-circuit.
¾ The electric system of crane is DC24V, cathode grounding. Only when it is with 24V
battery block, and sufficient electricity to start engine, and it can be used. When the
battery of crane is without electricity, and it can use auxiliary battery block to start the
engine.
4.4.3.1 Connection of auxiliary battery block（Fig 4.4.3.1）
1. Stop the engine.
2. Connect the one end of red connecting cable (13.21.1) to anode wiring end of crane
battery block (13.20), and the other connect to anode wiring end of auxiliary battery block
(13.21 )
4-3/17
3. Connect the one end of black connecting cable (13.21.2) to cathode wiring end of
auxiliary battery block (13.21), and connect the other end to the track shoe of crane. At last,
when connecting to track shoe, and it may happen spark. Try to keep far away from the
battery block when connecting the cable.
4. After connecting the cable, start the engine.
5. After connecting the engine, take following steps to disconnect the cable.
Fig 4.4.3.1
4.4.3.2 Disconnection of battery block
1. Disconnect the cable (13.21.2) (black) from the track shoe.
2. Disconnect the cable (13.21.2) (black) from cathode wiring end of auxiliary battery block.
3. Disconnect the cable (13.21.1) (red) from anode wiring end of auxiliary battery block.
4.Disconnect the cable (13.21.1) (red) from anode wiring end of auxiliary battery block.
4.5 Inspection and operation after starting the engine
4.5.1 Warm-up operation
1. If operate the machine without warm-up, and it will reduce the service life but also the
engine operates abnormally after running, then causing unexpected accidents.
2. If the engine or hydraulic pump happens abnormal noise, and shut down the engine
immediately. Then check out the accidents reason.
3.Under cold weather or low temperature, please do warm up the machine sufficiently.
4-4/17
4.5.1.1 Warm-up operation under normal temperature
1. Without load, operate the speed-up hand grip, make the engine 1000 rpm/min, keep
5~10min.
2. Check if abnormal noise or not.
4.5.1.2 Warm-up operation under low temperature
1. Without load, operate the speed-up hand grip, make the engine 1000 rpm/min, keep
10~20min.
2. Check if abnormal noise or not.
4.5.2 Inspection of engine parameter
¾ If the engine parameter happens any abnormal, please stop the engine
immediately and find out failure reason.
1. Check the engine water temperature display if normal.
2. Check engine oil pressure indicate if normal.
4.5.3 Inspection of engine’s sound and exhaust color
Check engine’s sound and exhaust color if normal.
¾ Inspection of exhaust color (inspection after warm-up operation without load) no color
or light blue: normal (totally burnt)
¾ Black: bad (not totally burnt); white: bad (burnt indoor temperature is low)
4.6 Inspection of moment limiter (overload protection device) (Fig 4.6)
After normal adjustment, the moment limiter can work automatically, so the crane operator
must be familiar with the operation of this moment limiter system, start crane operation only
after correct adjustment.
4-5/17
Fig 4.6
4.7 Stop engine
Stop the engine as following steps:
1. Except special conditions, before stopping the engine, and put hook on the ground or add
anchor weight.
2. Lower the engine speed to idle speed, and operate it for about 3min, to cool the engine.
¾ The engine is equipped with Turbo. If the engine stops without cooling, and the
parts need to be lubricated would be dry due high oil temperature, may cause
turbo damage.
3. Turn key switch (18.10.3) to STOP, and stop the engine.
4.Pull the pilot enable hand grip (18.12) to LOCK position.
4-6/17
5. If the emergency happens, and engine needs to stop immediately, turn emergency stop
switch (18.11.2) to STOP, and stop the engine.
4.8 Hook hoisting/lowering operation
¾ Push the right hand grip pilot valve to B/D, and hook lowers.
¾ Pull the right hand grip pilot valve to A/C, and hook hoists.
¾ Push the right hand grip valve to neutral position, and hoisting/lowering will stop
automatically, when the load stays in the sky, and the drum needs to be locked.
¾ If the operating grip returns to neutral position quickly, and the hook speed will
be changed quickly, so the dangerous impact may be caused. Otherwise, it may
cause wire rope disorder on the winch.
¾ When operating grip returns to neutral position, make sure the operating grip
return to neutral position correctly and slowly.
¾ When controlling the hand grip pilot valve to make the hook lower, but the hook
cannot be lowered, and the pawls may still lock the drum, at this time, hoist the
hook slightly, then make the hook lower.
¾ The hoisting rope would be broken, caused by hook touches the rod head, this
condition is called hook overhoist, it is no time to release the hoisting rope when
lowering boom, causing the hook overhoist, and hook overhoist will result in jib
and boom tip over backward or damage the rod head.
¾ Always keep suitable distance between hook and rod head, release the hoisting
rope at any time when lowering the boom.
¾ When lowering the load, it is forbidden to use drum locking, in case, the pawls or
drums would be damaged.
4-7/17
Fig 4.8
Table 4.8
No. Name Remark
A Aux. winch hoist
B Aux. winch lower
C Main winch hoist
D Main winch lower
18.10.1 Right operating grip
4.9 Locking operation of derricking gear pawl
¾ When lifting the load for long time, maintenance or safe transportation, and the main
derricking drum has set the pawl drum locking device, structure as shown below:
4-8/17
Fig 4.9
¾ Before derricking gear working, press the right control box switch derricking gear
pawl switch (18.10.11) as shown in Fig 3.2.3.2a, to make the switch to OPEN
LOCK position as shown in icon, then the main derricking drum pawls are
disengaged, stay in Fig 4.9 B, to enter into working status;
¾ When the system stops working, put above switch to LOCK position, and the pawls
are locked.
4.10 Boom derricking hoisting/derricking lowering operation
¾ During crane operation, slowly operate the boom derricking. If the speed is too
fast, and it may cause the load swing, working radius increase, causing the
stability of machine will be reduced. Take more attentions when operating long
boom.
¾ When main derricking operating grip returns to neutral position, to ensure hand
grip return to neutral position correctly and slowly.
¾ When no needs boom derricking operation, close the derricking gear pawl to lock
the main derricking operation to prevent mis-operation
¾ When boom angle reaches upper or lower limit, and reduce the derricking
operation speed.
4-9/17
Boom derricking hoist:
1. Derricking gear pawl engages;
2. Pull the left operating grip to A direction backward, to have boom derricking hoisting
operation.
Boom derricking lower:
1. Derricking gear pawl engages;
2. Pull the left operating grip to B direction forward, to have boom derricking lowering
operation.
Derricking stop:
1. Slowly push the operating grip to neutral position;
2. Close the derricking gear pawl.
Fig 4.10
Table 4.10
No. Name Remark
A Main derricking hoist
B Main derricking lower
4-10/17
4.11 Slewing operation (including slewing lock, brake and float operation)
¾ Slowly operate the slewing system. If operate too fast, and the load may
swing, working radius increase, so may cause dangerous conditions.
¾ Operate the slewing grip as reverse direction to stop superstructure ‘s
slewing. Slowly operate the grip to make the load no swing.
¾ Never use slewing brake to stop slewing operation. In case the load may
swing, moreover, make the slewing brake device, boom or additional
equipments damage. At the same time, slewing emergency stop may
happens great impact, and the machine may be caused overturn.
¾ Before slewing operation, the slewing locking switch must be pressed to
START position, to make slewing lockpin away from the lock groove.
¾ Never use slewing brake to stop slewing operation. In case the load may
swing, moreover, make the slewing brake device, boom or additional
equipments damage. At the same time, slewing emergency stop may
happens great impact, and the machine may be caused overturn.
¾ Only finish following operations and ensure safety, then the operator can
leave the seat.
Press slewing brake button, make slewing brake lamp is ON.
Press the slewing lock rod.
Stop the engine.
¾ Before slewing operation, firstly lift the slewing lock rod (18.10.10) to START,
and leave the slewing lockpin away from the lock groove.
¾ When the slewing float button is pressed down, and it may happen slewing
excursion, and it is allowed the machine to slew automatically on the windy
jobsite or on the slope.
4-11/17
Fig 4.11
Table 4.11
No. Name Remark
C Slewing rightward
D Slewing leftward
18.11.1.1 Slewing brake start button
18.11.1.2 Slewing brake close button
18.22.2.11 Slewing brake lamp
4.11.1 Slewing brake operation
During slewing operation, it needs to press slewing brake start button (18.11.1.1), when the
slewing brake lamp (18.22.2.11) is ON, to indicate the slewing brake is start and it can have
slewing operation.
When finishes the slewing action, it needs to press slewing brake button (18.11.1.2), and
slewing brake lamp is darken, to indicate the slewing brake is close, and limit the slewing
operation. When pressing the slewing brake button again, and slewing brake lamp is ON
again, to indicate the slewing operation.
4-12/17
4.11.2 Slewing float operation
¾ Slewing float operation is short-time working status, operate it more carefully.
Slewing operation is invalid during slewing float.
¾ Start slewing float operation, at the same time, it will start slewing brake.
When lifting the load, if the hook is not uprightness with barycenter of load, and press the
slewing float button switch (18.10.13) on the right operating panel, continuously hoist the
hook, and the superstructure will slew to hook uprightness with barycenter of load
automatically.
4.11.3 Slewing locking operation
When this crane finishes operation or transportation, and crane stops on the inclined ground,
it has been set up with locking device to fix the upper structure slewing. There are four
locking devices on the front, back, left, right, are controlled by slewing locking switch
(18.10.5), which is close to right control panel.
4.11.4 Slewing operation
Slewing operation is controlled by left operating grip’s (18.11.1) left operating lever, to
control slewing speed by adjusting hand grip’s radius and engine throttle big/small
¾ Left slewing: slowly push the hand grip to D, crane starts to slewing leftward, and
buzzer sounds, at the same time, the cautions lights are ON at both sides of
superstructure.
¾ Right slewing: slowly push the hand grip to C, crane starts to slewing rightward, and
buzzer sounds, at the same time, the cautions lights are ON at both sides of
superstructure.
¾ Stop slewing: slowly push the left slewing hand grip to neutral position.
4.12 Traveling operation
Traveling operation is controlled by traveling pedal and traveling operating lever. To control
traveling speed by adjusting traveling pedal position, traveling operating lever position and
engine throttle big/small.
Strictly take following regulations before crane traveling:
4-13/17
¾ Make sure all the personnel and barriers be out of traveling radius.
¾ Alarm the personnel surrounding the crane before operating traveling.
¾ The longer boom, and bigger the boom angle will be. Take more care if the road
surface is not even or traveling with load, and the director should direct how to
travel.
¾ Slewing brake is under brake position.
¾ Personal injuries may be caused if not take above regulations.
¾ Slowly operate the machine, in case, it will cause the hook swing, resulting the
machine damage.
¾ Never operate any hoisting winches during traveling.
Fig 4.12
4-14/17
Table 4.12
No. Name Remark
A Forward
B Backward
C Rightward
D Leftward
18 Cab
1.1 Traveling drive device
4.12.1 Traveling forward/backward
¾ Traveling forward: at the same push left (18.20), right traveling joystick (18.21) forward;
or at the same time step on the left (18.16), right traveling pedal (18.15) forward.
¾ Traveling backward: at the same pull left, right traveling joystick backward; or at the
same time step on the left, right traveling pedal backward.
¾ If not need traveling operation, return left, right traveling joystick and left, right traveling
pedal to neutral position.
Fig 4.12.1
4.12.2 Direction change during traveling
Only drive one side track to change traveling direction. Operate any traveling joystick or
traveling pedal.
Slewing leftward: operating right traveling joystick or right traveling pedal.
Slewing rightward: operating left traveling joystick or left traveling pedal.
4-15/17
4.12.3 Traveling direction change in original position
Drive the left right track as reverse direction, to change the traveling direction in original
position.
At the same time, move any traveling joystick forward and move the other traveling joystick
backward.
¾ Slewing leftward: move right traveling joystick forward or right traveling pedal and move
left joystick backward or left traveling pedal.
¾ Slewing rightward: move right traveling joystick backward or right traveling pedal and
move left joystick forward or left traveling pedal.
4.13 Wire remote control box operation
Fig 4.13
4-16/17
Table 4.13
No. Name Remark
23.40 Wire remote control box

Press this button, remote control box emergency
23.40.1 Emergency button power off to stop, and revolve clockwise with
electricity.
When the lamp is ON, means remote control box is
23.40.2 Working lamp
power on.
When press this button, and left counterweight
23.40.3 Left counterweight hoist button cylinder is hoisting; when uplift this button, and left
counterweight cylinder stops hoisting.
When press this button, and left counterweight
23.40.4 Left counterweight lower button cylinder is lowering; when uplift this button, and left
counterweight cylinder stops lowering.
When press this button, and right counterweight
23.40.5 Right counterweight hoist button cylinder is hoisting; when uplift this button, and right
counterweight cylinder stops hoisting.
When press this button, and right counterweight
23.40.6 Right counterweight lower button cylinder is lowering; when uplift this button, and right
counterweight cylinder stops lowering.
23.41 Engine block terminal
23.41.1 Engine block terminal socket
When operating the counterweight self-assembling cylinder, pull the 28 pump high pressure
switch (18.10.8) of cab right control panel to HIGH PRESSURE position, and as shown in
Fig 4.13, connect the wire remote control box (23.40)’s cable connector to the socket
(23.41.1) of engine block terminal, and operate the wire remote control box, to realize
counterweight self-assembling cylinder operation.
4-17/17
Chapter 5 Assembling and Disassembling the Crane
5.1 Assembling
5.1.1 Preparation and precautions before assembling.
¾ If the machine is assembled in following incorrect procedures, personal injury or death
may result.
¾ Before beginning work, sufficiently coordinate with all personnel concerned to ensure
safety during work.
¾ Hoisting/lowering boom should be at front of track crane, please refer to Chapter 1-1.3
¾ If the ground is soft, and put enough strength steel plate under track carrier.
¾ Use an assistant crane, sling ropes, and shackles with enough strength to provide a
sufficient margin when lifting loads
¾ Dimension and weights of each part, refer to Chapter 7-7.3.
5.1.1.1 Preparation before operation
1.Have all coordination handled by the job site conductor to ensure safety prior to beginning any
work.
2. Thoroughly inform all workers so they understand the types of work, procedures, and signals to
be used at the job site, etc.
3. Check all instruments and materials for any abnormality.
5.1.1.2 Selection of jobsite
1. Select a solid level surface wide enough to assemble the machine.
¾ Remove all obstacles from the area in which the crane will be moved
¾ Flatten indented surface areas. Horizontally reinforce any soft ground by placing high
strength planks beforehand.
¾ Depending on the boom combinations to be installed, to ensure boom’s hoisting
direction, and adjust if the boom hoisting is restricted or not. Refer to Chapter 6-6.1
5-1/93
5.1.1.3 Preparation of equipments
¾ Auxiliary crane. According to conditions of jobsite and types of operation, to select specified
auxiliary crane. And the selected one must have enough lifting capacity.
¾ Arrange protection items, sling tools, base machine attachments, and tools necessary for the
disassembly/assembly work.
5.1.1.4 Necessary personnel
¾ 4 persons above (operator, auxiliary crane driver, lifter and director)
5.1.1.5 Jobsite management
¾ Take all measures necessary to keep all unauthorized persons clear from the jobsite during
work.
5.1.2 Unloading the base machine from trailer (with track frame)
¾ When unloading the base machine from trailer, please drive the machine in low speed.
¾ Emergency stop may cause dangerous conditions. Please keep invariableness
traveling speed.
¾ Arrange a signal man in advance. If the left, right side of track carrier is discrepancy
with distance of trailer edge, please back off the machine to original position. Then
adjust the forward direction, when it is correct, and operate the machine again.
5.1.2.1 Park the trailer
1. Park the trailer on solid level ground.
2. Unfasten wire rope and/or chains from the machine and remove the stow-wood from track.
5-2/93
5.1.2.2 Drive the base machine off the trailer
¾ The ground should be firm and solid, and inclined degree is less than 1%, or it may
overturn.
¾ When driving the base machine off trailer, there dangerous area between front and rear
of superstructure, please far away this area.
¾ Allowable max. slope angle α should be less than 15°. Don’t try to operate on the slope,
which exceeds 15°(Fig 5.1.2.1)
¾ When driving the base machine off trailer, it is not allowed any operation except
traveling and derricking.
¾ It is not allowed to take any actions when not connecting or disconnecting the
hydraulic hose, in case, it may cause serious personal accidents.
¾ Arrange a director. To direct the crane downgrade operation, then the center of
machine can be aligned to center of ramp.
¾ Use trailer slope or add bracket and cushion plate to ensure the angle of slope.
¾ At the same time, operate the left, right traveling joystick backward. Ensure traveling
direction is parallel with trailer’s board.
1. Make sure the drive unit of undercarriage stay at rear of whole crane
2. Make sure slewing mechanism be in locking position.
3. Fill the trailer’s board up with stow-wood or support, to prevent trailer’s board, which is relative
to trailer, is moving. (Fig 5.1.2.3)
5-3/93
Fig 5.1.2.1
4. Adjust the width of board on the ramp to cooperate with the width of track frame.
5. Adjust the boom foot angle, to keep the angle between boom foot and crane body around 20°.
6. At the same time, move the left, right traveling joystick backward, to keep base machine’s
traveling direction parallel with trailer’s board direction.
5.1.3 Drive the base machine off the trailer (without track frame)
¾ The ground should be firm and solid, and inclined degree is less than 1%, or it may
overturn.
¾ When driving the base machine off trailer, there dangerous area between front and rear
of superstructure, please far away this area.
¾ It is not allowed to take any actions when not connecting or disconnecting the
hydraulic hose, in case, it may cause serious personal accidents.
¾ Arrange a director.
1.Put ① outrigger cylinder, and install ② support base on the outrigger cylinder;
5-4/93
Fig 5.1.3.1
2. Extend the outrigger cylinder to base machine, to disengage away from the trailer;
3. Drive the trailer away.
Fig 5.1.3.2
5-5/93
5.1.4 Extension of track frame
¾ Extending the width of the track frame on slopes may create a hazardous situation.
Carry out this work on a level surface only.
¾ Extend/retract the track frames only
after all counterweights have been removed.
¾ Never extend the track frames on the soft
ground. If it is soft, please put enough
strength steel plate.
¾ Clean the sliding surfaces on the chassis
and track frames. Coat a lubricant such as
gear compound to the sliding surfaces.
¾ The outer border dimension is 3.38m before track frame extension, width of outer
border dimension is 5.06m after track extension. Fig 5.1.4.1
1. Remove the clip board ○

6 from extension device.
2. Take lockpin of spindle ○

1 out, and take spindle ○
1 out.
3. Take the spindle ② out to the position that extension frame revolves the spindle hole out, and
put the spindle ②.
4.Rotate the extension frame ⑤ to the position that uprightness with track frame,
5-6/93
Fig 5.1.4.1
5. Install the clip board ⑥ well.
6. Pull the spindle ④ out.
7. Press slewing/extension shift button to extension side, adjust the operating grip to extend the
track frame. Till reach the spindle ② extension limit status.
8. When the track frame is extended, and insert the spindle ④ again, then connect the clip
board○
1 with bolt.
9.If the clearance between extension○

5 and track frame is too much, and adjust it by nut ○
3 .
¾ If it is difficult for track frame extension, and it can rotate the superstructure 90°. After
extending one track frame, rotate the superstructure 180°. Then extend the other track
frame. At the same time, operate the traveling joystick to ensure the track frame
extension fully.
5-7/93
5.1.5 Installation of cab pedal
¾ The oil on the pedal surface needs to be cleaned in time, to prevent slippery when
stepping on it.
1. The cab pedal is the transit step for driver to enter into the cab, generally put it on level position.
2. Align the linking hole of pedal to the linking hole at cab’s side, then connect and fix them by bolts
and washers.
Fig 5.1.5.1
5.1.6 Installation of counterweight
¾ If not follow correct procedures to install the counterweights, and it may cause
personal accidents.
¾ Before starting the work, fully coordinate relative personnel, to ensure personnel and
equipments safety during operation.
¾ Never allow the workers enter the space under the superstructure and the
counterweights when installing the counterweights, to avoid accidents.
¾ Never lift all counterweights as a unit, or slings, lifting lugs may be broken, possibly
resulting in falling of the counterweights.
5-8/93
¾ When the ground is soft, and it needs to put enough strength steel plate under tracks.
¾ The selected crane, lifting belt, shackles, etc. should have enough strength. In order to
provide sufficient safety during lifting.
¾ Be careful not to touch A-frame and other parts during lifting.
¾ Dimensions and weights of each part, refer to Chapter 7-7.3.
Fig 5.1.6.1
1. Check that the left, right track frame is fully extended.
2. Check that the A-frame is under working status.
3. Check that the top of boom foot on the stow-wood.
4. Make sure the cylinder ⑥ and fixed frame ① have been connected well with counterweight tray
③.
5. Dismantle the spindle ②.
6. Lift the counterweight tray③ to installation position by auxiliary crane.
7. Fix the counterweight tray to superstructure by spindle②, and fix it by lockpin.
5-9/93
Install the spindles from center of machine to outside of machine.
Fig 5.1.6.2
8. Dismantle the lifting belt from counterweight tray.
9. Attach the lifting belt to lifting lug ① of middle counterweight. And hoist it by auxiliary crane (Fig
5.1.6.3).
10. Install the middle counterweight ① on the top of counterweight tray ③.
11. Fix the middle counterweight① to counterweight tray ③with big screw rod ②.
¾ Dismantle the lifting belt from middle counterweight ①.
5-10/93
5.1.5c
Fig 5.1.6.3
12. Install the counterweight ②, ③, ④, ⑤ on the counterweight tray ① one by one. (Fig 5.1.5d)
When installing, keep the balance of left, right counterweight. Firstly, install the middle
counterweight, then install the both sides of counterweight. It is not allowed to install
single side counterweight, then install the other side.
5-11/93
13. Pass the locking device ⑥ through the middle hole of counterweight, from up to down through
the lower part of counterweight, and fix it by nuts, 3 bolts in total.
Fig 5.1.5d
5.1.7 Installation of track carrier
When the control pressure control switch is under OFF status, the drum operates the hand grip,
slewing hand grip, traveling hand grip, even operation, and crane will not have actions.
(1) Start the engine, make its Rev. is 1000rpm.

(2) Insert the slewing lockpin.
(3) Brake the slewing brake.
(4) Uplift the lower section, to support the
support cylinder, and drive trailer away.
Fig 5.1.7.1
Note; when the crane is not installed with full working equipments, that is to say only with
lower boom section, and working angle of lower boom section cannot exceed 73°, or it
cannot free fall down.
(5) Make sure which side of track carrier to be installed first.
Note: when installing the track carrier, according to the rule of driving wheel at rear, to
install the left, right track carrier correctly.
(6) Fix the wire rope on both sides of track carrier, and lift the track carrier by cylinder connected
5-12/93
with boom foot
Warning
z Don’t enter between track carrier and chassis, it is danger to be

crushed.
Fig 5.1.7.2
(7) Retract the crane derricking wire rope, and track carrier is slowly close to undercarriage.
(8) Rotate the extension frame to level position, and position it by clip frame. Insert the extension
frame to track, and connect them by positioning pin, limit pin, etc.
(9) Connect the track extension cylinder, after connection, and dismantle the lifting belt.
5-13/93
Fig 5.1.7.3
(10) Install the other side of track carrier, take above steps to install.
Fig 5.1.7.4
(11) Retract the outrigger cylinder.
(12) Stop engine.
5-14/93
Fig 5.1.7.5
5.1.8 Counterweight’s self-assembling
¾ If not follow correct procedures to install the welding counterweights, and it may cause
personal accidents.
¾ Before starting the work, fully coordinate relative personnel, to ensure personnel and
equipments safety during operation.
counterweights when installing the welding counterweights, to avoid accidents.
resulting in falling of the welding counterweights.
5-15/93
¾ When the ground is soft, and it needs to put enough strength steel plate under tracks.
2. Check that the A-frame is extended.
3. Put the counterweight tray to suitable position by self-assembling cylinder.
Fig 5.1.8.1
4. Put other counterweights on the counterweight tray by boom foot self-assembly cylinder.
5-16/93
Fig 5.1.8.2
5. Extend counterweight cylinder ②.
6. Connect the spindle ① and superstructure ③.
7. Retract the cylinder to suitable position, and fix the counterweight to superstructure by spindle
④.
Fig 5.1.8.3
5-17/93
5.1.9 Configuration of boom/fixed jib and pendant rope
5.1.9.1 Boom working condition
¾ Please use the pendant rope matched with boom length.
Table 5.1.9.1a
Boom pendant rope combinations（boom length 13 m～58m）
No. Name Length （m） Remark
13.2.1 3m pendant rope 3.02 Place on the 13.2
13.5.10 6.9m pendant rope 6.9 Place on the 13.5
13.1 Boom foot 5.8
13.6 Boom backstop rod —
13.2 3m insert 3
13.3 6m insert 6
13.4 9m insert 9
13.5 Boom head 7.2
Table 5.1.8.1b
Used
No. Diameter mm Types of pendant rope
position
13.2.1 Φ32 3m insert
13.5 Φ32 Boom head
5-18/93
Fig 5.1.8.1
5-19/93
5.1.9.2 Runner working condition
Table 5.1.8.2
Boom Runner Boom Runner
length(m) installation length(m) installation
13 ○ 37 ○
16 ○ 40 ○
19 ○ 43 ○
22 ○ 46 ○
25 ○ 49 ○
28 ○ 52 ○
31 ○ 55 ○
34 ○ 58 ○
“○”：can connect “×”：cannot connect
5-20/93
5.1.9.3 Fixed jib working condition
¾ If the pendant rope connection is incorrect, and boom will be damaged, causing
serious accidents. So the pendant rope must be connected strictly depending on
below table.
Boom and fixed jib combinations:
Table 5.1.9.3a
Boom Fixed jib length （m）
length 9 13.5 18
（m） 15° 30° 15° 30° 15° 30°
13 × × × × × ×
16 × × × × × ×
19 × × × × × ×
22 × × × × × ×
25 × × × × × ×
28 × × × × × ×
31 × × × × × ×
34 × × × × × ×
37 ○ ○ ○ ○ ○ ○
40 ○ ○ ○ ○ ○ ○
43 ○ ○ ○ ○ ○ ○
46 ○ ○ ○ ○ ○ ○
49 ○ ○ ○ ○ ○ ○
52 ○ ○ ○ ○ × ×
55 × × × × × ×
58 × × × × × ×
“○”：can connect “×”：cannot connect.
5-21/93
Fig 5.1.9.3
Table 5.1.9.3b
Fixed jib combinations
No. Name Length (m）
15.1 Fixed jib foot 4.5
15.2 Fixed jib insert 4.5
15.3 Fixed jib head 4.5
15.5 pendant rope1 8.33
5-22/93
15.0.1 pendant rope connected section 0.2
15.4.1 Strut body ——
15.4.2 Front pendant rope linking frame ——
15.4.3 Rear pendant rope linking frame ——
Table 5.1.9.3c
Fixed jib front pendant Fixed jib rear
Fixed jib
Fixed jib Fixed jib
length rope combination pendant rope
elevation combination
（m）
combination
15° 15.1+15.3 15.6 15.7

9
30° 15.1+15.3 15.6 15.7+15.8
15° 15.1+15.2+15.3 15.5+15.6 15.7

13.5
30° 15.1+15.2+15.3 15.5+15.6 15.7+15.8
15° 15.1+2×15.2+15.3 2×15.5+15.6 15.7

18
30° 15.1+2×15.2+15.3 2×15.5+15.6 15.7+15.8
¾ Check the length, diameter of pendant rope.
Table 5.1.9.3d
Length m Diameter mm Types of pendant rope
8.33 Φ28
18.9 Φ28
17.86 Φ28
1.53 Φ28
5-23/93
5.1.10 Installation of boom head
Fig 5.1.10a
5-24/93
¾ When installing connection pins, never enter inside the boom. Always remain
outside
¾ the boom and install the pins from outside of the boom.
¾ Support the boom foot with wire stands strong and stable enough to support the
boom when assembling the boom. Be sure to take all necessary measures to
prevent personal accidents occurring in advance.
Clean the connection pin holes and coat the pin hole surfaces with grease.
Check following points before installing the boom head:
¾ The track frame is fully extended.
¾ The boom foot is on the stow-wood.
¾ The derricking pulley block installed
on the boom foot.
¾ A-frame is hoisted.
¾ All counterweights are installed. Fig 5.1.10 b
1. Connect the one end of boom pendant rope 13.5.10 to boom head 13.5’s top lugs (Fig 5.1.10 c).
Fig 5.1.10c
2.Install the lifting belt to boom head’s lifting lug, and use auxiliary crane to hoist it (Fig 5.1.10c)
Note: hoist the boom head to connect the spindle ①.
3. Connect the boom head and boom foot’s top spindle ①.
5-25/93
4.Install the connection spindle ① outside the boom.
Note: fix the connection spindle with lockpin②
Fig 5.1.10d
5. Use the auxiliary crane to lower the boom head on the ground. Then, dismantle the lifting belt
from boom head (Fig 5.1.10 e)
Note: put the stow-wood at boom head.
Fig 5.1.10e
6. Start the engine.
7. Put the enable hand grip to START position.
8. When hoisting the boom, align the pin hole of boom head and boom foot bottom. Install the
connection spindle① from outside of boom. (Fig 5.1.10 f)
Note: fix the connection spindle by lockpin ②.
5-26/93
Fig 5.1.10f
9. Remove the connection spindle ④ and split pin⑤ at stay bar ③. (Fig 5.1.10 g)
Fig 5.1.10g
10. Connect the pendant rope 13.5.10 to stay bar ③ with connection spindle④. Use lockpin ⑤ to
lock the connection spindle④. (Fig 5.1.10 h)
5-27/93
Fig 5.1.10h
11. Slowly operate the main derricking hoisting, to make the derricking wire rope under tension
status, to ensure wire rope ⑥ in good order. (Fig 5.1.10i)
Note: when the wire rope ⑥ is retracted, the basic section of boom will give pre-tension force to
derricking wire rope, and it will not be disorder of wire rope.
Fig 5.1.10i
12. Put the enable hand grip to LOCK position.
13. Shut down the engine.
5.1.11 Installation of boom insert
Check the boom length, which is to be installed, as 5.1.9 configuration of boom/fixed jib and
pendant rope.
Note: connect each insert from boom foot in order, at last install the boom head.
¾ When installing connection spindle, never enter into boom inside. Bearing in mind that
install the spindle from outside of boom, to avoid danger.
5-28/93
¾ When installing boom, put the stow-wood under boom foot. Please take all necessary
measures to prevent personal accidents.
¾ Never put the fingers into pin hole when aligning the pin hole.
¾ Connect the pendant rope to derricking travelling block. Till the derricking travelling
block separates with boom foot, and hoist the boom head from the ground.
¾ When handling the wire rope, please use protective items, such as heavy glove.
¾ When using hammer to tack the spare parts, be cautions the metal splash, may cause
serious injuries. So please use protective items, such as protective glasses and safety
helmet.
¾ Clean the connection spindle and pin hole, and coat the grease on its surface.
Check following points before installing the insert:
¾ The track frame is fully extended.
¾ The boom foot or insert is on the stow-wood.
¾ A-frame is hoisted.
¾ All counterweights are installed.
1.Check working radius if satisfy the required boom length.
2.Check corresponding pendant rope if has fixed on the boom head or insert already.
Please connect one end of boom head pendant rope to the pin hole of boom head top to
prevent the pendant rope falling down from boom when hoisting the boom. Then fix the
pendant rope of both inserts to corresponding inserts.
3.Install the connection spindle ① from outside. (Fig 5.1.11 a)
Note: use lockpin② to fix the connection spindle. Never install the bottom connection pin.
5-29/93
Fig 5.1.11a
4. Use auxiliary crane to put each insert on the ground. (Fig 5.1.11 b)
Note: put each insert on the stow-wood.
Fig 5.1.11b
5. Connect all the inserts one by one. (Fig 5.1.11 c)
Note: except connection spindle of boom foot bottom, and install all the inserts bottom connection
spindle ①.
6. Respectively install the connection spindle① from outside boom on the upper part, and
install the connection spindle① from inside boom on the lower part. Then use lcokpin② to fix
all the connection spindles①.(Fig 5.1.11 c)
5-30/93
Fig 5.1.11c
7. Attach the lifting belt to boom head’s lifting lug, and use auxiliary crane to hoist the boom head.
Install the connection spindle ① from outside, and fix it by lockpin②. (Fig 5.1.11 d)
Fig 5.1.11d
8. Dismantle the lifting belt from boom head. Install connection spindle① at bottom, and fix it by
lockpin②. For it is difficult to align the pin hole, and attach the lifting belt to the position close to
insert’s connection end. Then use auxiliary crane to hoist the insert slowly. (Fig 5.1.11 e)
Fig 5.1.11e
5-31/93
9. Align the connection pin hole of insert bottom and boom foot. Install the connection spindle①
from outside, and fix it by lockpin②. (Fig 5.1.11 f)
Fig 5.1.11f
10. Connect the mast balancing frame 7.1 and insert pendant rope.
5.1.12 Installation of fixed jib
Fig 5.1.12a
5-32/93
Table 5.1.12a
Fixed jib working condition
No. Name Length （m）
15.1 Fixed jib foot 4.5
15.2 Fixed jib insert 4.5
15.3 Fixed jib head 4.5
15.4 Fixed jib strut 4.3
15.0.1 Stay bar 0.2
15.4.1 Strut body ——
15.4.2 Front pendant rope connection frame ——
15.4.3 Rear pendant rope connection frame ——
Fixed jib working condition table 5.1.12b
Fixed jib front Fixed jib rear

Fixed jib Fixed jib
Fixed jib combination pendant rope pendant rope
length（m） elevation
combination combination
15° 15.7
9 15.1+15.3 15.6
30° 15.7+15.8
15° 15.7
13.5 15.1+15.2+15.3 15.5+15.6
30° 15.7+15.8
15° 15.7
18 15.1+2×15.2+15.3 2×15.5+15.6
30° 15.7+15.8
5-33/93
Check the length, diameter of pendant rope.
Length mm Diameter mm Types of pendant rope
8.33 Φ28
18.9 Φ28
17.86 Φ28
1.53 Φ28
¾ When installing connection spindle, never enter into boom inside. Bearing in mind that
¾ When installing fixed jib, put the stow-wood under boom foot. Please take all
necessary measures to prevent personal accidents.
¾ Clean the connection pin hole, and coat grease on its surface.
1. Put the fixed jib strut 15.4 on the stow-wood. (Fig 5.1.12b)
2. Dismantle the pulley spindle ① and pulley ② of front pendant rope connection frame 15.4.2.
(Fig 5.1.12b)
3. Roll the pendant rope 15.6 to pulley ②, and install it to front pendant rope connection frame
15.4.2. Pass the pulley spindle ① through from up to down, and fix it by lockpin. (Fig 5.1.12b)
4. Install the pendant rope 15.7 to rear pendant rope connection frame 15.4.3, pass through the
pulley spindle, and fix it by lockpin. (Fig 5.1.12b)
5-34/93
Fig 5.1.12b
5. Hoist the strut body 15.4.1 to top of fixed jib foot 15.1 by auxiliary crane. Connect the strut body
15.4.1 and fixed jib foot 15.1 by spindles③, and fix them by lockpin. (Fig 5.1.12c)
Note: put the stow-wood between strut body 15.4.1 and fixed jib foot 15.1.
Fig 5.1.12c
6. Depending on fixed jib working condition, connect the fixed jib foot15.1, fixed jib insert 15.2 and
fixed jib head 15.3 one by one. At last, install the connection pin ⑤ and lockpin④. (Fig 5.1.12 d)
5-35/93
Fig 5.1.12d
Fig 5.1.12e
7. Use auxiliary crane to hoist the installed fixed jib 15 (Fig 5.1.12 e)
Note: keep the fixed jib level.
8. Dismantle the backstop spindle ⑥ before installing the fixed jib, and align the pin hole of boom
head 13.5 and fixed jib foot 15.1, install the spindle ⑦. Then use clip board and bolt to fix the
spindle ⑦. (Fig 5.1.12f)
5-36/93
Fig 5.1.12f
9. Connect the fixed jib pendant rope. depending on fixed jib working condition, select pendant
rope length to connect. Both ends of pendant rope need to install pendant rope connected section
15.0.1, then insert spindle ⑧, and fix it by lockpin⑨. (Fig 5.1.12 g, 5.1.12 h)
Fig 5.1.12g
5-37/93
Fig 5.1.12h
10. Use auxiliary crane to hoist the strut body 15.4.1. Connect the fixed jib pendant rope 15.7, 15.8
to boom head 13.5. (Fig 5.1.12 i)
When fixed jib elevation is 15°, and it no needs to install the fixed jib pendant rope 15.8;
when fixed jib elevation is 30°, and it needs to install the fixed jib pendant rope 15.8.
Fig 5.1.12i
5-38/93
5.1.13 Installation of runner
Fig 5.1.13a
Table 5.1.13
14. Runner working condition
No. Name Remark
14.1 Lower bracket
14.2 Stay bar
Clean the connection pin hole, and coat the grease on its surface.
1.Put the boom on the stow-wood.
Note: the stow-wood at least should be 450mm height, or it cannot install the runner.
2. Dismantle connection spindle ①from the stay bar 14.2. Dismantle the lower connection spindle
②from lower bracket 14.1. (Fig 5.1.13b)
5-39/93
Fig 5.1.13b
3. Use auxiliary crane to hoist the runner, and slowly close to boom head. Connect the boom head
and runner by connection spindle①, ②. (Fig 5.1.13c)
Fig 5.1.13c
5-40/93
5.1.14 Installation of holding luffing jib
The luffing jib of this crane can be installed on the 24.7~45.7m boom. The luffing jib length is
composed by lower section 6m+ 3m insert (2 sections) +6m insert (3 sections)+ jib top section 6m,
which can be combined as 18m, 21m, 24m, 27m, 30m, 33m, 36m, seven types in total, as shown
in Fig 5.1.14a and Table 5.1.14a.
Fig 5.1.14a
5-41/93
20.Holding luffing jib Table 5.1.14a
No. Name Remark
20.1 Boom 3m section Special for luffing jib
20.2 Travelling block
20.3 Boom head strut
20.4 Luffing jib strut
20.5 Balance device
20.6 Luffing jib head
20.8 Luffing jib foot
20.9 Luffing jib backstop
20.1 Boom head
20.12 Limit device
20.13 Boom backstop
5-42/93
5.1.14.1 Luffing working condition sections and pendant rope combinations
1. Boom combinations refer to Fig 5.1.14b and Table 5.1.14b
Fig 5.1.14b
Table 5.1.14b
Symbol Name
5.8m boom foot
3m insert
3m transit section
6m insert
9m insert
0.9m boom head
5-43/93
2. Luffing jib combinations refer to Fig 5.1.14c and Table 5.1.14c
Fig 5.1.14c
Table 5.1.14c
Symbol Name
6m luffing jib foot
3m insert
6m insert
6m luffing jib head
5-44/93
3. Boom pendant rope combinations refer to Table 5.1.14d
Table 5.1.14d
Boom length（m） Boom pendant rope combinations
24.7 2.5m pendant rope+6m pendant rope+9m pendant rope
27.7 2.5m pendant rope+9m pendant rope×2
30.7 2.5m pendant rope+3m pendant rope+9m pendant rope×2
39.7 2.5m pendant rope+3 pendant rope+9m pendant rope×3
4. Luffing jib front pendant rope combinations refer to Table 5.1.14e
Table 5.1.14e
Luffing jib length

Luffing jib front pendant rope combinations
（m）
18 5.9m pendant rope+2.9m pendant rope×2+5.2m pendant rope
5.9m pendant rope+2.9m pendant rope+5.8m pendant

21
rope+5.2m pendant rope

27
rope×2+5.2m pendant rope

33
5.9m pendant rope+2.9m pendant rope×2+5.8m pendant

36
5-45/93
5.Luffing jib rear pendant rope combinations refer to Table 5.1.1.14f
Table 5.1.1.14f
Boom length
Luffing jib rear pendant rope combinations
（m）
24.7 1.5m pendant rope+9m pendant rope
36.7 1.5m pendant rope+9m pendant rope×2+3m pendant rope
5.1.14.2 Installation steps of luffing jib working condition（take 24.7+18 as example）
¾ The selected auxiliary crane, lifting belt, shackles, etc should have enough strength. To
make sure supply enough safety during lifting and assembling.
If the crane not be assembled as correct steps, and may cause personal injuries.
Fully coordinate relative personnel before start working, to ensure personnel and
equipments safe during operation.
When boom length exceeds 39.7m’s luffing jib working condition, and it needs to
install additional counterweight, to check if install additional counterweight 6.7, refer to
Fig 5.1.14d.
Fig 5.1.14d
5-46/93
When installing connection spindle, never enter into boom inside. Bearing in mind that
When installing the boom, it needs to fasten and support the boom foot. Make sure to
take necessary measures to avoid personal accidents.
When installing boom, put the stow-wood under boom foot. Please take all necessary
measures to prevent personal accidents.
Clean the connection spindle and pin hole, and coat the grease on its surface.
1. Install boom of luffing jib working condition
Fig 5.1.14g
¾ Connect the boom insert 20.1, 13.3, 13.4 by boom spindles, and put them on the ground.
Refer to Fig 5.1.14g.
Fig 5.1.14h
5-47/93
Never put the fingers into pin hole when aligning the pin hole.
Connect the pendant rope to derricking pulley block. Till the derricking pulley block
separates with boom foot, and lift the boom head up from the ground.
When handle the wire rope, it is a must to use protective tools, such as heavy glove.
When using hammer to tack the parts, be cautions the metal splash, and may cause
serious injuries. Please use protective tools, such as protective glasses and safe
helmet.
Clean the connection pin hole, and coat grease on its surface.
¾ Connect boom head 20.1, connect boom head 20.1 upper joint and boom 9m insert 13.4 by
boom spindles, not connect lower part, connect 20.3 to 20.1. refer to Fig 5.1.14h
¾ Move the base machine with mast 7 and boom foot 13.1 to 3m transit section 20.1 by lifting
crane. Connect the upper boom spindles, not connect lower boom spindles.
¾ Connect the upper ear plate of boom foot 13.1 by pendant rope of mast 7, and pull the boom
foot up. Align the boom foot 13.1’s lower joint and 3m transit section 20.1’s lower joint, and
connect the lower spindles.
¾ Continuously use mast 7 to pull the boom foot 13.1, pull the whole boom up about 1m. make
boom head 20.1 to align with lower joint of boom 9m insert 13.4, connect the boom spindles.
¾ After connecting all boom spindles, and lower the boom, boom head 20.1 touches the ground.
5-48/93
Fig 5.1.14i
¾ Lower the mast 7, dismantle the pendant ropes, which are used for pulling the boom foot 13.1.
connect boom pendant rope 13.2.1, 13.3.1, 13.4.1. refer to Fig 5.1.14i.
¾ Connect boom backstop rod 20.13.
2. Install the luffing jib
Fig 5.1.14j
5-49/93
¾ Connect the luffing jib strut 20.4, and connect it by corresponding spindle. Refer to Fig 5.1.14j
¾ Connect the travelling block 20.2, use auxiliary crane to lift the travelling block 20.2, put it on
the boom, and put stow-wood under travelling block 20.2, threading method refers to chapter
5-5.1.11
¾ Connect the pendant rope 20.0.1, 13.4.1, connect them by corresponding spindle.
¾ Winding the main hoisting wire rope 13.0.1, and the rope head winds over the boom head
guiding pulley, threading method refer to chapter 5-5.1.11
Don’t hold the wire rope by bare hands, and it may scrap the hands by extruding
parts, please put on glove during operation.
Keep hands and clothes away from the running drum and moving wire rope.
Fig 5.1.14k
¾ Slew the crane, and slew the boom aside, or derrick the boom to a certain height, to clear the
ground, for installing the luffing jib sections.
¾ Install the luffing jib foot 20.8, luffing jib insert 20.7, luffing jib head 20.6, and connect them by
luffing jib spindles. Be cautions that put the stow-wood “a” under luffing jib sections, to prevent
damaging the rope anti-fall roller. Refer to Fig 5.1.14k.
5-50/93
Fig 5.1.14l
¾ Slew the crane or lower the boom, put the boom to upper part of luffing jib, align the boom
head and luffing jib foot, hoist the luffing jib foot by auxiliary crane, at the same time,
continuously lower the boom, and connect the luffing jib foot spindle. At this time, be cautions
that luffing jib and boom not bump, for easily causing dangers. Refer to Fig 5.1.14I.
¾ Keep the luffing jib head on the ground, hoist or lower boom to make the boom is paralleled
with luffing jib section. Connect the limit device, put the limit device pothook well, at this time,
boom and luffing jib is relatively fixed. Pass the limit device stay rope “a” through the boom
insert’s inside, to reach the boom foot. To ensure the installation worker can reach the stay
rope “b’ after hoisting the boom.
¾ Install the luffing jib front pendant rope and balance device 20.5, put them on the ground.
¾ Reeve the main hoisting wire rope through the lower part of luffing jib, through the luffing jib
head guiding pulley, and connect the hook. Threading method refers to chapter 5-5.1.11.
5-51/93
Fig 5.1.14m
¾ Winding the main derricking wire rope, hoist the boom, leave the space for installing the luffing
jib backstop rod 20.9.
¾ Install the luffing jib backstop 20.9, refer to Fig 5.1.14n
Fig 5.1.14n
¾ Lift the travelling block device 20.2 with auxiliary crane, release the luffing jib derricking wire
rope, lower the luffing jib strut, to make the hinge, which is connected by strut and luffing jib
front pendant rope, close the ground, then use the spindles to connect luffing jib front pendant
rope and strut. Refer to Fig 5.1.14n.
¾ Complete luffing jib installation.
5-52/93
5.1.15 Installation of hook and wire rope
¾ Do not hoist the boom more than 30° without connecting the hook. The wire rope may
fall by its own weight.
¾ Wire rope will be twisted by the curvature on the sheave or loads during operation.
Therefore, when the socket pin is removed to replace or reinstall the wire rope, the wire
rope may unexpectedly be untwisted, possibly creating a hazardous situation.
Especially, when working in high places, use a safety belt or take necessary safety
measures before removing the wire rope.
Hook and wire rope reevings selection (Table 5.1.15):
Wire rope diameter: φ26mm
Table 5.1.15
Hook Reevings and rated lifting capacity (t)

Weight
Type 11 10 9 8 7 6 5 4 3 2 1
85t 1.05t 85.0 80.0 72.0 64.0 56.0
50t 0.55t 48.0 40.0 32.0
25t 0.41t 24.0 16.0
9t 0.25t 8.0
¾ Do not use a hook without the maximum gross rated load clearly marked.
¾ Reevings of wire rope is decided by load capacity. Please refer to load chart.
¾ When the reeving is 1, only use runner to lift, and only use auxiliary hoist to hoist the
wire rope.
5-53/93
5.1.15.1 Installation of wire rope under boom working condition
Use main hoisting wire rope to lift under boom working condition, below is threading method of
main hoisting wire rope:
1. Put the hook to be used in front of the boom. (Fig 5.1.15.1 a)
Fig 5.1.15.1a
2. Connect the main hoisting wire rope ① by the boom head right guiding pulley② and hook
pulley③. ④ is guiding pulley for runner working condition. (Fig 5.1.15.1b)
Fig 5.1.15.1b
¾ Max. load capacity should be corresponding with reevings.
¾ Be careful not to allow the main hoisting wire rope overly loose, in case the wire rope
will be disorder.
5-54/93
3.Install the hook and reeve the load wire rope refer to threading method as shown below.
(1) Threading method of wire rope—85t hook (Fig 5.1.15.1 c)
11 reevings 10 reevings 9 reevings
8 reevings 7 reevings
Fig 5.1.15.1c
(2) Threading method of wire rope—50t hook (Fig 5.1.15.1 d)
6 reevings 5 reevings 4 reevings
Fig 5.1.15.1d
5-55/93
(3) Threading method of wire rope—25t hook (Fig 5.1.15.1 e)
3 reevings 2 reevings
Fig 5.1.15.1e
5.1.15.2 Installation of wire rope under runner working condition
1. Put the hook to be used in front of the fixed jib or runner.
2. Let out the aux. hoisting wire rope⑤, connect it by guiding pulley④ and hook pulley⑥. (Fig
5.1.15.2 a)
Fig 5.1.15.2a
5-56/93
3.Take following threading method, to install hook and reeve the lifting wire rope.
Threading method of runner wire rope—9t hook (Fig 5.1.15.2 b)
Fig 5.1.15.2b
5.1.15.3 Installation of wire rope under fixed jib working condition
Use auxiliary hoisting wire rope to lift under fixed jib working condition, below is threading method
for auxiliary hoisting wire rope.
1. Connect the aux. hoisting wire rope ⑤ with hook through the pulley ⑦of fixed jib strut body, then
pass the hook pulley ⑥of fixed jib head.
Threading method of wire rope—25t hook (Fig 5.1.15.3)
Fig 5.1.15.3
5-57/93
5.1.15.4 Installation of wire rope under luffing jib working condition
Fig 5.1.15.4a
Threading method of main hoisting wire rope
1. Put the hook to be used in front of the luffing jib head.
2.Wind the main hoisting wire rope ① to the guiding pulley ⑨ of luffing jib head strut through the
11through the luffing

guiding pulley⑧ of boom 3m section, then connect with luffing jib hook pulley○
jib head guiding pulley⑨. (Fig 5.1.15.4 a)
3. Refer to below threading method to install hook and reeve the lifting wire rope.
Wire rope threading method---25t hook (Fig 5.1.15.4b)
5-58/93
Fig 5.1.15.4b
Threading method of aux. hoisting wire rope
Use aux.hoisting wire rope as luffing jib derricking wire rope under luffing jib working condition,
below is threading method for aux.hoisting wire rope.
Wind the aux.hoisting wire rope ⑤ between travelling block device 1○2 and pulley block 1○2 of
boom 3m section as shown in Fig 5.1.15.4 c
Fig 5.1.15.4c
5-59/93
5.1.15.5 Main derricking wire rope
¾ Under normal conditions, it is no need to dismantle the main derricking wire rope when
assembling and dismantling the base machine.
When maintenance or adjustment, if needs to dismantle the main derricking wire rope, and refer to
Fig 5.1.15.5. Get the wire rope from top of derricking drum ① firstly, and wind the guiding wheel②
of superstructure, then wind it between upper pulley block ④ of mast and lower pulley block ③ of
superstructure one by one as shown in Fig.
Fig 5.1.15.5
5-60/93
5.1.16 Installation of rope socket
¾ Correct and wrong installation method of wire rope into rope socket is shown as below.
¾ When lifting the hook with even reevings, and locking position of rope socket is on the
boom head. When lifting the hook with odd reevings, and locking position of rope
socket is on the hook.
Correct Wrong
1. After attaching the rope socket① to end of wire rope, and connect the ① to boom head or hook
by spindle②, lockpin③. (Fig 5.1.16)
Fig 5.1.16
5-61/93
5.1.17 Connection of boom cable
The moment limiter configuration under boom working condition is shown as below:
Fig 5.1.17a
Table 5.1.17a
No. Name Remark
23.9 Wind speed sensor
23.10 Boom force sensor
23.12 Boom angle sensor
23.13 Boom foot junction box
23.20 W101（15 core-14m）cable Boom foot junction box to electric control cabinet
5-62/93
23.21 W301（3 core-2m）cable Angle sensor to boom foot junction box
23.22 W103II（10 core-65m）cable drum Boom foot junction box to boom head junction
box
23.23 W401(2 core-3m) cable Boom head junction box to main hook overhoist
prevention device
23.4 Main hook height limit switch
23.25 W402（2 core-7m）cable Boom head junction box to aux. hook overhoist
prevention device
23.5 Aux. hook height limit switch
23.27 W701(3 core-4m) cable Boom head junction box to wind speed sensor
23.28 Boom head junction box
According to chapter 5, after connecting each boom section and pendant rope as requirements of
working condition, and start to connect the boom cable:
1. Take W301 cable (23.21) out from box, one end connects boom foot junction box (23.13) W301
connection, and one end connects boom angle sensor;
2. Install W103II cable drum (23.22) to cable drum’s installation frame, release the cable, one end
connects to boom foot junction box (23.13) cable connection, and one end connects to boom head
junction box (23.28) cable connection;
3.Install the main hook height limit switch (23.4) to boom height limit switch’s installation angle
steel, and take W401 cable (23.23) out, connect one end to boom head junction box (23.28) W401
connection, and one end connects to main hook height limit switch (23.4) connection;
4. Install the aux.hook height limit switch (23.5) to height limit switch’s installation angle steel, and
take W402 cable (23.25) out, connect one end to boom head junction box (23.28) W402
connection, and one end connects to main hook height limit switch (23.5) connection; if not
connect the aux. hook, and this cable is no need to connect, connect the short-connect plug W405
of boom head junction box to W402 connection. This step is quite necessary, if not connect this
short-connect plug, and it will cause the hook overhoist prevention limit always stay limit status;
5.After installing the wind speed sensor (23.9) and its installation bracket [including height light
(23.16)] to boom head, and take W701 cable (23.27) out, one end connects the boom head
junction box (23.28), and one end connects to wind speed sensor.
5-63/93
6. After connecting boom foot and superstructure, connect W101 cable (23.20) from electric
control cabinet to boom foot junction box (23.13) cable connection;
7. Thus, the boom cable connection is completed.
Note: don’t dismantle the boom angle sensor (23.12) and boom force sensor (23.10) when
shipping out, and it is no need to re-install.
¾ Moment limiter configuration under luffing jib working condition, as shown below:
Fig 5.1.17b
Table 5.1.17b
No. Name Remark
23.29 W105（5core-30m）cable drum Luffing jib foot junction box to luffing jib head
W107 cable
23.30 Luffing jib foot junction box
23.31 Luffing jib angle sensor
23.32 W431（3core-5m）cable Luffing jib foot junction box to luffing jib backstop
5-64/93
limit switch
23.33 Luffing jib backstop limit switch
23.34 W303（3 core-3m）cable Luffing jib foot junction box to luffing jib angle
sensor
23.35 W203（3 core-13m）cable Luffing jib foot junction box to luffing jib force
sensor
23.36 Luffing jib force sensor
23.37 Aux. hook height limit switch Compound use with boom working condition’s
aux. hook overhoist prevention device
23.38 Wind speed sensor Compound use with boom working condition’s
wind speed sensor
23.39 W107（5 core-0.5m）cable Connect with hook overhoist prevention device
and wind speed sensor
According to chapter 5, after connecting each boom section and pendant rope as requirements of
working condition, and start to connect the luffing jib cable:
1. Pull the cable of boom foot W1033II cable drum (23.22) out, till it connects the luffing jib foot
junction box (23.30)’s 10-core cable connection;
2. Take W431 cable (23.32) out, one end connects to luffing jib foot junction box (23.30) W431
connection, and one end connects to luffing jib backstop limit switch (23.33) cable connection;
3. After installing the force sensor (23.36), take W203 cable (23.35) from box, one end connects to
luffing jib foot junction box (23.30) W203 connection, and one end connects to luffing jib force
sensor (23.36)
4.Take W303 cable (23.34) out from box, one end connects to luffing jib foot junction box (23.30)
W303 connection, and one end connects to luffing jib angle sensor (23.31);
5. Take W105 cable drum assy. (23.29) out from box, install it to cable drum installation frame, and
release the cable, one end connects to luffing jib foot junction box (23.30) W105 connection, and
one end extends to luffing jib head;
6. Take aux.hook overhoist prevention device (23.37) from box, and install it to luffing jib hook
overhoist prevention device’s installation angle steel;
7. Take wind speed sensor (23.38) and its installation frame out from box, and connect with wind
speed sensor’s installation plate;
8. Take W107 cable (23.39) out from box, connect its 5-core connection with W105 cable (23.29),
connect its 3-core cable with wind speed sensor (23.38) cable connection, connect its 2-core cable
5-65/93
with aux. hook overhoist prevention device (23.37) cable connection.
9. Thus, the luffing jib cable connection is completed.
Note: for luffing jib angle sensor adjusts the angle well beforehand, don’t dismantle it when
shipping out, and it is no need to re-install.
5.2 Disassembling
5.2.1 Preparation and precautions before disassembling
¾ If the machine is assembled in following incorrect procedures, personal injury or death
may result.
¾ Before beginning work, sufficiently coordinate with all personnel concerned to ensure
safety during work.
¾ Hoisting/lowering boom should be at front of track crane, please refer to Chapter 1-1.3
¾ If the ground is soft, and put enough strength steel plate under track carrier.
¾ Use an assistant crane, sling ropes, and shackles with enough strength to provide a
sufficient margin when lifting loads
¾ Dimension and weights of each part, refer to Chapter 7-7.3.
5.2.1.4 Preparation before operation
1.Have all coordination handled by the job site conductor to ensure safety prior to beginning any
work.
2. Thoroughly inform all workers so they understand the types of work, procedures, and signals to
be used at the job site, etc.
3. Check all instruments and materials for any abnormality.
5.2.1.5 Selection of jobsite
1.Select a solid level surface wide enough to assemble the machine.
5-66/93
¾ Remove all obstacles from the area in which the crane will be moved.
¾ Flatten indented surface areas. Horizontally reinforce any soft ground by placing high
strength planks beforehand.
¾ Depending on the boom combinations to be disassembled, to ensure boom’s lowering
direction, and adjust if the boom hoisting is restricted or not. Refer to Chapter 6-6.2
5.2.1.6 Preparation of equipments
¾ Auxiliary crane. According to conditions of jobsite and types of operation, to select specified
auxiliary crane. And the selected one must have enough lifting capacity.
¾ Arrange protection items, sling tools, base machine attachments, and tools necessary for the
disassembly/assembly work.
5.2.1.7 Necessary personnel
¾ 4 persons above (operator, auxiliary crane driver, lifter and director)
5.2.1.8 Jobsite management
¾ Take all measures necessary to keep all unauthorized persons clear from the jobsite during
work.
5.2.2 Disconnection of boom cable
Before disassembling the boom, disconnect the connected cable first, and dismantle or
disassemble the boom.
As shown in Fig 5.1.17a and Fig 5.1.17b boom/luffing jib working condition cable composition and
connection, to disconnect the cable as its opposite installation order.
Disconnect the boom cable:
1. Disconnect the connection of W701 cable(23.27) and boom head junction box (23.28) and wind
speed sensor (23.9);
2. Disconnect the connection of W402 cable (23.25) with boom head junction box (23.28) and aux.
hook overhoist prevention device, if not connect this cable, and this step can omit;
3. Disconnect the connection of W401 cable (23.23) with boom head junction box (23.28) and
main hook overhoist prevention device;
5-67/93
4. Disconnect the connection of W103II cable drum (23.22) with boom head junction box (23.28)
and boom foot junction box (23.13), and wind the cables to the drum, then take this cable drum out
from boom;
5. Disconnect the connection of W301 cable (23.21) with boom foot junction box (23.13) and boom
angle sensor;
6. Disconnect the connection of W101 cable with boom foot junction box (23.13), put the W101
cable to superstructure, avoid bump;
7. Thus, all the cables have been disconnected under boom working condition, after counting all
the disassembled cables, and put them into package box.
Disconnect the luffing jib cable:
1. Disconnect the connection of W107 cable (23.29), wind speed sensor, aux. hook overhoist
prevention device, W105 cable;
2. Disconnect the connection of W105 cable drum assy. (23.29) and luffing jib foot junction box
(23.30), and wind the cables to the cable drum, then dismantle the cable drum from boom;
3. Disconnect the connection of W303 cable (23.34) with luffing jib angle sensor (23.31) and luffing
jib foot junction box (23.30)
4. Disconnect the connection of W203 cable (23.35) with luffing jib force sensor (23.36) and luffing
jib foot junction box (23.30);
5. Disconnect the connection of W431 cable (23.32) with luffing jib backstop limit switch (23.33)
and luffing jib foot junction box (23.30);
6. Disconnect the connection of W103II cable drum (23.22) with luffing jib foot junction box
(23.30),and wind the cables to the cable drum;
7. Thus, all the cables have been disconnected under luffing jib working condition, after counting
all the disassembled cables, and put them into package box.
5-68/93
5.2.3 Disassembling the runner
1.Put the boom on the stow-wood.
Note: the stow-wood at least should be 450mm height, or cannot install the runner.
2. Use the auxiliary crane to hoist the runner 14.
3. Dismantle the connecting pin ① between runner rear support 14.2 and boom head 13.5.
(Fig 5.2.3a)
4. Dismantle the connecting pin ② between runner front support 14.1 and boom head 13.5.
(Fig 5.2.3a)
5. Use auxiliary crane to separate the runner 14 and boom head 13.5.
6. Pass the spindle ①through the pin hole of runner rear support 19.2, and fix it by lockpin.
(Fig 5.2.3b)
7.Pass the spindle ②through the pin hole of runner front support 19.1, and fix it by lockpin.
(Fig 5.2.3b)
Fig 5.2.3a
Fig 5.2.3b
5-69/93
5.2.4 Disassembling the fixed jib
¾ When dismantling the connection spindle, never enter into boom inside. Bearing in
mind that dismantle the spindle from outside of boom, to avoid danger.
¾ When dismantling the jib, put the stow-wood under boom foot. Please take all
necessary measures to prevent personal accidents.
1.Lower the boom and fixed jib on the stow-wood.
Note: after dismantling the fixed jib backstop spindle①, and the boom can be lowered
continuously, in case, it will damage the boom sections.
2. Firstly, use the auxiliary crane to hoist the fixed jib strut body 15.4.1, and dismantle the
spindle③, which is connected by fixed jib rear pendant rope ② and boom head13.5. (Fig 5.2.4a)
Fig 5.2.4a
5-70/93
3. Dismantle the pulley spindle④ and pulley⑤ in the front pendant rope linking frame 15.4.3, and
disconnect the fixed jib rear pendant rope②. At last, re-install the pulley spindle④ and pulley⑤
into front pendant rope linking frame 15.4.3.(Fig 5.2.4 b)
Fig 5.2.4b
4.Firstly, use auxiliary crane to lower fixed jib front strut body 15.4.1 slowly on the top of fixed jib.
And dismantle the spindle③, which is connected by fixed jib front pendant rope⑥ and fixed jib
head. (Fig 5.2.4c)
Note: when lowering the fixed jib strut body, put the stow-wood between fixed jib foot and fixed jib
strut body 15.4.1.
Fig 5.2.4c
5-71/93
5.Dismantle the pulley spindle④ and pulley⑤ in the front pendant rope linking frame 15.4.2, and
disconnect the fixed jib front pendant rope⑥. At last, re-install the pulley spindle④ and pulley⑤
into front pendant rope linking frame 15.4.2.(Fig 5.2.4 d)
Fig 5.2.4d
6. Dismantle the connection spindle ⑦ and clip board ⑧ between fixed jib foot 15.1 and boom
head 13.5. (Fig 5.2.4 e)
Fig 5.2.4e
7. Use the auxiliary crane to hoist the dismantled fixed jib 15, and put it on the stow-wood. Then
dismantle the fixed jib. (Fig 5.2.4 f)
5-72/93
Fig 5.2.4f
8. Dismantle the spindle ⑨ and lockpin⑩, which is connected by strut body 15.4.1 and fixed jib
foot, and use auxiliary crane to hoist the strut body to the ground. (Fig 5.2.4 g)
Fig 5.2.4g
9. Dismantle the connection spindle and lockpin among each sections of fixed jib one by one. (Fig
5.2.4h)
Fig 5.2.4h
5-73/93
5.2.5 Disassembling the boom
5.2.5.1 Disassembling the basic boom
¾ When dismantling the connection pins, never enter inside the boom. Always remain
outside the boom and install the pins from outside of the boom.
¾ Support the boom foot with wire stands strong and stable enough to support the boom
when disassembling the basic boom. Be sure to take all necessary measures to
2. Put the pilot enable hand grip to START position.
3. Operate the main derricking lowering, and lower the boom head on the stow-wood.
(Fig 5.2.5.1a)
Fig 5.2.5.1a
4. Slowly operate the main derricking lowering, till the boom head pendant rope 13.5.10 totally
lower on the boom. Dismantle the spindle ④ and split pin ⑤ at stay bar③, and disconnect the
pendant rope 13.5.10. (Fig 5.2.5.1 b)
5-74/93
Fig 5.2.5.1b
5. Install the linking spindle ④ and lockpin ⑤ at stay bar ③. (Fig 5.2.5c)
Fig 5.2.5.1c
6. Dismantle the lower spindle ① and lockpin ②. Fig 5.2.5.1d.
Fig 5.2.5.1d
5-75/93
7. Operate the main derricking lowering again, and lower the boom foot on the stow-wood.
Dismantle the upper connection pin① and lockpin ②. (Fig 5.2.5.1 d)
Fig 5.2.5.1d
8. Attach the lifting belt to boom head. Use auxiliary crane to hoist the boom head to suitable
position, for the disassembled boom will not obstruct the disassembly job. (Fig 5.2.5.1 e)
Fig 5.2.5.1e
9. Dismantle the sling wire rope from boom.
10. Put the pilot enable switch to LOCK position.
5-76/93
5.2.5.2 Disassembling the insert
¾ When dismantling the connection pins, never enter inside the boom. Always remain
outside the boom and install the pins from outside of the boom.
¾ Support the boom foot with wire stands strong and stable enough to support the boom
when disassembling the basic boom. Be sure to take all necessary measures to
2. Put the pilot enable hand grip to START position.
3. Operate the main derricking lowering, and lower the boom head on the stow-wood.
(Fig 5.2.5.2a)
Fig 5.2.5.2a
4. Slowly operate the main derricking lowering, till lower the boom head pendant rope 13.5.10
totally on the boom. Dismantle the spindle ④ and split pin ⑤ at stay bar③, disconnect the pendant
rope 13.5.10. (Fig 5.2.5.2b)
Fig 5.2.5.2b
5-77/93
5. Install the connecting spindle④ and lockpin⑤ at stay bar ③. (Fig 5.2.5.2c)
Fig 5.2.5.2c
6. Close the lifting belt with connection part of inset, and use auxiliary crane to hoist the insert.
Dismantle the lower spindle ①and lockpin ②. (Fig 5.2.5.2 d)
Fig 5.2.5.2d
7. Operate the main derricking lowering again, and lower the boom insert on the stow-wood.
Dismantle the upper connection pin①and lockpin ②. (Fig 5.2.5.2 e)
Fig 5.2.5.2e
8. Dismantle the lifting belt from insert.
9. Mover the base machine backward, for not obstruct the disassembly job.
5-78/93
10. Put the pilot enable switch to LOCK position.
12. Disconnect the each section of pendant rope.
13. Dismantle the connection pin ① and lockpin ② of each insert. Use auxiliary crane to hoist the
each sections to suitable position, for the disassembled boom will not obstruct the disassembly job.
(Fig 5.2.5.2 f)
Fig 5.2.5.2f
5.2.6 Disassembling the luffing jib (take 24.7+18 as example)
After lowering the luffing jib, and dismantle the luffing jib working condition.
Fig 5.2.6a
¾ Use auxiliary crane to hoist the travelling block device 20.2, and release luffing jib derricking
(aux. winch) wire rope, to make the connection of luffing jib front pendant rope and luffing jib
strut 20.4 loosen, dismantle the connection spindle between luffing jib front pendant rope and
luffing jib strut 20.4. dismantle the connection spindle between luffing jib front pendant rope
and luffing jib head. Retract the luffing jib front pendant rope and balance device 20.5. refer to
Fig 5.2.6a
5-79/93
Fig 5.2.6b
¾ Dismantle the luffing jib backstop rod 20.9, refer to Fig 5.2.11b
Fig 5.2.6c
¾ Release main derricking wire rope, lower the boom 13, be cautions that put the stow-wood “a”
under luffing jib in advance, to prevent the rope-support roller of luffing jib section from
damages.
¾ Dismantle the hoisting wire rope 13.0.1’s rope socket on the luffing jib head. Wind the hoisting
5-80/93
wire rope 13.0.1, retract the hook.
¾ Lower the boom to make the luffing jib touch the ground, and make the boom parallel with
luffing jib. Dismantle the limit device 20.12. retract the limit device 20.12 and stay rope “b”
¾ Use the auxiliary crane to hoist one side of luffing jib foot 20.8, at the same adjust the boom
13, dismantle luffing jib foot 20.8’s spindle. At this time, be cautions luffing jib 20 and boom
section 13 not bump, to avoid dangers. Refer to Fig 5.2.6c
Fig 5.2.6d
¾ Use auxiliary crane to lower the luffing jib foot 20.8 on the ground, and lower the luffing jib
section on the stow-wood “a”.
¾ Make sure the luffing jib section 20 and boom section 13 not interfere, and slew the crane to
slew the boom 13 to luffing jib section 20’s aside. Refer to Fig 5.2.6d.
Fig 5.2.6e
5-81/93
¾ Lower the boom, and boom touches the ground.
¾ Dismantle the luffing jib derricking (aux. winch) wire rope socket, and wind the aux.winch wire
rope. Dismantle the luffing jib rear pendant rope 13.4.1, 13.0.1 and travelling block device
20.2.
¾ Dismantle the luffing jib strut. Refer to Fig 5.2.6e.
Fig 5.2.6f
¾ Release the main derricking wire rope, dismantle the boom pendant rope 13.4.1, 13.3.1,
13.2.1. refer to Fig 5.2.6f.
Fig 5.2.6g
¾ Connect the ear plate of boom foot 13.1 by mast 7 with pendant rope, use mast 7 to hold the
boom 13 and keep boom head 20.1 on the ground. Dismantle the lower spindles between
boom head 20.1 and boom foot 13.1.
5-82/93
¾ Release the main derricking wire rope, lower the boom slowly on the ground. Continuously
release the main derricking wire rope, dismantle the connection pin between mast 7 with
pendant rope and boom foot 13.1’s ear plate. Refer to Fig 5.2.6g.
¾ Dismantle 20.3, boom head 20, and dismantle other sections. Refer to Fig 5.2.6h.
¾ Luffing jib working condition disassembly is completed.
Fig 5.2.6h
5.2.7 Disassembling the counterweight
¾ If not follow correct procedures to disassemble the counterweights, and it may cause
personal accidents.
counterweights when disassembling the counterweights, to avoid accidents.
¾ Without extending the track frame fully, and slew the superstructure with
counterweight, may cause the machine overturn.
5-83/93
2. Check that the A-frame is under working status.
3. Check that the top of boom foot on the stow-wood.
4. Dismantle the locking devices⑥, 3 in total.
5. Hoist the counterweight⑤, ④, ③, ② respectively by auxiliary crane.
¾ Pull the lifting belt of auxiliary crane up, for the lifting belt not loosen.
6. Put the disassembled counterweights at reserved position.
7. Dismantle the big screw rod ⑦.
8. Hoist the middle counterweight ⑧ by auxiliary crane, and put it to reserved position.
¾ When disassembling, keep the balance of left, right counterweight. It is not allowed to
disassemble single side counterweight, then disassemble the other side. Disassemble
the middle counterweight finally, or may cause the crane body damage or overturn.
Fig 5.2.7.1
5-84/93
9. Dismantle the connection spindle ② between superstructure (4) and superstructure
counterweight tray③.
10. Lift the counterweight tray ③ by lifting belt, and put it to designated position, and dismantle the
lifting belt.
Fig 5.2.7.2
5-85/93
5.2.8 Retraction of track frame
Retracting the width of the track frame on slopes may create a hazardous situation. Carry
out this work on a level surface only.
¾ Retract the track frames only after
all counterweights have been removed.
¾ Never retract the track frames on the
soft ground. If it is soft, please put enough
strength steel plate.
¾ The outer border dimension is 5.06m
before track frame retraction, outer border
dimension is 3.38m after track retraction,
and track width 0.86m.
Fig 5.2.8.1
1. Remove the screw on the baffle plate⑥, and remove the baffle plate ⑥.
2. Adjust the nut ③ to make a certain clearance between extension frame ⑤ and track frame⑦.
3. Remove the bolt on the clip board ①, and remove clip board ①.
4. Remove spindle ② and ④.
6. Move the pilot enable hand grip to START position.
7. Press slewing/ extension&retraction button to extension&retraction side. Retract the track width
by operating the hand grip, till retract to limit.
¾ If it is difficult for track frame retraction, and it can rotate the superstructure 90°. After
retracting one track frame, rotate the superstructure 180°. Then retract the other track
frame. At the same time, operate the traveling joystick to ensure the track frame
retraction fully.
5-86/93
Fig 5.2.8.2
9.Install the spindle ④.
10. Fix the extension frame ⑤ and track frame by spindle ②.
11. Fix the spindle by clip board①, and tighten it by screw.
Fig 5.2.8.3
5-87/93
5.2.9 Disassembling the cab pedal
Dismantle the 4 bolts and shims, which are connected by cab pedal and cab, then the pedal can
be disassembled.
If not disassemble the cab pedal, and transport width will exceed 3.3m
The disassembled bolts need to be installed to linking hole outside the cab, to prevent loss.
Fig 5.2.9
5.2.10 Drive the base machine onto trailer（with track frame）
¾ If the machine climb the slope with superstructure counterweight, and it may overturn.
¾ Carefully check the slewing lock device is locked or not.
¾ When driving onto the trailer, never allow any operations except traveling and
derricking.
1.Mat the trailer board with wooden block or support, to prevent trailer’s board, which is relative to
trailer, is moving.
2. The traveling motor stays at rear of machine. Align the center of undercarriage with the center of
superstructure. Start the slewing locking device, make sure the superstructure cannot slew.
3.Adjust the width of board on the ramp to cooperate with the width of track frame.
5-88/93
¾ Before climbing the slope, align the direction of track and slope grade.
¾ Allowable max. slope angle α should be less than 15°. Don’t try to operate on the slope,
which exceeds 15°.
4. Adjust the angle of boom foot, keep the angle between boom foot and crane body around 40°.
5.At the same time, move the left, right traveling joystick forward, to keep base machine’s traveling
direction parallel with trailer’s board direction.
¾ Arrange a director. To direct the crane upgrade operation, then the center of machine
can be aligned to center of ramp.
¾ If there is clearance difference between track and left, right ramp edges, and the
machine will be back to original position. Then after adjusting direction, to operate the
machine again.
Fig 5.2.10
5-89/93
6. Wedge the wooden block to track. Fix the track to trailer board by rope slings with enough
strength.
7. Lower the boom on the stow-wood with 400mm height.
¾ Add protective device between track and rope slings, to prevent equipments abraison
or damages.
5.2.11 Disassembling the self-assembly counterweight
¾ If not follow correct procedures to disassemble the counterweights, and it may cause
personal accidents.
counterweights when disassembling the counterweights, to avoid accidents.
¾ Without extending the track frame fully, and slew the superstructure with
counterweight, may cause the machine overturn.
2. Connect the self-assembly cylinder ② to superstructure.
3. Retract the self-assembly cylinder, and dismantle the connection spindle between
superstructure and counterweight.
4. Slowly extend the cylinder, and lower the counterweight device.
5. Dismantle the hydraulic oil pipe and quick-coupler.
5-90/93
Fig 5.2.11.1
6. Lift the lower boom section, and lower the cylinder at lower boom section.
Fig 5.2.11.2
7. Disassemble the counterweight device, put one by one onto trailer.
Fig 5.2.11.3
5-91/93
5.2.12 Drive the base machine onto trailer (without track frame)
1. Extend the outrigger cylinder, and make the track carrier is off ground within 500mm.
2. Dismantle the connection spindle between extension frame and track carrier.
3. Hoist the track carrier by self-assembly cylinder, and put it on the trailer.
Fig 5.2.12.1
4. Dismantle the other side track carrier, the method same as above.
Fig 5.2.12.2
5-92/93
5. Extend the outrigger cylidner to suitable position.
Fig 5.2.12.3
6. Drive the trailer to the lower part of base machine. Mat the crossite under chassis.
7. Retract the outrigger cylinder.
Fig 5.2.12.4
5-93/93
Chapter 6 Hoisting and Lowering the Boom
6.1 Boom hoisting

6.1.1 Boom hoisting
6.1.1.1 Conditions for the boom hoisting
¾ Before hoisting the boom, reinforce the ground, such as paving steel plate to keep the
crane level on the ground.
¾ If the boom is lifted under the direction, where hoisting is limited, the crane may be
tipped over. So before hoisting the boom in ▲condition in the table 6.1.1.1the wedge
should be paved in front or behind the track.
The boom hoisting condition is decided by the boom combination types and location direction.
¾ Just front (F) Boom hoisting on front direction( Boom section is located on the side of track
shoe tension device).
¾ Just behind（B）Boom hoisting on behind direction( Boom section is located on the side of the
drive device).
¾ Just side（S）Boom hoisting on side direction( Boom section is located on the vertical
direction of the track.
Table 6.1.1.1
Boom Front(F) Side(S)

length /Behind(B)
(m)
13 ● ●
16 ● ●
19 ● ●
22 ● ●
25 ● ●
28 ● ●
6-1/32
31 ● ●
34 ● ●
37 ● ●
40 ● ●
43 ● ●
46 ● ●
49 ● ●
52 ● ●
55 ● ×
58 ▲ ×
×：Prohibit boom hoisting ●： Boom hoisting (without wedge)

▲：Boom hoisting( with wedge)
6.1.1.2 Inspection before boom hoisting
After inspection for the crane, once again to check whether all the parts have been already
installed or connected. If having any question, install them according to correct installation
procedure.
1.Inspect all pins and lock pins installation
¾ Boom connecting pin
¾ Boom pendant rope connecting pin
¾ Wire rope socket connecting pin
2.Inspect the rope socket installation
¾ Main hoisting wire rope socket
¾ Boom derricking drum socket
3.Inspect tighten of bolt
4.Inspect connection of cable
6-2/32
¾ Hook upper limit device cable
¾ Boom angle sensor cable
¾ Force sensor cable
¾ Anemometer cable
¾ Other cables
5.Inspect the length of boom pendant rope
6.Inspect the installation and twisting of wire rope
7.Inspect the wire rope has been placed on the boom head without limit.
8.Inspect the installation of boom backstop device pin.
9.Inspect whether the tools have left in the crane.
10.Once again inspect whether to meet the boom hoisting configuration
¾ The ground is level and firm.
¾ There are not any obstacles in the hoisting area, such as high voltage electric wire, etc.
¾ Inspect whether wind power to affect the hoisting of boom.
11.Inspect whether the boom hoisting is equipped with wedge c
¾ Boom hoisting condition according to Table 6.1.1.1
12.Inspect the safety devices
¾ Hook upper limit device
¾ Boom upper limit device
¾ 3-layers protection device
¾ Two workers(operator and commander) are needed, when boom is lifted. Commander
responsibility is to predict potential danger and timely inform the operator the
possibility of danger.
¾ When operating overload release switch to make crane entering into release overload
status, operation of overload limit such as: hook hoisting operation and main
derricking lowering operation will be forced to allow again, at this time, please
operate the crane slowly.
6-3/32
¾ Slowly twine the derricking drum wire rope, pay attention to avoid the disorder of wire
rope and drop out the wire rope. Until the derricking wire is straight.
¾ Refer to max. working radius of connected boom.
¾ When boom is hoisting, if the display is presented the working radius is within max.
working radius range, and the hook block could be hoisted.
6.1.1.3 Boom hoisting operation
Fig 6.1.1.3a
Fig 6.1.1.3b
6-4/32
1. The crane is under release overload status.
2.Push the main derricking hand grip.
3.Twine main derricking wire rope and release the hoisting wire rope to make the hook block 17
placed on the ground.
4.Until the boom angle is 30°—80°,the main derricking hand grip comes back to neutral
position(At this time, the crane has already recovered to working condition),then lift the hook
block.
6.1.2 Runner hoisting
6.1.2.1 Conditions for the runner hoisting
¾ Before hoisting the runner, reinforce the ground, such as paving steel plate to keep
the crane level on the ground.
¾ If the runner is lifted under the direction, where hoisting is limited, the crane may be
tipped over. So before hoisting runner in ▲condition ,the wedge should be paved in
front or behind the track.
¾ Just front (F) Boom hoisting on front direction( Boom section is located on the side of
track shoe tension device)
¾ Just behind（B）Boom hoisting on behind direction( Boom section is located on the side
of the drive device)
direction of the track.
Table 6.1.2.1
Boom length Front(F)/Behind(B) Side(S)
(m)
13 ● ●
16 ● ●
19 ● ●
22 ● ●
6-5/32
25 ● ●
28 ● ●
31 ● ●
34 ● ●
37 ● ●
40 ● ●
43 ● ●
46 ● ●
49 ● ●
52 ● ×
55 ▲ ×
58 ▲ ×
×：Prohibit boom hoisting ●：Boom hoisting(without wedge )
6.1.2.2 Inspection before runner hoisting
procedure.
¾ Runner connecting pin
¾ Aux.hoisting wire rope socket
¾ Derricking drum socket
6-6/32
¾ Anemometer cable
¾ Other cables
5.Inspect the length of boom pendant rope
8.Inspect the installation of boom backstop device pin.
11.Inspect whether the boom hoisting is equipped with wedge
¾ Runner hoisting condition according to Table 6.1.2.1
6-7/32
6.1.2.3 Runner hoisting operation
Fig 6.1.2.3a
Fig 6.1.2.3b
6-8/32
Fig 6.1.2.3c
block.
6.1.3 Fixed jib hoisting
6.1.3.1 Conditions for the fixed jib hoisting
¾ Before hoisting the fixed jib, reinforce the ground, such as paving steel plate to keep
¾ If the fixed jib is lifted under the direction, where hoisting is limited, the crane may be
tipped over. So before hoisting the boom in ▲condition, the wedge should be paved
in front or behind the track.
track shoe tension device)
¾ Just behind（B）Boom hoisting on behind direction( Boom section is located on the side
of the drive device)
direction of the track
6-9/32
Table 6.1.3.1a
（F）Boom hoisting on front direction

Boom Fixed jib length (m)
length 9 13.5 18
（m） 15° 30° 15° 30° 15° 30°
37 ● ● ● ● ● ●
40 ● ● ● ● ● ●
43 ● ● ● ● ● ●
46 ● ● ● ● ● ●
49 ● ● ▲ ▲ ▲ ▲
52 ▲ ▲ ▲ ▲ ▲ ▲
×：Prohibit boom hoisting ●: Boom hoisting (without wedge)
Table 6.1.3.1b
（B）Boom lifting on behind direction
Boom Fixed jib length（m）

length
9 13.5 18
（m）
15° 30° 15° 30° 15° 30°
37 ● ● ● ● ● ●
40 ● ● ● ● ● ●
43 ● ● ● ● ● ●
46 ● ● ● ● ● ●
49 ● ● ▲ ▲ ▲ ▲
52 ▲ ▲ ▲ ▲ ▲ ▲
×：Prohibit boom hoisting ●: Boom hoisting (without wedge)

6-10/32
Table 6.1.3.1c
（S） Boom hoisting on side direction
Boom Fixed jib length (m)

length
9 13.5 18
（m）
10° 30° 10° 30° 10° 30°
25 ● ● ● ● ● ●
28 ● ● ● ● ● ●
31 ● ● ● ● ● ●
34 ● ● ● ● ● ●
37 ● ● ● ● ● ●
40 ● ● ● ● ● ●
43 ● ● ● ● ● ●
46 ● ● ● ● × ×
49 × × × × × ×
52 × × × × × ×
×：Prohibit boom hoisting ●：Boom hoisting (without wedge)

6.1.3.2 Inspection before fixed jib hoisting
procedure.
1.Inspect all pin and lock pin installation
¾ Fixed jib connecting pin
¾ Fixed jib strut connecting pin
6-11/32
¾ Fixed jib pendant rope connecting pin
¾ Aux. hoisting wire rope socket
¾ Derricking wire rope socket
¾ Anemometer cable
¾ Other cables
5.Inspect the length of boom and fixed jib pendant rope
8.Inspect the installation of boom backstop rod and fixed jib backstop pin.
¾ Fixed jib hoisting condition according to Table 6.1.3.1a, 6.1.3.1b, 6.1.3.1c
6-12/32
6.1.3.3 Fixed jib hoisting operation
Fig 6.1.3.3a
6-13/32
Fig 6.1.3.3b
Fig 6.1.3.3c
6-14/32
block.
6.1.4 Luffing jib working condition hoisting
6.1.4.1 Conditions for the luffing jib working condition hoisting
¾ Before hoisting the luffing jib, reinforce the ground, such as paving steel plate to keep
¾ If the luffing jib is lifted under the direction, where hoisting is limited, the crane may
be tipped over. So before hoisting luffing jib in ▲condition ,the wedge should be
paved in front or behind the track.
track tension device)
¾ Only hoisting the luffing jib at just front direction.
Table 6.1.4.1a
Luffing jib length

18 21 24 27 30 33 36
Boom length
24.7 ● ● ● ● ● ● ●
27.7 ● ● ● ● ● ● ●
30.7 ● ● ● ● ● ● ●
33.7 ● ● ● ● ● ● ●
36.7 ● ● ● ● ● ● ●
39.7 ● ● ◎ ◎ ◎ ◎ ▲
6-15/32
42.7 ▲ ▲ ▲ ▲ ▲ ▲ ▲
45.7 ▲ ▲ ▲ ▲ ▲ ▲ ▲
Note: ●：boom can hoist（without wedge） ◎：boom can hoist（with wedage）
▲：boom can hoist（add additional counterweight）
Luffing jib derricking range refer to Table 6.1.4.1b
Table 6.1.4.1b
Luffing jib length

18 21 24 27 30 33 36
Boom length
24.7 ● × × × × × ×
27.7 ● ● × × × × ×
30.7 ● ● ● × × × ×
33.7 ● ● ● ● × × ×
36.7 ● ● ● ● ● × ×
39.7 ● ● ● ● ● ◎ ×
42.7 ● ● ● ● ◎ ◎ ◎
45.7 ● ● ● ● ◎ ◎ ◎
Note: the meanings of above signal as shown below:
“●”：The boom can be derricking within 90°~60°
“◎”：The boom can be derricking within 90°~70°
“×”：Cannot have any boom lifting and luffing jib combinations
6-16/32
6.1.4.2 Inspection before luffing jib working condition hoisting
procedure.
¾ Luffing jib connection pin
¾ Luffing jib strut connecting pin
¾ Luffing jib pendant rope connecting pin
¾ Aux. hoisting wire rope socket
¾ Derricking wire rope socket
¾ Anemometer cable
¾ Other cables
5.Inspect the length of boom and fixed jib pendant rope
8.Inspect the installation of boom backstop rod and fixed jib backstop pin.
6-17/32
¾ Luffing jib hoisting condition according to Table 6.1.3.1a, Table 6.1.3.1b, Table 6.1.3.1c.
6-18/32
6.1.4.3 Luffing jib working condition hoisting operation
Fig 6.1.4.3a
After installing the luffing jib, and enwind the main derricking wire rope 7.0.7, to
make the boom and luffing jib hoist slowly.
Fig 6.1.4.3b
6-19/32
Continuously retract the boom derricking wire rope 7.0.7, hoist the boom, to stop
when boom angle reaches 90°.
Fig 6.1.4.3c
The operator pulls the rope of limit device by hands, and disengage the limit hook,
to make the luffing jib and boom lower part separate.
Fig 6.1.4.3d
6-20/32
Retract the luffing jib derricking wire rope, and hoist the luffing jib
Fig 6.1.4.3e
Continuously retract the luffing jib derricking wire rope, and hoist the luffing jib to
reach working angle.
Luffing jib hoisting is completed.
6.2 Boom lowering

6.2.1 Boom lowering
6.2.1.1 Site selection for lowering boom
¾ Confirm whether the site and space is enough and the ground is firm and level
¾ Before lowering the boom, if the ground is uneven, please level the ground. If the ground is
so soft, the steel plate should be paved.
¾ Depending on conditions of boom hoisting, to confirm the position and disassembly direction
of base machine and working equipments.
6-21/32
6.2.1.2 Direction selection for lowering boom
¾ If lowering boom on the direction, where the hoisting is limited, and the machine will
be tipped over.
¾ When lowering the boom, before the boom angle exceeds the working range, and the
hook must be placed on the ground.
¾ According to conditions of boom hoisting. It is required that when lowering the boom,
and it should lower at just front direction.
6.2.1.3 Inspection before boom lowering
The following inspections should be done before lowering the boom. If any abnormity is found out,
please solve them before lowering the boom.
1.Before lowering the boom, kindly confirm whether meet all the requirements.
¾ The ground should be firm and level
¾ There are no obstacles within the range of lowering boom

2.When inspecting the boom lowering, confirm whether the direction of boom lowering is right.
3.Inspect whether the moment limiter is correctly set.
¾ Two workers(operator and commander) are needed, when boom is lowered.
Commander responsibility is to predict potential danger and timely inform the
operator the possibility of danger.
¾ It is forbidden that the working personnel, commander and observer are under the
boom.
6.2.1.4 Boom lowering operation
1.The crane is in normal working condition.
6-22/32
2.Put the boom derricking drum operating grip to lowering position. Slowly lower the boom until
the boom frame reach max. working radius, and the crane will automatically stop lowering the
boom action. (moment limiter automatic limit operation)
¾ Before crane stops, when lowering the boom, and speed should be slow.
3. Turn boom derricking drum operating grip to neutral position, and turn the overload release
switch right once time (reset to neutral position after loosen hand)in the sliding electric control
cabinet, to make the crane enter into release overload status.
¾ Refer to max. working radius of connected boom. When the moment limiter displays
that real-time working radius reach the max. working radius required by working
condition, and the hook needs to be lowered on the ground. (at this time, the crane
enters into overload release status, lower the boom continuously if it is allowed
constrainedly)
¾ Lower the boom carefully and slowly, to avoid producing the impact load.
4.Release the wire rope slowly, put the hook on the ground.
¾ Lower the hook to suitable place to avoid causing obstacles when lowering the
runner.
5. Move the boom derricking drum operating grip to lower position again, and slowly lower the
boom.
6. Use the stow-wood to support boom
The height of the stow-wood ① is about 300mm.
Fig 6.1.4.3f
6-23/32
6.2.2 Runner lowering
6.2.2.1 Site selection for lowering runner
¾ Before lowering the runner, if the ground is uneven, please level the ground. If the ground is
¾ Depending on conditions of runner hoisting, to confirm the position and disassembly
direction of base machine and working equipments.
6.2.2.2 Direction selection for lowering runner
¾ If lowering runner on the direction, where the hoisting is limited, and the machine will
be tipped over.
¾ According to conditions of runner hoisting. It is required that when lowering the
runner, and it should lower at just front direction.
6.2.2.3 Inspection before runner lowering
The following inspections should be done before lowering the runner. If any abnormity is found
out, please solve them before lowering the runner.
1.Before lowering the runner, kindly confirm whether meet all the requirements.
¾ There are no obstacles within the range of lowering runner

2.When inspecting the runner lowering, confirm whether the direction of runner lowering is right.
¾ Two workers(operator and commander) are needed, when boom is lowered.
Commander responsibility is to predict potential danger and timely inform the
operator the possibility of danger.
¾ It is forbidden that the working personnel, commander and observer are under the
boom.
6-24/32
6.2.2.4 Runner lowering operation
¾ Before crane stops, when lowering the boom, and speed should be slow.
constrainedly)
4.Release the hoisting wire rope slowly, put the hook and runner hook on the ground.
¾ Lower the hook to suitable place to avoid causing obstacles when lowering the
runner.
boom.
6-25/32
6. Use the stow-wood to support boom.
The height of the stow-wood is about 300mm.
Fig 6.2.2.4
6.2.3 Fixed jib lowering

6.2.3.1 Site selection for lowering fixed jib
¾ Before lowering the boom, if the ground is uneven, please level the ground. If the ground is so
soft, the steel plate should be paved.
¾ Depending on conditions of fixed jib hoisting, to confirm the position and disassembly direction of
base machine and working equipments.
6.2.3.2 Direction selection for lowering fixed jib
¾ If lowering fixed jib on the direction, where the hoisting is limited, and the machine
will be tipped over.
¾ According to conditions of fixed jib hoisting. It is required that when lowering the fixed jib,
and it should lower at just front direction.
6.2.3.3 Inspection before fixed jib lowering
The following inspections should be done before lowering the fixed jib. If any abnormity is found
out, please solve them before lowering the fixed jib.
6-26/32
1.Before lowering the fixed jib, kindly confirm whether meet all the requirements.
¾ There are no obstacles within the range of lowering fixed jib.

2.When inspecting the fixed jib lowering, confirm whether the direction of fixed jib lowering is
right.
¾ Two workers(operator and commander) are needed, when boom is lowered. Commander
responsibility is to predict potential danger and timely inform the operator the possibility
of danger.
¾ It is forbidden that the working personnel, commander and observer are under the boom.
status, operation of overload limit such as: hook hoisting operation and main derricking
lowering operation will be forced to allow again, at this time, please operate the crane
slowly.
6.2.3.4 Fixed jib lowering operation
¾ Before crane stops, when lowering the boom, and speed should be slow
6-27/32
constrainedly)
4. Slowly release the hoisting wire rope, and lower the boom hook, fixed jib on the ground.
¾ Lower the hook to suitable place to avoid causing obstacles when lowering the fixed
jib.
boom.
6. Use the stow-wood to support boom
7.The fixed jib working condition lowering is completed.
¾ The height of the stow-wood is about 300mm.
Fig 6.2.3.4a
6.2.4 Luffing jib working condition lowering
6.2.4.1 Site selection for lowering luffing jib
¾ Before lowering the boom, if the ground is uneven, please level the ground. If the ground is
¾ Depending on conditions of luffing jib hoisting, to confirm the position and disassembly
direction of base machine and working equipments.
6-28/32
6.2.4.2 Direction selection for lowering luffing jib
¾ If lowering fixed jib on the direction, where the hoisting is limited, and the machine
will be tipped over.
¾ According to conditions of luffing jib hoisting. It is required that when lowering the
fixed jib, and it should lower at just front direction.
6.2.4.3 Inspection before luffing jib lowering
The following inspections should be done before lowering the luffing jib. If any abnormity is found
out, please solve them before lowering the luffing jib.
1.Before lowering the luffing jib, kindly confirm whether meet all the requirements.
¾ There are no obstacles within the range of lowering the luffing jib.
2.When inspecting the luffing jib lowering, confirm whether the direction of luffing jib lowering is
right.
¾ Two workers(operator and commander) are needed, when boom is lowered. Commander
responsibility is to predict potential danger and timely inform the operator the possibility
of danger.
¾ It is forbidden that the working personnel, commander and observer are under the boom.
status, operation of overload limit such as: hook hoisting operation and main derricking
lowering operation will be forced to allow again, at this time, please operate the crane
slowly.
6-29/32
6.2.4.4 Luffing jib working condition lowering operation
Fig 6.2.4.4a
¾ Enwind the main derricking wire rope 7.0.7, and hoist the boom 13, then make the boom
reach 90°.
¾ Hoist the hook, to reach upper limit.
¾ Lower the luffing jib, to make the luffing jib reach min. working angle. Release the moment
limiter protection.
6-30/32
Fig 6.2.4.4b
¾ Continuously lower the luffing jib.
Fig 6.2.4.4
6-31/32
¾ Continuously lower the luffing jib, to make luffing jib parallel with the boom, and manually
control the limit device pothook by stay rope, lock the luffing jib and boom, make it cannot
move comparatively.
Fig 6.2.4.4d
¾ Lower the boom.
Fig 6.2.4.4e
¾ Lower the boom to close the ground. Boom lowering is completed, and dismantle the boom
section.
6-32/32
Chapter 7 Transportation
7.1 Precautions when transporting on the road

When using trailer to transport this crane and transfer on the jobsite, maybe it is possible
to have various assembly and transportation status according to transportation and types
of trailer, before transportation and transfer, sufficiently consider the parts’ width, height,
length and weight etc, abide by following items：
NOTE:
z When transportation, max.weight, width, height will be limited and admission would be
approved in advance from local government, understanding local all details on rule of law.
z Check traveling route’s relevant condition in advance such as weight restriction and size
restriction etc.
z Refer to relevant chapter about size and weight and abide by crane assembly/disassembly
status and transportation condition about every part’s requirement.
7.2 Crane transfer

7.2.1 Attentions when transfer and transportation
z Confirm slewing arrester on the superstructure to be in the state of brake.
z Confirm all joysticks and switches to be in the neutral position.
z Confirm all outshoots those have been dismantled
z Use tightwire or chain for fixture in order to prevent parts moving.
z Retract outrigger cylinder to transportation device, use the fixing pin to fix; if not,
outrigger cylinder would be easy to shake out during transportation, which will
result in severe accident.
7.2.1.1 Disassembly and transportation
According to the following procedure when crane needs to be disassembled and transported
under working condition( Boom configuration)
① Lower the boom 13 on the ground, dismantle the connection of mast balance frame 7.1 and
boom pendant rope, the connection of boom foot( 13.1 )and 3m boom insert(13.2),the connection
of each boom section, connection of each pendant rope.(Fig 7.2.1.1a)
7-1/12
7.2.1.1a
Fig 7.2.1.1a
Runner is same as above
During fixed jib condition, firstly lower the boom 13 and fixed jib head (15) on the crosstie. At this
time, use the aux. crane to dismantle the connection of strut(15.4)and boom (13), then slowly put
the strut(15.4) down. Remove strut(15.4),pendant rope and fixed jib sections.The disassembly of
boom(13) is same as above. Fig 7.2.1.1b
7.2.1.1b
Fig 7.2.1.1b
② Fix the dismantled pendant rope to its corresponding boom sections, and transport is according
to decided transport plan.
7-2/12
③Lift up boom foot 13.1 and use the aux. crane to remove the superstructure
counterweight(6).And transport the superstructure counterweight 3 (Fig.7.2.1.1c)
7.2.1.1c
Fig 7.2.1.1c
7.2.1.2 Disassembly and transportation of base machine
After dismantling the working equipments and superstructure counterweight, and transport base
machine (including undercarriage, superstructure, mast device, boom foot) as integration.
① Start the track retraction cylinder., to make track frame turn from working status to transport
status. (Fig.7.2.1.2a)
7.2.1.2a
Fig 7.2.1.2a
② Select suitable trailer, drive it to jobsite. Start the base machine, to drive it onto trailer.
When the base machine climbs on the trailer, make sure the 1.5 drive device (reduction gear side)
is at traveling backward direction. Track tension device is located at front.
7-3/12
7.2.1.2b
Fig 7.2.1.2b
③Put the boom foot 13.1 down, lock slewing brake and fix by wire rope or chain. Fig.7.2.1.2c
7.2.1.2c
7.2.1.3 Separated transportation of base machine
① Rotate the outrigger assy. A 1.14, outrigger assy. B 1.15 to 45° position. Fig 7.2.1.3 a
7.2.1.3a
7-4/12
② Remove the positioning pin of chassis extension frame and fixed pin of telescopic cylinder.
Dismantle the traveling motor’s tubing and quick coupler.
③ Control the six valve hand grip, to extend the outrigger cylinder slowly, and stop after the track
shoe slightly on the ground. Use auxiliary crane to hoist the track frame slightly, and separate
with the chassis slowly. Fig 7.2.1.3b.
7.2.1.3b
Fig 7.2.1.3b
④ Retract the cylinder, outrigger cylinder, lower the base machine on the trailer. Fig 7.2.1.3c
Fig 7.2.1.3c
7-5/12
7.2.2 Operation condition of crane disassembly
The stability of machine is decided by the weight of counterweight, whether ins tall the boom, track
and retraction of cylinder. please refer t to Table.
¾ If the crane is operated with the mark “X”, and it will be overturned. Under this
condition, don’t operate the crane.
7.2.2.1 Supplements of terms and conditions
¾ When installing the boom, the boom angle should be 0°.
¾ When the crane is in upslope and downhill, the angle should be kept within 0°-15°.
¾ When it is over15°,the crane cannot travel. (Fig 7.2.2.1a)
¾ The slewing operation should be done on firm and level ground.
7.2.2.1a
Fig 7.2.2.1a
7-6/12
7.3 Transportation weight and dimension
7.3.1 Base machine
Base machine ×1
Length 11.72m
Width 3.5m
Height 3.5m
Weight 49.7t
Crane body ×1
Length 11.67m
Width 3.05m
Height 3.06m
Weight 30.1t
Track assy. ×2
Length 6.5m
Width 1.05m
Height 1.07m
Weight 9.8t
7.3.2 Counterweight Casting counterweight

Bracket with self-assembly×1
Length 3.37m
Width 1.13m
Height 1.91m
Weight 5.6t
Casting counterweight block ×8

Length
1.49m
Width
1.12m
Height
0.43m
Weight
2.52 t
7-7/12
Casting counterweight block ×1
Length 0.79m
Width 0.66m
Height 0.89m
Weight 1.83 t
7.3.3 Boom
Boom upper section ×1

Length 7.8m
Width 1.61m
Height 1.84m
Weight 1.62t
3M insert ×1
Length 3.13m
Width 1.63m
Height 1.76m
Weight 0.47t
6M insert ×1
Length 6.13m
Width 1.63m
Height 1.76m
Weight 0.75 t
9M insert ×4
Length 9.13m
Width 1.63m
Height 1.76m
Weight 1.04t
7-8/12
Jib lower section ×1
Length 4.76m
Width 0.66m
Height 0.50m
Weight 0.19t
Jib 4.5M section ×2

Length 4.58m
Width 0.64m
Height 0.59m
Weight 0.13t
Jib upper section ×1

Length 4.83m
Width 0.6m
Height 0.72m
Weight 0.28t
Jib strut ×1
Length 4.43m
Width 0.66m
Height 0.62m
Weight 0.34t
7-9/12
3m transit section ×1
Length 3.11m
Width 1.63m
Height 2.48m
Weight 1.15t
Travelling block ×1
Length 1.24m
Width 0.62m
Height 0.65m
Weight 0.31t
boom head strut ×1

Length 1.89m
Width 0.79m
Height 1.16m
Weight 0.40t
Boom head ×1
Length 2.63m
Width 1.63m
Height 1.70m
Weight 0.76t
Luffing jib head ×1

Length 6.50m
Width 1.29m
Height 1.28m
Weight 0.77t
7-10/12
Luffing jib foot ×1
Length 6.16m
Width 1.63m
Height 1.18m
Weight 0.73t
Luffing jib 3m section ×1

Length 3.14m
Width 1.29m
Height 1.18m
Weight 0.27t
Luffing jib 6m section ×1

Length 6.08m
Width 1.29m
Height 1.18m
Weight 0.47t
Luffing jib strut ×1

Length 4.5m
Width 1.5m
Height 1.17m
Weight 0.94t
7-11/12
7.3.4 Hook
85t Hook ×1
Length 1.94m
Width 0.68m
Height 0.54m
Weight 1.03t
50t Hook ×1
Length 1.78m
Width 0.68m
Height 0.4m
Weight 0.75t
25t Hook ×1
Length 1.65m
Width 0.68m
Height 0.36m
Weight 0.44t
9t Hook ×1
Length 0.95m
Width 0.36m
Height 0.36m
Weight 0.25t
7-12/12
Chapter8 Maintenance Instructions
8.1 Maintenance safety instructions
8.1.1 General
1.This section is about safety instruction, which focuses on the danger that may occur during
lubrication and maintenance to crane.
2.Safety measures and application will be explained in corresponding sections.
3. Adjustment, maintenance and replacement of parts should be performed at stipulated time and
strictly in conformity to relevant rules and instructions.
4.Keep joysticks, pedals, platform and deck clear of dust, snow and ice.
5.Abrasion safety costume, goggles, mask and other safety outfit required by work condition.
6.Unauthorized persons are forbidden to approach crane during lubrication and maintenance
7. For accessories must meet the technical requirements stipulated by the manufacturer, only
use those stipulated by the manufacturer or with its use permission.
Attention: relevant safety instructions must be followed when performing lubrication,
repair, maintenance and adjustment.
8.1.2 Selection and qualification of maintainer

Maintenance, especially on electric system, hydraulic system, diesel engine and brake device,
must be performed by professional personnel.
8.1.3 Risks during maintenance

Special attention should be paid and work requirements in corresponding sections strictly
followed when lubricating and maintaining the parts which are possible to cause danger.
Attention: on-professional person are not allowed to maintenance the crane and not
allowed to select the spare parts not appointed by FUWA.
8-1/59
8.1.3.1 Being crushed or cut
Relevant parts: Pinions of slewing reduction gear 、Track traveling mechanism、Wire rope、
pulleys and winch
Fig 8.1.3.1
8.1.3.2 Slip ,stumble and fall
Only use stipulated pathway and ladder of non-slip design

with enough handrails for operators to hold to keep balance
Fig 8.1.3.2
8.1.3.3 Scald
Relevant parts ：
Diesel engine with exhaust system; hydraulic system at work
8.1.3.4 Gas, dust and smoke Fig 8.1.3.3
Keep working area well ventilated while refilling oil
8.1.3.5 Danger by remaining pressure in hydraulic system
In some situations, the machine may stop working because of broken pipes, hoses or hydraulic
valves components while unreleased pressure possibly remains in the system, which may cause
danger.
8-2/59
¾ When the crane is repaired or disassemble hydraulic parts, the pilot joystick should be
retrieved and other joysticks also come back to central position. Master hydraulic switch is
installed in pilot system, namely to control solenoid valve. When the solenoid valve is in
power-losing condition, pilot oil line and return oil line is connected to relieve the pressure of
pilot system.
¾ Multiple valve is most adopted y type, When the operating unit is stopped working, two
working joint of motor and cylinder connect to the oil tank to achieve the pressure release of
main oil route.
¾ The multiple unit valve of cylinder system is controlled by solenoid valve and hand-operated
valve. If the multiple way valve is solenoid valve, the pressure locking switch is installed in
the return way, when the pressure locking switch is open, the oil line is connected to relieve
the pressure of system. If the multiple valve is hand-operated valve, the oil line is connected
to retrieve the pressure of system.
¾ The pressure switch is installed in cooling system, namely control solenoid valve, when the
solenoid valve is in working condition, the cooling oil line and return oil line is connected.
8.1.4 Precautions before lubrication and maintenance
Warning
z For crane inspection, lower the boom down to the ground, stop engine, engage
all the locks, take down switch key or battery wire to prevent unexpected
persons starting the engine during maintenance.
z Incompliance with the rules above may lead to serious personal injury.
1. Make the rules and instructions known to maintainers and employ a supervisor.
2. Turn off the diesel engine for inspection. Refer to Diesel Engine Operation Instruction for more
information about its inspection and maintenance.
3. During lubrication and maintenance, only let engine work when it is required so for particular
purpose.
4. Park the crane: park it on firm ground (with enough supporting capacity), or take similar
measures to prevent it moving (using wedges to fasten track shoes for instance.)
5. Make sure that unauthorized personnel not start the crane (by locking the cab door) and
restrict working area by warning barrier around.
6. Before commencing maintenance, it is very important to remove the lubricant, fuel or any
additive agents off joints and couplers. Use non-fabric cloth and non-corrosive detergent to clean.
8-3/59
7. Openings and splits on the machine, which are negatively susceptible to liquid and moisture,
should be covered or strapped over before cleaning by spurting water, steam (high-pressure
detergent) or any other detergents (in favor of personal safety or mechanical performance,
transfer case for instance.)
8. After cleaning, uncover openings and splits for inspection to make sure there is no water
leakage in these parts.
9. After cleaning completed, inspect all the fuel pipelines, engine pipes and hydraulic pipelines to
see if any leakage, crack or damage or loosened joints.
10. In case of any defects found, repair or replace the components immediately.
11. Prepare proper containers and adhesives beforehand to receive the lubricant that may spill
out during maintaining and mounting.
8.1.5 Fire prevention
8.1.5.1 Precaution against fire
Remove the dirt, especially flammable material, on the crane to keep it clean. When maintaining,
clean hydraulic system, the engine and fuel system thoroughly. Remove all the remnant lubricant,
fuel and detergent.
Fig 8.1.5.1
8.1.5.2 Other inspection and replacement
1.Inspect all the locking joints, wire-plug joints and patch boards.
If any broken, repair or replace the components immediately.
2.Equip the cab with manned extinguisher for emergency use
3. Sign of manned extinguisher (as showed in Fig 8-1-5-2)
Fig 8.1.5.2
8-4/59
8.1.6 Special notices for lubrication and maintenance
Proper space and aiding device are needed for lubrication and maintenance.
Please follow the procedures and operation instruction.
The term “operation instruction” refers to operation instruction and lubrication and maintenance
manual.
1. Carefully shut the working area.

2. Stably rest the large component to be replaced on aiding device and make sure it will not
receive any damage or the possibility of damage.
3. Only use well-functioned aiding device with enough supporting capacity.
4. Do not stand, walk or work under the hoisted load.
5. Only the experienced personnel are allowed to load the crane and give signals to the
operator. The signalers must be on guard in the view of crane operator or within the range of
audible vocal communication or effective telecommunication. (See “Safety Instruction” in Part
1 of Crane Operation Instruction.)
6. If taking down safety device is unavoidable in the process of maintenance, do remount and
inspect it when maintenance is finished.
7. Make sure all the consumable substances and components replaced with meet the standards
of safety and environmental protection.
8. Keep oiled cloth and flammable material away from fire risk and be careful delivering them.
9. Inspect the electric devices of crane at regular time; replace or repair loosened joints and
burnt wires immediately.
10. Only qualified electricians or the well-trained personnel under supervision of the former are
allowed to repair the electric and electronic system in compliance with the electric technical
requirements.
11. Only use the original fuse with stipulated amperage. In case of power breakdown, stop the
crane immediately.
12. Inspect to see if there is any leakage or spoiled disappearance on hoses or at joints of the
hydraulic system. Repair or replace if any.
13. Only the personnel professional and experienced at hydraulic devices are allowed to carry
out the lubrication and repair of the devices (with the system pressure decreased).
14. To spray lubricant may lead to personal injury or fire.
15. Follow relevant safety instructions for this product when dealing with lubricant, grease and
other chemicals.
8-5/59
16. Be cautious of getting scalded and burnt when dealing with thermal consumables.
17. Make sure there is no tool left on the devices after the work, for any left protruded tools may
cause fatal and bodily danger.
18. Perform inspection regularly according to stipulated schedule.
19. Don’t use electric welding to weld the crane body, take following notes under special
conditions to weld:
¾ Shut off the power (put the key switch to “OFF”). Cut off the battery power line (-).
¾ When the moment limiter is close to welding, and it needs to dismantle it, to avoid damages.
¾ Cannot add 200V above voltage continuously.
¾ Set the grounding within 1m welding point.
¾ No seal or bearing between welding point and grounding point.
8.1.7 Safety instruction for repair
This lubrication and maintenance instructions do not include any information about those for
repair work. If needed, please contact our customer service department. Yet there are still some
general instructions on repair below:
1. It is only under the definite permission that welding, burning and grinding work is allowed to
be performed, or there will be tremendous danger of fire and explosion.
2. Before welding, burning and grinding work, clean the dust and flammable substances off the
crane and its vicinity and keep working area well ventilated (or there will be explosion
danger).
3. Before commencing the work on hydraulic system, open relevant parts to decrease pressure.
4. Do not make any change or adding to the crane without manufacturer’s permission, or there
will be danger to the crane.
8.2 Periodic replacement of easy-damaged spare parts
8.2.1 Periodic replacement of easy-damaged spare parts
The periodic replacement of the spare parts of crane is needed to prolong the service life of crane
and improve safety of crane. Record the crane working hour, according to the requirement to
replace the recommended spare parts. If the service life has already reached to the service life
listed below to replace the spare parts timely.
8-6/59
Easy-damaged spare parts Table 8.2.1
Position Periodic replacement of

Regular replacement time
easy-damaged spare parts
Engine filter element
Refer to Engine Maintenance Manual
Fuel filter element
Air filter element
Engine Water inlet hose
Two years or 4000 hours( whichever
comes first)
Water return hose
Two years or 4000 hours(whichever
comes first)
Wire rope
One year or 2000 hours(whichever
comes first)
Boom head pulley
Two years or 4000 hours(whichever
Attachment
comes first)
bearing for boom head pulley
Three years or 4000 hours(whichever
comes first)
Oil suction filter element
Half year or 500 hours(whichever comes
first)
Return oil filter element
Half year or 500 hours( whichever
comes first)
Air filter
Half year or 500 hours( whichever
Hydraulic
comes first)
system
Initial replacement: 250 hours
Pilot filter element Later: Half year or 500hours (whichever
comes first)
Flexible shaft controller
One year or 2000 hours(whichever
comes first)
Note: Above easy-damaged spare parts should be checked periodically according to
chapter8.3, 8.4 and 8.5. If any damaged parts are found, replace timely.
8-7/59
8.2.2 Precautions for replacement of easy-damaged spare parts
¾ When replacing the parts, the engine should be stopped and all joysticks come back to
central position. And replace the spare parts without capacity. The plate written “checking
and repairing” put on the door of cabin to avoid anyone to operate the crane.
¾ Select fine weather and firm and level ground to replace the spare parts.
¾ It is better to replace the spare parts in room or clean and less dust place.
¾ After replacing the recommended spare parts, check whether each components of crane is
normal condition or, if so, the operation of crane can be done.
¾ After replacing the easy-damaged spare parts, the crane should be keep clean.
8.3 Inspection and maintenance time table
To prolong the crane’s service life, the following parts to needs to be replaced with oil periodically.
Oil replacement time Table 8.2.3
Position Time Contents Remark
Daily or every working 8hrs Refill Check oil level
Working 50hrs Oil replace Only for 1st use

Engine oil
Every half year or every working Oil replace
1000hrs
Fuel tank Replace Temperature
change
Monthly or every working 150hrs Drain

Hydraulic
Yearly or every working 2000hrs Oil replace
Oil tank
Replace Temperature
change
Monthly or every working 150hrs Refill Check oil level

Reduction gear
Every half year or every working Oil replace
oil
1000hrs
Engine cooler Daily or every working 8hrs Refill Check water level,
8-8/59
coolant
Every half year or every working Replace Replace coolant
1000hrs
Note; refer to 8.3,8.4, 8.5 periodical maintenance and inspection.
8.3 Inspection and maintenance time table
8.3.1 Daily inspection and maintenance time
Daily inspection and maintenance time table 8.3.1
Inspection Inspection
Interval No. Location Remark
items method
Daily or Mechanical
every Level, oil

1 Visually inspect
working Engine oil capacity leaks
8hrs 2 Engine Radiator Water height Visually inspect
Tension, Visually inspect

3 Engine fan belt
abrasion
Hoses and linking hoses abrasion,

4 Inspect
leakage
Starting
5 Engine start Listen, operate
facility, noise
6 Engine exhaust Color, smelly Visually smell
Tension, Visually inspect

7 Track and track shoe
crack
Drive wheel, upper Leakage, Visually inspect

8
roller ,lower roller, Idler lubrication
9 Visually inspect
Bolt and nut Missing Sag
Deformation Visually inspect

10 Pulley and pulley block
abrasion
Visually inspect
11
Hook block Damage
8-9/59
Deformation
Wire rope, pendent rope, Deformation, Visually inspect

12
wire rope buckle abrasion
Deformation, Visually inspect

13 Guiding roller
abrasion
Deformation
14 Boom frame Visually inspect
crack
Deformation,
15 Backstop rod Visually inspect
Crack
16 Boom foot lubrication Missing Visually
17 Fuel oil Level Visually inspect
Operate,
18 Brake and locking device Normal
Inspect
Visually
19 Angle sensor Normal
Inspect
Visually
20 Glass of cabin Crack
Inspect
Visually
21 Ladder, handrail Missing, sag
Inspect
Overhoist prevention
22 Performance Operate
device
23 Slewing lock Performance

Operate
24 Slewing brake Invalidation

Operate
Hydraulic
25 Reduction gear oil Leakage Visually inspect
Missing, Visually
26 Hydraulic oil tank capacity
leakage measure
27 Hydraulic oil temperature

Temperature Sense,
8-10/59
Too high, too measure
low
Hydraulic system Sense

28 Abnormal
pressure
measure
Hydraulic system noise Abnormal

29 Listen, touch
and vibration
Clamp, Operate,
30 Joystick
non-working inspect
Electric
Performance
31 Moment limiter Inspect, test
Display
Working
32 Battery Inspect
condition
33 Battery electrolyte Liquid level Test
8.3.2 Monthly inspection and maintenance time table

Monthly-inspection and maintenance time table 8.3.2
Inspection
Inspection
Interval No. Location methods Remark
items
Mechanism
Monthly or
Clogging Visually
every 150 1 Engine oil filter
uncleanness inspect
hours Clogging Visually
2 Fuel oil filter
uncleanness inspect
Clogging Visually
3 Air filter
uncleanness inspect
Clogging Visually
4 Radiator and hose
damage inspect
Track, track shoe,
track frame, Deformation, Visually
5
chassis crack inspect
8-11/59
Drive wheel, guide
wheel, upper roller, Leakage and Visually
6
lower roller lubrication inspect
Visually
Missing ,
7 Spindle inspect
damage
Visually
8 Bolts and nut Missing and slag
inspect
Wire rope and Abrasion, Visually
9
pendent rope damage inspect
Pulley and pulley Deformation,

10 Visually
block abrasion
inspect
Visually
Deformation,
11 Boom frame inspect
crack
Deformation, Visually
12 Backstop rod
crack inspect
Hook block and Damage, Visually
13
bearing deformation inspect
Visually
14 Spindle Missing damage
inspect
15 Bolt and nuts Missing slag Visually

inspect
Deformation. Visually
16 Drum
crack inspect
Brake and lock Operate,
17 Normal
device inspect
Deformation Visually
18 Superstructure
inspect
crack
Visually
Bolt of slewing Missing
19 inspect
bearing slag
Inspect
20 Safety device Damage
operate
8-12/59
Visually
21 Anger sensor Normal
inspect
Over-hoist
Inspect,
22 prevention device Normal
operate
and alarm device
Visually
23 Safety logo Missing, damage inspect
Machine
24 Normal Operate,
performance inspect
Hydraulic
Oil lever of reducer Visually

25
gear oil Missing inspect
Sediment and Release the

26 Filings
water Inspect water
27 Hydraulic cylinder
leakage inspect
Visually
28 Cooler Leakage damage
Monthly or inspect
every 150 Visually
29 Rotary joint Leakage damage
hours inspect
Hydraulic pump
30 and hydraulic Abnormal
Measure
motor pressure
Electric
Performance Operate
31 Limit device
Normal inspect
8-13/59
8.3.3 Quarter inspection and maintenance time table
Quarter inspection and maintenance time table 8.3.3
Interval No. Location
items method Remark
Hydraulic
Suction and return filter

1 Clogging Filings Visually inspect Replace
element
2 Pilot filter element Clogging Filings Visually inspect

Replace
Quarter or
every 500
3 Air filter Visually inspect Replace
hours Clogging
4 Bolt and nut Slag Inspect
5 Hose Slag Inspect
6 Hydraulic hose Abrasion Visually inspect
Electric
7 Plug-in connector Slag Inspect

8 Naked wire Maturing Damage Visually inspect
8.3.4 Year inspection and maintenance time table
Year inspection and maintenance time table 8.3.4
Inspection
Interval No. Location Inspection items Remark
method
Every Mechanism
year or Wire rope, Pendent Abrasion, Visually

1
2000 rope, Rope wedge
damage inspect
hours
Stay bar,rod Visually
2 Damage, crack
inspect
8-14/59
Visually
3 Drum Damage, crack
inspect
Superstructure, Deformation, Visually

4
track frame crack inspect
Deformation,
Visually
5 Boom frame welded section
inspect
corrosion
Missing spare
6 Links Visually
parts
inspect
Hydraulic
7 Hydraulic oil Pollution Inspect Replace
8 Hydraulic system Abnormal Inspect
pressure and flux

Electric
Abrasion, Visually
9 Force sensor
damage inspect
8.3.5 Overhaul
The machine which has worked for 3or 4years needs to overhaul. The machine should be fully
disassembled during overhaul and contract with the OEM for inspection and maintenance.
8.4 Mechanical inspection and maintenance time table

The inspection and maintenance should be implemented by day, by month and by year.
Daily inspection is implemented after working 8 hours or one day. Monthly inspection is
implemented after working one month or 150 hours. Year inspection is implemented after working
one year or 2000 hours.
8-15/59
8.4.1 Mechanical inspection and maintenance time table
Daily inspection and maintenance items (before and after everyday work) 8.4.1a
Inspection
Interval Location Inspection
points
method
Daily or 8
Visually
working 1 Engine oil capacity Level, leakage
inspect
hours
2 Visually
Radiator Water level
inspect
Tension, Visually
3 Fan belt inspect
Engine abrasion
Abrasion,
4 Hose, linking pipeline
leakage Inspect
Starting facility, Listen,

5 Engine start
noise operate
6 Engine exhaust Color, smelly Smell
7 Track and track shoe Tension, crack Visually

inspect
Idler ,Driving
Visually
wheel ,Lower roller, Leakage, inspect
Undercarriage 8
Upper roller lubrication
9 Bolt and nut Missing Sag Visually

inspect
Deformation Visually
Attachment 10 Pulley and pulley block inspect
abrasion
Damage Visually
11 Hook blocks inspect
Deformation
Visually
inspect
12
Wire rope, pendent rope Deformation,
and wire rope buckle abrasion

8-16/59
Deformation,
13 Roller Visually
abrasion inspect
Deformation , Visually
14 Boom frame
crack inspect
Deformation,
15 Backstop rod Visually
Crack
inspect
16 Boom foot lubrication Missing Visually
Visually
17 Fuel tank capacity Level
inspect
18 Brake and lock device Normal Operate,
inspect
Visually
Others inspect
Visually
20 Cabin glass Crack
inspect
Visually
21 Ladder and hand rail Missing, sag
inspect
23 Slewing lock Performance Operate
24 Slewing brake Invalidation Operate
Monthly inspection and maintenance items 8.4.1b
Interval Location
item method
Monthly or Clogging Visually

Engine 1 Engine oil filter
every
uncleanness inspect
8-17/59
Working
Clogging Visually
150hrs 2 Fuel oil filter
uncleanness inspect
Clogging Visually
3 Air filter
uncleanness inspect
Clogging Visually
4 Radiator and pipeline
damage inspect
Track, track shoe,

5 track frame and
crack inspect
chassis
Driving wheel, Idler,

Leakage and Visually
6 Upper roller, lower
Undercarriage lubrication inspect
roller
Missing , Visually
7 Spindle
damage inspect
Missing and Visually

8 Bolt and nuts
slag inspect
Pendent rope and Abrasion, Visually

Attachment 9
Wire rope damage inspect
Pulley and pulley Deformation, Visually

10
block abrasion inspect
11 Boom frame
crack inspect
12 Backstop rod
crack inspect
Hook blocks and Damage, Visually

13
bearing deformation inspect
Missing Visually
14 Spindle
damage inspect
15
Bolt and nuts Missing slag Visually
8-18/59
inspect
Deformation. Visually
16 Drum
crack inspect
Brake and lock

17 Performance Operate,
device
inspect
18 Superstructure
crack inspect
Bolts of slewing Visually

19 Missing, slag inspect
bearing
Inspect,
20 Safety device Damage operate
Others
Visually
inspect
Over-hoist
Inspect,
22 prevention device Normal
operate
and alarm device
Missing, Visually
23 Safety logo
damage inspect
Machine Operate,
24 Normal
performance inspect
Year Maintenance and inspection 8.4.1c
Interval Location
Items method
year or 2000 Wire rope, pendent rope,

1 Abrasion, damage Visually
hours rope wedge
inspect
8-19/59
Visually
2 Stay bar, rod Damage, crack
inspect
Visually
3 Drum Damage, crack
inspect
Superstructure, track Visually

4 Deformation, crack
frame
inspect
Deformation, welded Visually

5 Boom frame
section corrosion
inspect
Visually
6 Links Missing spare parts
inspect
8.4.2 Grease maintenance

8.4.2.1 Interval sheet for grease
Interval sheet for grease 8.4.2.1
Inspection and interval for grease(Hour)

No. Location Position Remark
8 50 250 500 1000
Slewing
1 4 △ ☆
bearing
2 Cylinders 2 △ ☆
3 A-frame 4 △ ☆
4 Drum pawl 1 △ ☆
Drum bearing
5 3 △ ☆
base
6 Boom foot 2 △ ☆
7 Pulley △ ☆
8 Boom head △ ☆
9 Wire rope △ ☆
Track linking
10 △ ☆
pin
Note：△ means inspection oiling time point, ☆ means fill the grease.
8-20/59
8.4.2.2 Precautions for grease
¾ When lubricating the clutch and brake links, care should be exercised so as to apply
lubricant as sparingly as possible . Wire off the surplus grease.
¾ Before lubricating, clean out dirt accumulated around the nipples. Keep the oil gun clean.
The required grease should feature that it will not liquefy with temperature rise and will not
freeze below zero degree.
¾ Use the same brand of oil and grease
¾ Grease the wire rope to avoid rusting, and always grease in use
¾ Always grease the drum, pulley block, guide wheel, lower roller and upper roller.
¾ Track pin should be oiled with waste oil.
The method is as follows Fig 8.4.2.2
8.4.2.2
With brush With cotton yarn With cotton yarn
Fig 8.4.2.2
8.4.3 Bolt inspection and fastening table

During daily inspection and monthly inspection, the bolts and nuts should be checked. if any
loosening is found, repair is need.
Bolt inspection and tighten Table 8.4.3
Bolt performance
8.8 grade 10.9 grade 12.9 grade
grade
(N/mm2)
640 900 1080
Yield strength
Bolt type Tightening torque(Nm)

M10 50 70 85
M12 85 119 140
M14 135 190 220
M16 200 285 345
8-21/59
M18 270 390 460
M20 400 580 680
M22 540 780 930
M24 680 900 1100
M27 950 1300 1600
M30 1300 1800 2300
M33 1900 2500 2800
M36 2400 2800 3500
M39 3200 4300 5200
M42 3800 6000 6500
M45 4500 6400 7400
M48 5500 7800 9500
M52 7500 10000 12500
M56 9000 12000 14000
M60 10800 15500 19000
M64 12800 18500 22000
M68 15500 22500 26500
¾ If the tighten torque is oversize, the aux. tools and spanner is needed.
¾ The inspection of bolts should be abide by according to the stipulated time
¾ Some points are hard to fix, after tighten, if the loosen still exists, all the around spare parts
should be dismantled, then fasten again.
8.4.4 Adjustment of track tension device

It is harmful for the track too tighten and too loosen, if it is loosen, causing the track protruding
part abrasion fast, even the traveling track roller will disengage from the normal track traveling
rail.
If too tight, it will get more pressure and abrasion on pins, making them easier to broken.
Traveling on soft ground, track can be loosened a little while on rocky ground, tightened. It is
advantageous to travel with driving wheel at rear.
8.4.4.1 Inspection
¾ Park the crane on firm ground, the track linking with the ground is in tension condition.
¾ Slew the superstructure to the correct angle between superstructure and tracks
¾ Slewing is under brake status
¾ Lower the boom frame to the ground.
¾ Clean the area around the track.
¾ Turn off the engine.
¾ Inspect tension device to see if any leak.
¾ Inspect the pin to see if they match the track shoe
¾ Inspect the track if any crack, deformation or damage.
8-22/59
¾ Repair broken component
3.4.5.1
Fig 8.4.4.1
（1.3 Track roller 1.5 Upper roller 1.6 Idler 1.7 Track Ⅰ Jack-up）
8.4.4.2 Adjustment
Adjust tension of the track through Idler
Park the crane on firm ground, the track, which is connected with ground is in tension condition
The brake is under slewing status.
The sag quantity of track shoe between Upper roller and Idler is more than 35±5mm( Fig
8.4.4.1),the tension of track is needed. Procedure as follow.
(1)Start the engine
(2)Travel forward, conveying loose sections to top of track frame.
(3)Turn off the engine
(4)Take down side lid and connect the jack-up
(5)Remove adjustment retainer plate
(6)Operate the jack-up and tension the track
(7)Insert some necessary shims, thickness the same as original ones.
(8)Install the retainer plate for shim stack
(9)Retract tighten cylinder, tension frame at ease.
(10)Start up engine
(11)Travel 5m to see adjusted tension
(12)Remove jack-up and restore the lid.
8.4.5 Inspect and replace the wire rope
The service life of the wire rope is much more different due to their separate working condition. It
is therefore very important that the wire rope be inspected at regular intervals. Replace the
damaged ropes immediately after inspection.
8-23/59
8.4.5.1 Inspection
Daily inspection
Inspect any visible parts of the wire rope. Especially pay attention to the anchor of the wire rope
on the machine. Find the causation and replace the wire rope if any damaged and distortional
parts are found.
Inspection parts: Entire wire rope
A. Rope ends anchor
B. The part which cross through and round the pulley
C. The part which round the pulley during hoist
load repeatedly
D. The part which near the balance pulley. Easily
to be abraded part due to external part
E. Internal inspection for corrosion and ageing Fig 8.4.5.1
8.4.5.2 Replacement
Replace wire rope depending on the degree of breakage,

abrasion, corrosion of it. Replace and discard
immediately the rope in one of the following conditions
A. Broken wire
The rope is cut for more than 10% of the wires
consisting of the entire strand within 1 pitch of the rope
(except core). It is very difficult to inspect the broken Fig 8.4.5.2 a
wires of inner part of the wire rope. Bend the wire rope exertive, if the broken wires appear from
the groove, it means the wire rope has reached the fatigue limit. The wire rope must be changed.
B. End wires broken
When the wires are broken which at or near the

end, despite small quantities, that means the stress
is high in this part. Cut the broken part if the rope is
long enough and then reassemble the rope.
Fig 8.4.5.2b
8-24/59
C. Broken wires gathered
Broken wires gathered within6d(d: wire rope diameter)or any strand, despite small quantities
D. Broken wires increase
Broken wires increase after the wire rope is used for a period. The interval of the broken wires
appearing becomes shorter and shorter.
E. Abrasion
Abrasion will reduce the diameter of the wire rope and decrease the intensity of the wire rope.
When abrasion of outer layer reaches 40%of its diameter, or rope diameter reduce7%of its
original diameter.
F. Rope strand breaking
Rope diameter reduces due to the rope core damage when rope strand breaks.
G. Elasticity decrease
Rope diameter reduces, distance of strand increase,
wires and strands tightly close to each other, this is the
description of rope elasticity decrease.
The wire rope are not broken,
but the wire rope can not be bent easily.
The rope may break suddenly when loading.
Such kind of rope should be discarded immediately.
H. Rope erosion
The rope is eroded seriously in its outer and inner. Fig 8.4.5.2 c
I. Rope distortion
As the steel wire rope loses the normal form, the visible distortions are as follows: wave
shape, birdcage distortion, rope strand pushes out from the rope, steel wire pushes out from the
rope and rope diameter increases or decrease partly, as well as part seriously distortion of
flattening, twisted, loose and bend.
Except above mentioned items, the main reason of rope damaged is caused by fatigued using of
the rope in some working conditions. Even the disfigurement can not be seen from appearance,
internal wire rope broken may occur. Hereby, new wire rope should be used in time after the old
one has used more than 2500hours,even the results of above inspection are good enough.
8.4.6 Inspection of pulley block and lifting boom
8-25/59
Warning
z Wear a pair of gloves to protect hands when handling rough wire ropes.
z Keep hands and clothes away from rotary drum and running wire ropes.
z The ladder, platform, and handrail to climb and stand on should be kept clean,
operators wearing safety belt to prevent falling from height.
z Inconformity to these regulations may lead to serious personal injury or death.
¾ Check boom head pulley, guiding pulley, aux. hook pulley, jib head pulley, support boom if
deformation, damage and abrasion.
¾ Check bolt, nuts if loosen and fall down.
¾ Check boom inserts and boom head’s wire rope roller if deformation, damage and abrasion.
¾ Check boom and jib if deformation and damage, don’t use deformation or damaged boom
and jib.
¾ Replace or repair the deformation or damaged boom and jib.
Notice
For the main boom and jib is made of high strength materials, if special technical
support is needed, please contact local service department of FUWA.
¾ Check linking pin, suspension rope and lockpin if damage and fall down.
¾ Check wire rope, sling if damage and deformation.
¾ Don’t use broken and twist wire rope, suspension rope.
8.4.7 Inspection and maintenance of hook
Perform daily inspection and pay attention to dangerous flaws.

Daily inspection and maintenance includes:
(1) Clean the hook;
(2) Lubricate sheaves, transfer device and greasing inlet (if equipped with one)
(3) Inspect all the bolts, nuts and make sure no one split pin is missing and all are split.
Notice
z Don’t use welding method to repair the hook and clip, don’t weld on
any slings without approval of manufacturer, and use suitable
method to weld.
(4)Inspect sheave edge and groove to see if they are even. It indicates bearing or shaft sleeve is
8-26/59
broken if sheave shakes.
(5)Inspect the matching of wire rope and sheave groove. Too thick wire rope will crack sheave
edge, worsening the abrasion of wire rope and sheave. The sheave groove must be smooth and
wider than wire rope diameter
(6) Make sure all the rotary parts could rotate freely without excessive clearance. Abnormal
rotation indicates damage of bearing and shaft sleeve or poor lubrication.
(7) Inspect the rotary connector: turn it by hand. It indicates its bearing is broken if turning meets
obstacle.
(8) Inspect overload damage of hook: side plate stretched, shaft hole expanded, bolt bent or
stretched.
(9) Inspect the abrasion and broken-wire degree at fixed end of wire rope. Tighten the bolts of
rope clip.
(10) Inspect anti-unhooking device: make sure it is complete and intact.
(11) Inspect all hooks and clips.
Notice
The hook or clip ring should check at least once a year, please use be painted,
magnetic powder, ultrasonic or X-ray methods
8.4.8 Maintenance of fuel tank
Check the fuel tank’s oil level (see fuel display in the cab) daily or every working 8hrs, if the fuel
level is too low, and it will affect the engine normal working, then need to refiil it. With the change
of environmental temperature, and change different brand fuel, details refer to engine
maintenance manual.
Notice
z Don’t weld on the fuel tank and near the fuel tank without approval of
manufacturer, if need welding, and consult the manufacturer.
8.5 Hydraulic inspection and maintenance

The inspection and maintenance should be implemented by day, by month and by year.
Daily inspection is implemented after working 8 hours or one day. Monthly inspection is
implemented after working one month or 150 hours. Year inspection is implemented after working
one year or 2000 hours. When hydraulic system inspection and maintenance, replace the
easy-damaged parts every quarter or work every 500 hrs.
8-27/59
8.5.1 Hydraulic inspection and maintenance time table
Hydraulic inspection and maintenance time table 8.5.1
Inspection
Interval No. Location Inspection items Remark
method
1 Gear oil of reducer Leakage Inspect
Hydraulic oil tank

2 Missing, leakage Inspect,
capacity
measure
Hydraulic system Sense,

3
Daily or
temperature Too high, too low measure
every 8
hours Hydraulic system Sense,
4 abnormal
pressure measure
Hydraulic system noise

5 abnormal Listen, touch
and vibration
Operate,
6 Joystick Tighten, failure
inspect
7 Reducer gear oil level Missing Visually, inspect
8 Oil sediment and water Filing Inspect Release
water
Deformation,
Monthly 9 Hydraulic cylinder Visually, inspect
or every leakage
250 hrs 10 Cooler Leakage, Failure Visually, inspect
Leakage, Failure
11 Rotary joint Visually, inspect
Hydraulic pump,
12 hydraulic motor Abnormal Measure
pressure
Every Suction and return filter

13 Sag, filings Visually, inspect Replace
quarter or
element
8-28/59
every 500 14 Pilot filter element Sag, filings Visually, inspect Replace
hours
15 Air filter Sag Visually, inspect
Replace
16 Bolts and nut Loose Inspect
17 Hose Loose Inspect
18 Hydraulic hose Abrasion, Ageing Visually, inspect
Degeneration,
19 Hydraulic oil pollution Inspect Replace
Yearly or
every
2000
Hydraulic system
hours 20 Abnormal Inspect
pressure, flow
8.5.2 Reducer inspection and maintenance
8.5.2.1 Reducer inspection and oil replacement
Reduction gear Table 8.5.2.1a
Oil Interval(hour)
No. Part Remark
capacity 8 250 500 1000
Main and Aux. Oil capacity

△
hoisting inspection Approx
1
reduction gear 4.5L
Oil replacement △
Traveling Oil capacity Approx △

2
reduction gear Oil replacement 8.75L △
Oil capacity △
Approx
3 Derricking
Oil replacement 2.5L △
reduction gear
Oil capacity Approx △

4 Slewing reducer
Oil replacement 6.5L △
8-29/59
8.5.2.2 Reduction gear engine oil
Reduction gear engine oil before out of factory Table 8.5.2.2
Min. using temperature

No. Name
1 Great wall gear lubrication oil (GL-5)85W90 Below 20 degree
2 Great wall gear lubrication oil (GL-5)85W140 10 degree
The reduction gear is used Great wall gear lubrication oil(GL-5)85W90 or Great wall gear
lubrication oil (GL-5)85W140,when the reduction gear is left the factory. According to the min
temperature, select the replacement gear oil. When replacing, the original gear oil should be fully
discharged and new gear oil need to be injected and discharged twice. Then the needed gear oil
could be injected and begin to work. When replacing other brand oil, the original gear oil should
be fully discharged and new gear oil need to be injected and discharged twice. Then the needed
gear oil could be injected and begin to work. After replacing the reduction gear engine oil, operate
the crane slowly to avoid reduction gear damage due to replace the oil.
8.5.2.3 Main, aux. hoisting reduction gear oil volume inspection and replacement
8.5.2.3
Fig 8.5.2.3
1.Oil outlet M20×1.5 2. Oil outlet M20×1.5
3.Oil level or refilling port M18×1. 5. Reduction gear brake port M12×1.5
8-30/59
8.5.2.3.1 Oil volume inspection
The crane is located on firm ground and remove the oil screw plug. If the oil level could be seen ,it
means the oil volume is sufficient.
The oil is inspected by each 250 hours and the oil replacement capacity is about 3.5L.
The oil is replaced by each 1000 hours
8.5.2.3.2 Gear oil replacement
Remove off the oil level plug first, and remove off oil outlet plug, then exhaust oil can be realized.
Secondly, install the oil outlet plug, fill the gear oil from oil inlet till the oil hole, oil volume is 3.5L to oil
hole and install the oil level plug.
8.5.2.4 Oil volume inspection and replacement of traveling reduction gear
8.5.2.4
Fig 8.5.2.4
1.Refilling or oil level plug M18×1.5 2. Oil outlet plug M18×1.5

means the oil volume is enough
Oil volume check once 250 hours, oil volume is 8.75L, the oil change needs every other 1000 hours.
8-31/59
8.5.2.5 Oil volume inspection and replacement of derricking reduction gear
8.5.2.5
Fig 8.5.2.5
1.Refilling screw plug M12×1.5 2.Ventilation screw plug M12×1.5 3. Oil outlet screw plug
M12×1.5 4. Reduction gear brake port M12×1.5 5. Oil outlet screw plug M12×1.5
means the oil volume is enough.
Oil volume check once 250 hours, oil volume is 2.5L, the oil change needs every other 1000 hours.
8.5.2.6 Oil inspection and replacement of slewing reduction gear
8.5.2.6
Fig 8.5.2.6
1. Brake port M12×1.5 2. Refilling screw plug or oil level M18×1.5
3. Oil outlet screw plug M33×2
8-32/59
8.5.2.7 Precautions for reduction gear inspection and oil replacement
¾ When oil change, the ejective oil must overpass the clean cloth then flow into the container, and
observe whether there is metal powder or not. If the metal powder is found, stop all operations of
crane, and contact with aftersales of crane manufacturer, to confirm the reduction gear damage
or not.
¾ Oil inspection, if the oil volume is not enough, the oil should be added. The oil should be added
according to required oil capacity
¾ When oil is replaced, the residual oil should be drained, the same brand and grade of oil could be
added directly. If change other brand, the new oil should be added and drained two times .Then
add new gear oil.
¾ When the crane is used after Oil replacement, engine should be in the idle state for 5 minutes.
Then slowly operate the reduction gear to prevent hurting the reduction gear due to less
lubrication.
8.5.2.8 Common faults inspection of reduction gear
Common faults Table 8.5.2.8
Inspection
Item Reason
part
Oil too much/breather damages
Float seal abrasion/seal deformation/seal lubrication not

Oil seal
sufficient
Heavy pressure cause oil seal damage/service life is at term

Oil
Bolt loosen/O-ring defect/ granule polluted/connection edge
Leakage Connection
damages
Screw hole Bolt loosen
Breather Oil too much/heat expand/positioning not well
Others Shell body cracks
Too hot Oil too much or too less
Oil adherence or specification is wrong
Shell body Overload use
Environment temperature is high
Gear problem
8-33/59
Lubrication not good
Oil seal Seal defect
Assembly not good
Lubrication not good
Bearing clearance too small

Bearing
Installation not good
Bearing abnormal
Linking frame Linking frame rigidity is not enough
Connector Not align
Vibration/ Bearing Bearing damage
Noise Gear Gear damage
Overload
Others
Primary drive frame is abnormal
8.5.3 Hydraulic oil tank maintenance

The hydraulic oil level is inspected by daily or 8 hours. If the oil level is much lower, it will
influence the work of hydraulic system. Meanwhile the oil should be added. The pollution of
discharge of hydraulic oil tank is to be done by monthly or 150 hours. The inspection and
replacement of hydraulic oil is to be done by yearly or 2000 hours. In the sheet 8.5.3 the hydraulic
oil is recommended to choose. Due to the delivery of crane in different season, the hydraulic oil is
also differently adopted. Details could be consulted the manufacture.
Type of crane hydraulic oil Table 8.5.3

Temperature: in temperature is minus 15 Temperature: in temperature is minus 30
degree degree
Import
“Shell Tellus” No.46 hydraulic “Shell Tellus” No.T46 hydraulic oil(Winter)
oil( Summer)
Temperature: Min temperature is minus 25
degree
Domestic
“Great wall densification” No.40 hydraulic
oil
8-34/59
8.5.3
Fig 8.5.3
1. Air filter 2.Oil Return filter 3.Oil Return filter element 4. blowdown valve
5.Oil Suction filter element 6. Liquid meter
7. Hydraulic oil tank window washer 8.Oil Suction filter 9. Shutoff valve
8.5.3.1 Inspection for the hydraulic oil level;

The liquid meter (Fig 8.5.3, No.6)on the hydraulic
tank reflect the status of the hydraulic oil.
When the liquid meter could not be reflected the
oil capacity, the crane should be stop working.
Then refuel oil into the hydraulic oil tank. The newly refuel
oil should be keep the same brand with the original
oil in the oil tank. The hydraulic oil of the crane when
8.5.3.2
delivery is 510L, the most capacity of the oil in the oil tank
should not be exceeded the 80% of the oil tank height. Fig 8.5.3.2
8-35/59
8.5.3.2 The sediment drainage of the oil tank
The sediment of oil tank should be drained by 250 hours, excretion is proceeded by the
blowdown valve(No.1 in Fig.8.5.3.2)under hydraulic oil tank. During the oil excretion, first remove
the plug( No.2 in the fig 8.5.3.2) under blowdown valve, then open the valve. After finishing the
excretion, the valve should be closed
8.5.3.3 Hydraulic oil replacement
During the process of crane working, the hydraulic oil need to be released periodically to inspect
the oil whether is polluted and observe whether any metal filings could be found or not. We
suggest to replace the oil by one year or 2000hours. If it is not convenient to replace oil, the
inspection of the oil should be done. After inspection, the oil still could be used. The periodical
inspection of oil is need, if finding any oil could not be used, the oil should be replaced.
When the oil is replaced, choose the environment without wind and dust to prevent the dust or
sand entering into hydraulic oil tank. Open the cover in the air filter and refuel 510L hydraulic oil.
If the replaced oil is not the same with the original hydraulic oil, the oil tank should be fully
cleaned. All the hydraulic oil in hose and hydraulic parts are replaced.
After exhaust the hydraulic oil of pipeline and hydraulic components, when refill the hydraulic oil
to crane, except the hydraulic oil tank to add the required hydraulic oil, and open all hydraulic
pumps, hydraulic motor leakage port, to fill the hydraulic oil till the oil overfull at the leakage port.
Avoid components damage due lack of hydraulic oil for hydraulic pump and hydraulic motor.
8.5.3.4 Oil suction and return filter
The suction filter element and return filter element is replaced by 500 hours, remove suction
filter( No.8 in the Fig.8.5.3) and return filter bolts( No.2 in fig8.5.3) and slowly screw off the filter
element. Then the clean filter is installed on the filter and screw up the bolts of suction and return
filter.
8.5.3.5 Air filter replacement
The air filter is replaced by 500 hours. First remove the bolts of air filter and screw off the original
air filter. Then install the new air filter on the hydraulic tank, tighten the bolts of filter.
8.5.3.6 Oil quality inspection of hydraulic oil
The hydraulic oil is replaced by yearly or 2000 hours. The quality of hydraulic oil is inspected by
half year or 1000 hours to judge whether the hydraulic oil could be used or not. Refer to Table
8.5.3.7
8-36/59
Inspection of hydraulic oil quality Table 8.5.3.6
Inspection contents Store items Judgment Judgment method
In the engine startup condition,
Transparent Appearance get the sample of oil from the

The dust and metal powder
tube, new comparison hydraulic oil tank and hose and
are invaded from the outside
oil compare turbidity degree with the
new oil
Hydraulic oil tank become
opacified,, the bottom of the water
could be seen by heat slightly
opacifying sample. Get the
opacifying sample, insert the

Transparent
Appearance red-hot iron and send out the
tube and
Moisture comparison voice of splashed. The opacifying
container,
by heating oil drip onto the red-hot iron, the
new oil
voice of splashed will be also sent
out. In front of the engine
starting, screw off the oil drain
valve to get the sample to
observe the settlement of
moisture.
Get the oil sample from the
hydraulic oil tank or pipe. Pour
Transparent into the container, and compare

Appearance
Bad tube or the color and taste with new oil.
comparison
container The oxidation oil will become
dark brown, metamorphic oil will
have the smell of stink
8-37/59
¾ The cleanliness degree of hydraulic system will affect the service life of hydraulic
components, regularly inspect the hydraulic oil particles. If the particle is large and huge,
some hydraulic oil could be drained and replace new hydraulic oil.
¾ If the hydraulic oil is release from oil tank to find out metal powder, the operation of the
crane should be stopped and contact with the after-sales service engineer of manufacture to
inspect the damage of hydraulic pump and hydraulic motor. Then make sure the source of
the metal powder. Personally disassembly hydraulic pump and hydraulic motor is forbidden
¾ The water in the hydraulic oil tank should be discharged by monthly or 250 hours to avoid the
water working in high temperature. It will aggravate the emulsification of hydraulic oil
¾ Emulsification hydraulic oil should be replaced timely or influence the service life of hydraulic
components .It will lead to the damage of hydraulic parts.
8.5.4 Hydraulic system oil temperature
In order to improve the service life of hydraulic parts. During the operation of hydraulic system,
we need to pay attention to the temperature of oil and hydraulic components. The oil is varied
along with the temperature, meanwhile the viscosity is also varied. If the hydraulic temperature is
too low( below -25℃),the liquidity becomes worse. If the urgent operation is adopted at this time,
it will lead to the damage of hydraulic and suction air of hydraulic pump. If the temperature is too
high (above 80℃), the damage of the hydraulic oil become quickly and the speed of hydraulic oil
degradation becomes fast. If the abrasion of hydraulic parts become severe, the damage of the
hydraulic filter become quickly. So it will influence the service life of hydraulic elements. When
star up the engine in cold environment, the pre-heating of the engine should be adopted. Timely
observing the cooler temperature. If the temperature is too high, the operation of the crane
should be stopped.
Temperature inspection of hydraulic system Table 8.5.4
Inspection
Inspection Method Judgment Purpose
contents
Hydraulic oil To find out the abnormal
temperature Engine 1000 r.p.m Normal phenomenon of hydraulic
8-38/59
Temperature system earlier and improve the
30℃-80℃ service life of hydraulic
components
5℃ higher than To find out the abnormal

Pump Touch, temperature
oil tank phenomenon of hydraulic
temperature gauge
temperature pump earlier
5℃ higher than To find out the abnormal

Motor Touch, temperature
oil tank phenomenon of motor earlier
temperature gauge
temperature
40℃-55℃
To find out the abnormal
Cooler Touch, temperature Normal
phenomenon of hydraulic
temperature gauge Temperature
system
8.5.5 Hydraulic pump and motor maintenance
8.5.5.1 Hydraulic pump maintenance
¾ Suction hose of hydraulic pump is in oil and air leakage condition, the hydraulic pump is
forbidden to use when starting up the engine. At this time, hydraulic pump will absorb huge
air. Hydraulic pump absorb oil less, the pump will send out much noise. The abrasion of
pump elements lead to the damage of hydraulic pump. Timely replace the broken hydraulic
pump suction hose.
¾ Relief valve and safety valve could not be adjusted personally. When the relief valve and
safety valve need to adjust, contact with the service department of OEM, or it will influence
the lifting capacity of the crane.
¾ To avoid the hydraulic pump to work in over-load condition for long time. It will damage the
hydraulic pump and hazard to crane.
¾ To avoid hydraulic pump to work in max. speed condition for long time, it will shorten the
service life of hydraulic pump.
¾ When the huge oil is leaked from hydraulic oil tank, the leakage month is needed to open and
insert the hydraulic oil to see the overflow of oil from hydraulic pump. To avoid the oil is less,
or it will lead to the damage of hydraulic pump.
¾ The filter of the hydraulic pump suction port is needed to replace periodically to ensure the
8-39/59
circulation of hydraulic pump, or it will influence the service life of hydraulic pump.
¾ The hydraulic pump could not be disassembly personally, having any question, contact with
the service department.
8.5.5.2 Hydraulic motor maintenance
¾ The hydraulic motor could be working in low speed condition for long time. When the motor
works in low speed, the flow of the hydraulic motor is also less. The hydraulic motor will
appear creeping phenomenon.
¾ When the huge oil is leaked from hydraulic oil tank, the leakage month is needed to open and
insert the hydraulic oil to see the overflow of oil from hydraulic motor. To avoid the oil is less,
or it will lead to the damage of hydraulic motor.
¾ The hydraulic hose connecting with hydraulic motor could not appearance any leakage points.
The air sneak into the oil in the hydraulic motor, which will lead to the damage of hydraulic
motor.
¾ To avoid the hydraulic motor to work in over-load condition for long time. It will damage the
hydraulic motor and hazard to crane.
¾ The quick joint connecting with hydraulic motor to avoid to lead to less hydraulic oil to
damage the hydraulic motor.
¾ The hydraulic motor could not be disassemble personally, having any question, contact with
the service department.

8.5.6 The tighten torque sheet for hydraulic piping
The hydraulic hose in the hydraulic system is needed to tighten the torque of hose and hose
joints by quarter or 500 hours to reduce the leakage oil due to the shake. The tighten torque of
hydraulic piping taken as piping tighten moment Table 8.5.6. when exceeding the torque
tightness listed above, and the seal of pipe joint will be deformation, especially when tighten the
casting parts, cracks may be easily appeared, pay more attentions.
8-40/59
Hydraulic piping tighten torque Table 8.5.6
Diameter 1/8″ 1/4″ 3/8″ 1/2″ 3/4″ 1″ 1¼″ 1½″
Hose joint ,pipe

thread(High － 50 70 95 180 210 350 550
Tighten
pressure)
torque
Pipe
N.M
thread( Low 15 20 30 50 70 110 160 200
pressure)
8.5.7 Pressure test of hydraulic system

When the hydraulic system malfunction, it could be judged by pressure test. Prepare related tools
to test the hydraulic components, namely to understand the using condition of hydraulic
components.
8.5.7.1 Pressure test of hydraulic pump
Fig 8.5.7.1
1.Test port screw plug 2. Pressure test coupler (joint dimension 9/16-18UNF-2B )
3. Pressure gauge (range 400Bar) 4. Main pump
For testing the main pump pressure test, prepare two pressure gauge (rang:400bar)and two
pressure test couplers (joint dimension 9/16-18UNF-2B ). Remove the plug( No.1) and screw up
the pressure test coupler( No.2).Then open the thread cap on the pressure test coupler and
8-41/59
connect the pressure gauge port with pressure test coupler. According to requirement to test
pressure. After finishing pressure test, screw up the plug (No.1) on the hydraulic pump.
8.5.7.2 Pressure test for hoisting hydraulic motor
8.5.7.2
Fig 8.5.7.2
1.Pressure test coupler 2. Pressure gauge( range:400Bar) 3. Main hoist 4. Aux. hoist
For the hydraulic motor test, prepare two gauge( range:400 Bar)and open thread cap on the test
joint( No.1).Connect the gauge port(No.2) with the pressure test coupler. According to
requirement to test the pressure, screw up the thread cap on the pressure joint after finishing the
pressure test.
8.5.7.3 Pressure test for derricking hydraulic motor
8.5.7.3
Fig 8.5.7.3
8-42/59
1.Pressure test coupler 2.Pressure gauge(range:400Bar) 3. Derricking
For the derricking pressure test, prepare two gauge( range:400 Bar)and open thread cap on the
test joint( No.1).Connect the gauge port(No.2) with the pressure test coupler. According to
pressure test.
8.5.7.4 Pressure test for traveling hydraulic motor
Fig 8.5.7.4
1.Pressure test coupler 2. Pressure gauge(range:400Bar)
For the traveling hydraulic pressure test, prepare two gauge( range:400 Bar)and open thread cap
on the test joint( No.1).Connect the gauge port(No.2) with the pressure test coupler. According to
pressure test.
8-43/59
8.5.7.5 Pressure test for slewing hydraulic
8.5.7.5
Fig 8.5.7.5
1.Pressure test coupler 2. Pressure gauge (range: 400Bar) 3. Slewing pump
For the hydraulic motor pressure test, prepare two gauge( range:400 Bar)and open thread cap
on the test joint( No.1).Connect the gauge port(No.2) with the pressure test coupler. According to
pressure test.
8.5.7.6 Pressure test for pilot
Fig 8.5.7.6
8-44/59
1.Pilot valve 2. Pressure test coupler 3.Pressure gauge(range:100Bar)
For the pilot hydraulic pressure test, prepare one gauge( range:100 Bar)and open thread cap on
the test joint( No.2).Connect the gauge port(No.3) with the pressure test coupler. According to
pressure test.
8.5.8 Hydraulic faults inspection
Troubles Reason analysis Remedy
Damage of hydraulic pump, no pressure Test main pump pressure and inspect
and no flow whether any flow

Leakage of system lead to the loss of Inspect whether the leakage of pressure
Non-hoisting
pressure
and weak Tighten main valve and no action of valve Inspect the switching of main valve
hoisting element element
Brake of reduction gear is whether closed Inspect the reduction gear brake pressure
Damage of hoisting motor and driving Inspect the driving pressure of hoisting
torque become less motor and damage of the motor
Damage of hydraulic pump, no pressure Test the main pump pressure and any flow
and flow
Leakage in system lead to loss of pressure Inspect whether to influence the leakage of
the pressure
Cannot lower Tighten main valve and no action of valve Inspect the switching of main valve
element element
Reduction gear brake is whether to open Inspect the reduction gear brake pressure
Damage of hoisting motor Inspect the damage of motor
Balance valve is whether to open Pilot pressure of control balance valve.
Abnormal Sound from reduction gear Inspect the damage of reduction gear
sound of Sound from motor Inspect the damage of motor
operating
winch
8-45/59
The slewing lock is not released Release slewing lock
Slewing reduction gear brake is closed Inspect the slewing brake pressure
Damage of slewing pump Inspect slewing pump pressure
Switching valve is whether to switch to Inspect the switching valve condition
slewing working condition

Cannot
slewing Damage of slewing control valve Inspect the pressure of slewing control
valve
Damage of slewing motor Inspect the pressure and leakage of
slewing motor
Decrease the capacity
Weak in Overload
slewing Leakage of slewing motor increases Inspect the leakage port of motor and
operation
replace slewing motor
Leakage of slewing system Test pressure and find out leakage point
Resistance of traveling increases Inspect the traveling device whether to
tighten
Rotary joint faults Inspect central slewing joint and replace it

No action on
traveling and Brake or brake valve faults of traveling Test the reduction gear brake pressure and
weak on reduction gear replace brake valve
traveling
The leakage of traveling motor become Inspect traveling motor port and switching
huge motor
Faults on hydraulic pump Inspect the pressure flow of hydraulic
pump
8-46/59
8.6 Electric components maintenance
8.6.1 Electric components maintenance time table
Electrical components maintenance time table 8.6.1
Interval No. Location Inspection point Inspection Remark
method
Daily or Performance
1 Moment limiter Inspect
every display
working 2 Battery Storage status Inspect
8hrs
3 Battery electrolyte Liquid level Inspect
Monthly Performance and

3 Each electric limit device Operate, inspect
or every normal use
working
250hrs
Every 4 Plug-in connector Slag Inspect

quarter or
Aging and
every 5 Naked wire Inspect
working abrasion
500hrs
Yearly or 6 Force sensor Abrasion and Inspect

every
crack
working
2000hrs
8-47/59
8.6.2 Battery maintenance
The battery is the power for starting the engine, the electric control system, lamps and auxiliary
electric devices. Its technical performance accords with “Lead and Acid Battery for Crane
GB5008-91” which issued by the People’s Republic of China. It is very important part for the
machine. So maintain the battery carefully and keep it in good condition.
8.6.2.1 Inspect level of battery electrolyte
1.Normal electrolyte level: 15mm~20mm above electrode plate. Add distilled water in case of
insufficient electrolyte.
2.Check liquid level from outside.
Clean the level gauge (Fig 8.6.2.1) with a piece of wet cloth and see through it. Make sure the
level is between U. L. and L. L. Add electrolyte when the level is lower than L. L. and screw on
plug after adding.
Danger
z Do not wipe battery with dry cloth, or it may make static electricity,
causing flame or explosion.
¾ Inconformity to this regulation may lead to serious personal injury or
death.
Attention
z Suck excessive electrolyte above max. level with an injector.
z Electrolyte must not be added to higher than stipulated scale, or excessive electrolyte will
leak, corroding battery.
z To counteract with sodium bicarbonate, flush it, or consult battery manufacturer.
8-48/59
8.6.2.2 Inspection of battery charging
The amount of charge can be measured by relative

density of electrolyte.
Normal relative density at 20 0C: 1.25-1.27
Recharge it when under 1.25.
If the battery doesn’t use for long time, please demount
it from the crane and keep it in cool, dry place.
8.6.2.3 Maintenance during using
¾ Maintenance for the battery for every 250 hours.
¾ Disconnect the circuit of the battery, when weld
is performed
¾ Check whether the terminals are tight to avoid striking
fire caused by terminal loose
¾ Keep surface or battery clean. Apply grease or vaseline
to battery to prevent rusting.
¾ Tighten the plug on the battery to prevent the acid spill.
¾ Check the level of electrolyte in each cell. Keep the
level up to 15mm-20mm above the plates.
Fill distilled water when the electrolyte level is
low due to the evaporation of the electrolyte.
¾ Do not fill electrolyte.
¾ Check the charging condition daily.
Check whether the indication of ammeter
which is in the cabin is normal.
Fig 8.6.2.1
Warning
z For the electrolyte is dilute sulfuric acid, to avoid contact with skin, eyes or clothes. If it is
touched with electrolyte, please flush or see doctor immediately.
z Wear a pair of goggles to protect eye from electrolyte.
z Do not get battery wire through short circuit.
z Inconformity to this regulation may lead to serious personal injury or death.
8-49/59
8.6.2.4 Storage and maintenance without operating
¾ The battery should be kept in clean, dry and the ventilation storeroom, the temperature
is ５℃－４０℃ when not using. It is should be stored without electrolyte. Under special
situations or after the battery discharges, it should versatility once a month, and every
three months have entire charge/discharge circle.
Attention
z Dismount from deck and store the battery at cool and dry place but no lower than 00C
if it is idling for long.
z Take down wires off battery terminals to prevent discharge.
¾ Don’t confect the electrolyte with the water, well water and impurity water.
¾ When not use the battery on the crane, remove the joint of one side, and check it once a
month, charge it in time, and use it after charging.
¾ The electrolyte contains vitiriol, which is corrosive for one’s skin, eyes, and clothes, so
prevent it from spilling out. Take the following measures when accidents happen.
A. Wash immediately after touching exterior.

B. Gargle after it enters mouth, and drink some water or milk, then seek for medical treatment .
¾ There is some flammable gas in the battery, so keep the exhaust hole ventilation, protect it
away from fire when use or storage, to prevent it from explosive.
8.7 Notes for maintenance and inspection

¾ The crane will abrasion and some connections will be loosen after long-time using. So right
repair and adjustment can prolong crane's use life, preventive maintenance should be done
in order to ensure the crane to be in good condition. Inspection, maintenance and service is
very imperative job, especially work in bad weather, the following notes must be taken.
¾ When the weather is fine, please inspect it on the firm and level ground.
¾ Don’t inspect and adjust with load. The engine must be shut down and without load, please
hang brand "under maintenance" over the door of cab
¾ Use clean lubricating grease to be kept in the room and never get dust and water into vessel.
¾ Keep crane clean for checking oil leakage, flaw, or connecting piece is loose or not,
especially try to keep grease fitting, venthole as well as oil fitting clean in case dust in.
¾ When perform inspection and maintenance, please set up “Maintaining, no startup” on the
switch of keys.
¾ Please put the rubbish with oil or other flammable materials to the safety place.
¾ Grasp the storage place and using method of the fire extinguisher.
¾ Pay attention to rotational parts, it's dangerous to be entangled when inspecting fan belt or
8-50/59
water pump and inspection should be performed after stopping the engine.
Notes for welding
¾ Power off (position switch to "OFF"), cut off electric battery's power line（+,-） and pull out
connecting line of engine. Don't bring to bear voltage exceeding over 200V continuously.
Grounding is set up within the 1 meter range of welding point. No seal or bearing between
welding point and grounding point. When welding close to moment limiter, limiter need to be
dismantled in case being damaged.
¾ The pump, valve ,motor and cylinder or some hydraulic components are not allowed to be
disassembled.
¾ It is better to inspect and maintenance the hydraulic components in the clean place
¾ Pay attention to water temperature or oil temperature, it's dangerous to infuse water, oil or
replace filter element when stopping engine just now, the work above can be done after
temperature is cooling down. However, temperature up to 200C-500C is a suitable range for
infusing oil if oil temperature is too low.
¾ Dispose of scrap oil by industry drainage and put it into vessel
¾ Inspect the waste oil and filter
¾ When replace oil and filter, check there is any metal filings or sundries. If finding out metal
fillings or any sundries, judge whether the pump, motor or valve has been damaged. If so,
the crane could not be worked, maintenance should be done.
¾ Prevention for invasion of dusty.
¾ Hydraulic oil pipe and hydraulic element dismantled must use jam or sealing cover to protect
in order to prevent dust from going into.
¾ Clean integration surface, when dismantling O-ring or other washer, sealing piece needs to
clean or replace new one and daub a layer of thin oil on the sealing piece when reassembly.
¾ Pay attention to inner pressure and dismantle it in advance when dismantling the pipeline,
joint or other relevant spare parts such as hydraulic system, compressive air system and fuel
system.
¾ Precaution for cleaning the machine. Don’t spurt water to the electric components and joints
8.8 Inspection and maintenance at special working condition

8.8.1 Rain and snow operation
Before operation: Check kinds of stuffs, bolts for loosen; make sure actions of clutch and brake
After operation：cleaning crane, check bolts and nuts for loosen, falling off. And fill oil, lubrication.
8.8.2 Seashore operation
Before operation: Check kinds of stuffs, bolts for loosen，add the grease to the rusted ones,
especially the control lever and link rod.
After operation: clean up the salt on the crane thoroughly, and add grease to the rusted parts.
8-51/59
Maintain the electric components carefully to prevent it rust.
8.8.3 Dusty environment
Air filter：Clean the filter element and dust collector in advance
Fuel device：Clean the spare parts of filter ahead of time
Electric components：Clean the startup machine and sensor interface carefully.

8.8.4 Stone environment
Generally, the crawler tension is loosen sometimes, beware of damages, cracks, abrasion and
scars on the traveling device, check bolts and nuts for loosen, falling off.
8.8.5 Rockfall site
The cab should be installed shield.
8.8.6 Cold area
Use good quality and low viscid lubrication oil. Charge the battery before working.
The hydraulic oil movement of viscosity is very sensitive to temperature.
The lower the temperature, the greater the viscosity. The liquidity of oil is poor. When it is
worked in cold area (below minus 25 degree ) , pay attention to the cold start-up of the crane.
Before or after the engine start up, the preheating is needed. Replace hydraulic oil for low
temperature.
8.8.7 Other working environment
For the installing parts of A-frame, tensioner, working equipments are different, and so as its
abrasion degrees. During daily inspection, check the abrasion of pulleys and replace in time.
When maintain and install the lower guiding pulley, exchange direction can prolong guide track’s
servicing life.
8.9 Machine storage and use
8.9.1 Storage
8.9.1 Short term storage
¾ Clean: clean the machine and inspect the traveling device
¾ Lubrication: Lubricate the spare parts on the easy corrosion
¾ Battery: Charge the battery and remove the terminal
¾ Dust prevention, moistureproof: Fully drain the cooling water, put the non-water sign, cover
the moisture proof sealer on the engine
¾ Tool: Counting the tools and store.
8-52/59
8.9.2 Long term storage
If the machine is stored for long time(more than two weeks), the following work is need to be
done.
¾ Clean: clean the machine and inspect the traveling device
¾ Lubrication: Lubricate the spare parts on the easy corrosion
¾ Battery: Charge the battery and remove the terminal
¾ Dust prevention, moistureproof: Fully drain the cooling water, put the non-water sign, cover
the moisture proof sealer on the engine
¾ Tool: Counting the tools and store.
¾ Lock: All the handles move to the neutral position and lower the lock device. Then fasten the
pawl.
¾ Boom: Put the boom frame on the ground.
¾ Periodical lubrication running: the crane should operate in low speed with no load monthly,
this is in order to prevent abrasion from membrane damages or rust during the next actual
running, in addition, please notice the temperature changes of cylinder cover.
a. Lubricate running is that the continuous movements of traveling, swing and hoisting after the
crane warms up.
b. Beware of lubricant quality during the crane is running again. For the lubricant is easy to
deteriorated due to lack of running.
c. After long term shut down, the oil of main pump, motor shell body will leak out through the
working pipeline (or replace the main pump, motor), and fill the hydraulic oil to the shell body
when the crane restarts. If any abnormal, stop operation and contact with manufacturer service
department.
8.9.2 Use after store

The crane resume to use after store for long time, following work should be done.
8.9.2.1 Use after short term storage
¾ Clean the whole crane, keep it dry and lubricate all.
¾ Inspect the level of hydraulic oil tank, inspect any oil leakage, inspect abrasion and crack of
hydraulic hose.
8-53/59
¾ Inspect whether suction filter, return filter and pilot filter have any sundries
¾ Inspect the volume of reducer gear oil
¾ Inspect charging of battery
¾ Inspect whether the engine cooling liquid is enough.
8.9.2.2 Use after long-term storage
¾ Clean the crane wholly, and check the travel device for any abnormal. Wipe the lubrication
on the corrosive parts.
¾ Lubricate the swing gear carefully.
¾ Replace the gear oil and hydraulic oil.
¾ Replace all the filter cores.
¾ Install battery and charge the battery
¾ Lubricate the parts with easy rusted.
¾ Add cooling liquid to engine
¾ Cover the crane to prevent dusty and moisture
¾ Lubricate running: the crane should operate in low speed with no load monthly, this is in
order to prevent abrasion from membrane damages or rust during the next actual running, in
addition, please notice the temperature changes of cylinder cover.
When reusing the machine:
¾ Point check each point. Refill the engine oil, water when it is not sufficient. Especially, take
notice the water volume of cooling water tank. The lubricating engine oil will deteroprate
during storage, so please pay special attentions.
¾ Remove off the rust-proof oil wholly.
¾ Fully crane warming running after the engine starts up, point check each basic operation
performance.
8-54/59
8.10 Painting repairing
When the crane is under transportation, installation, testing and disassembly, will cause the paint
layer falling off. If not repair in time, the corrosive parts will extend, which will affect the outer
quality, moreover, it jeopardy some structure parts. If the stay bar, boom and other parts rusted,
will cause accidents. So in order to prevent that happening, please repair after the damage are
found and take the following measures:
8.10.1 Paint selection
Our company applies bi-component paint as paint coating material, which is compriser of paint
solidifying agent and thinner, expoxy polyamide as priming paint,expoxy polyamide or
polyurethane as mid layer, aliphatic acrylic polyurethane as finish paint. Only use premium paint.
During the paint repairing, the quality of the painting should be guaranteed.
8.10.2 Paint confection
Before confection, it is important to know the approximate volume of paint to be consumed so as
not to confect more than needed. Confecting agents must apply particular solidifying agent and
thinner that are produced by the same manufacturer. When confecting, give paint a stir to even it
first and add solidifying agent strictly according to the proportion provided by paint manufacturer;
give another stir to the mixture and add thinner according to work requirement on viscosity; stir
once more; place it stilly for 15~20 minutes; then it can be used through filter. Filtering
requirements: 80 mesh/inch2 strainer for priming paint, 120 mesh/inch2 strainer for finish paint.
The paint must be used up within 4 hours after confected, no more time permitted.
8.10.3 Requirements on surface treatment
This step is very important: completely remove the rust off the area uncoated by paint (to Sa2.5
level or St3 level) to make a clean surface without oil, rust, dirt, acid, alkali or water. Meanwhile,
completely peel off the unstuck old paint along the edge of naked area; rub the edge of old
coating with 320~400 abrasive paper to make a 5 mm wide bevel; scrub dirt and dust off the
naked area with a piece of cotton yarn (special-used sticky cloth recommended) containing
thinner (or 120 # gasoline); wait till it is dried and spray paint
Note: there are some machines with the words “removable protective layer” sprayed on the
surface. It is necessary to remove this layer around naked area prior to repainting work.
1. Remove the layer with ethanol cotton yarn
2. Scratch open the layer with finger nail and tear it off with adhesive tape clinging to it.
8-55/59
8.10.4 Paint coating repair
For the area requiring low decoration standard, this method can be applied called “wet-on-wet
brush painting”: paint priming paint twice (dry coating 60-70 micron thick); half an hour later paint
mid layer paint twice (dry coating 50~60 micron thick); 1~2 hours later, paint finish paint 2 or 3
times (dry coating 50-70 micron thick). The repainted surface must be even and flat without grain
or obvious brushing trace.
Note: lower viscosity of paint for more unobvious brushing trace.
For the area requiring high decoration standard, spray painting should be applied to mend naked
area: spray priming paint twice on well-treated surface. Wait till it is dried and spray mid layer
paint twice. After it has been dried, roughen the mid layer paint and original paint coating around
spoiled area by softly rubbing with 400# abrasive paper, thus increasing adhesion (the more
grained, the better). After that, spray finish paint two or three times (thickness as above). Remove
fogy paint dispersed beyond the target painting area with water in 10 minutes after painting work
or by erasing it with 2000# abrasive paper (with proper strength, or too much may penetrate paint
coating). Then carry out G3 polishing wax treatment. The new paint is required to polish brightly
and be flat with similar color to original paint, no dripping, grain, mixed color or color difference
permitted.
Note: in case of tight schedule, it is feasible to spray finish paint on the dry area with mid layer
paint, which has been burnished by watered 400-600# abrasive paper after mid layer paint is
dried for three hours, thus shortening the time for drying and weakening polishing trace due to
insufficient hardness.
Attention:
(1) Raw surface treatment is the basis for painting work, which must be carried out in accordance
with work requirements to ensure paint coating quality.
(2) Paint repair should be done in time and to the full. It is forbidden to directly spray finish paint
without spraying priming paint and mid layer paint.
(3) No painting work in windy, rainy or snowy day.
(4) Work environment temperature and interface temperature: 10---30℃
(5)Distance between sprayer and target area: 25-30 cm.
(6) Nozzle diameter: 1.2-1.5 mm; spraying pressure: 3-5kg/cm2
(7) Make precise solidifying agent proportion in confection to ensure coating quality.
(8) Use up the confected paint within four hours or it will solidify or decrease in activeness,
affecting coating quality.
(9) Polish finish paint completely dried
(10) Keep fire source away from painting site
(11) Painter must abrasion anti-poison gauze mask and labor prote
8-56/59
Attachment 1:Tools List
GB/T5356 Inner hexagon spanner (4-19) (9 pieces) 1

GB/T4388 Double end wrench (8-36) (15 pieces) 1
GB/T4388 Double end wrench 41×46 1
GB/T4388 Single end wrench 55 1
GB/T4388 Single end wrench 50 1
GB/T3390 Socket wrench (32 pieces) 1
GB/T4440 Spanner 300 1
II 号锉纹 File 8" 1
0-1983 Tool box 22” 1
GB10693-89 Hammer 18 pound 1
GB10693-89 Hand Hammer 2 pound 1
GB6295.1-86 Combination plier 200 1
GB10639-89 screwdriver 300 1
GB10639-89 screwdriver 150 1
GB10640-89 Cross screwdriver 150 1
WT1-0-3 Oil pot (1kg) 1
WT1-0-124 Crowbar 800×25 1
(S6)BW8.5-1 Shackle 2
W01-03 Nylon belt 6m 1
WAF26 Sling rope 8m 2 Only for export
HJS20B-150 Jack 1
DY-451 Grease nipple 400cc 1
Tools for disassembling the winch fixed
F82GJ-1 shaft 1
F82GJ-2 Self-assembly slings 1
For holding
Lifting rope φ8×40m 1 luffing jib
F82GJ-4 Spindle 4 Only for export
HPS70-2 Manual hydraulic pump station 1
F82GJ-3 Linking plate 2 Only for export
Self-with diesel
FWX85MTOOLS Diesel engine attachment tools 1 engine
8-57/59
Attachment 2
Wire rope inspection record 1
Crane model: Wire rope

Data for wire rope: Install date：
Twist direction: Right/Left Retirement date
Twist direction: Interaction/ Direction
Diameter(mm) Min broken pull
Tensile Strength Rated capacity
Surface disposal: glaze/galvanization
Rope core type: steel/natural or synthetic Measured Diameter

fiber/mix
Wire rope type Load:

Wire rope length (m)
Linking type of wire rope
8-58/59
Wire rope inspection record 2
Broken wires of wire Abrasion Corrosion Decrease Wire rope Lengt Overall Damage
rope of wire diameter h of evaluatio and
rope meas n deformati
ure on
No.(6d) No.(30d) Damage Corrosion Actual scaled- point Damage Type and
degree degree diameter down degree level
percent
Date Signature
Manufacture of wire rope Working hours
Notes Scrap reasons
8-59/59
Chapter 9 Technical Data
9.1 Main technical data
Item Unit Data
Max. rated lifting capacity t 85
Boom length m 13～58
Jib length m 9～18
Boom+ jib max.length m 49+18
Boom+ luffing jib max.length m 45.7+36
Boom derricking angle º 30～90
Hooks t 85/50/25/9
※0～105
Hoist m/min
Wire rope speed
※0～105
Lower m/min
Working speed
※0～60
Boom hoist m/min
0～60
Boom lower m/min
Slewing speed r/min 0～2.5
Traveling speed km/h ※1.5
Main hoisting reevings 11 Single line pull 8t

Gradeability
% 30
(with basic boom, cab at rear)
209/2000(imported)
Diesel engine rated output power/Rev. KW/r/min
194/2200（domestic）
Whole crane mass (with boom foot) t 80
Grounding pressure (with basic boom) MPa 0.073
Counterweight t 27.5
Note: speed with ※ changes with load.
9-1/25
9.2 Overall dimensions
9-2/25
9.3 Hydraulic system diagram
9.3.1 Main winch free-fall (domestic)
9-3/25
9.3.2 Non-free fall (domestic)
9-4/25
9.3.3 Double free-fall (Rexroth)
9-5/25
9.4 Electric system diagram and wiring diagram
9.4.1 Mechanical engine electric diagram
9-6/25
9.4.2 Electrical control engine
9-7/25
9.4.3 Controller
9-8/25
9.4.4 Winch pawl, free-fall working principle
9-9/25
9.4.5 Slewing, traveling, cylinder
9-10/25
9.4.6 Hirschmann moment limiter
9-11/25
9.4.7Auxiliary equipments
9-12/25
9.5 Load chart
9.5.1 Notes for load chart
1. The crane conforms to GB3811-standard, at the same time meet the ISO4302, ISO4305 ,
ISO4308 standard.
2. The value shown in the load chart is, on the level and firm ground, maximum allowable value
under ideal operating conditions.
3. Max rated total load is within 75% of tipping load.
4. When the applied load is between the loads in the chart, the larger load is preferred for safety
concern.
5．Working environment temperature is -20～+40℃, comparative humidity is less than 85%. It is
allowed to reach 100% when the time is short.
6. The actual lifting capacity should make the value in the load chart deduct the dead weight of the
hook.
7．When installed with jib, actual lifting capacity of boom is the value is Table 1 deduct the listed
weight below and main hook+ aux. hook’s weight.
Table 1
Jib length（m）９ 13.5 18
Deducted weight (kg) 750 1000 1300
8. The length of boom, which is equipped with jib, is 37~52m.
9. The balance counterweight is 27.5t.
10．When installed with runner, actual lifting capacity of boom is the value in Table 1 deduct the
runner (0.31t) and main hook+aux. hook weight.
Hook weight and hoisting wire rope reevings and max. value of rated load
Hook Reevings and max.lifting capacity (t)
Weight
blocks 11 10 9 8 7 6 5 4 3 2 1
85t 1.05t 85.0 80.0 72.0 64.0 56.0
50t 0.55t 48.0 40.0 32.0
25t 0.41t 24.0 16.0
9t 0.25t 8.0
9-13/25
9.5.2 Boom load chart
9-14/25
9.5.3 Runner load chart
9-15/25
9.5.4 Fixed jib load chart
9-16/25
9-17/25
9.5.5 Luffing jib load chart
9-18/25
9-19/25
9-20/25
9-21/25
9.6 Working range
9-22/25
9-23/25
9-24/25
9-25/25
Chapter 10 Appendix
10.1. Freefall operation
Under hook free-fall mode, after winch hoisting, and the hand grip is on neutral position,
open the clutch to make the drum and reduction gear disengage, quick free-fall operation is
ready, at this time, step on the free-fall valve, and disc brake is held, slightly uplift the pedal,
point brake dynamic controls the lowering speed of brake winch, and avoid the actions too
fast by person, to improve safety.
Fig 10.1
Main winch free-fall operation:
¾ Firstly make sure the main hoisting pawl switch (18.10.12) is on the release lock
position;
¾ Rotate the main winch free-fall switch (18.22.7) to A-direction, at the same time, step on
the main winch free-fall pedal (18.14), to make pedal limit switch touch off, at this time,
10-1/6
the free-fall buzzer (18.22.3) starts to buzzer caution, to indicate that start the free-fall
function;
¾ Slowly uplift the main winch free-fall pedal (18.14), to make it disengage with limit
switch, and adjust the speed of free fall;
¾ After operation, rotate the main winch free-fall switch (18.22.7) to B direction, at the
same time, step on the main winch free fall pedal (18.14), to make the pedal limit switch
touch off, at this time, free-fall buzzer (18.22.3) stops buzzer caution, and indicate that
exit the main winch free fall function.
Aux. winch free-fall operation:
¾ Firstly make sure the aux. hoisting pawl switch (18.10.7) is on the release lock position;
¾ Rotate the aux. winch free-fall switch (18.22.8) to C-direction, at the same time, step on
the aux. winch free-fall pedal (18.17), to make pedal limit switch touch off, at this time,
the free-fall buzzer (18.22.3) starts to buzzer caution, to indicate that start the free-fall
function;
¾ Slowly uplift the main winch free-fall pedal (18.17), to make it disengage with limit
switch, and adjust the speed of free fall;
¾ After operation, rotate the aux. winch free-fall switch (18.22.8) to D direction, at the
same time, step on the aux. winch free fall pedal (18.17), to make the pedal limit switch
touch off, at this time, free-fall buzzer (18.22.3) stops buzzer caution, and indicate that
exit the aux. winch free fall function.
10.2 Hoisting pawl locking operation
¾ When lifting the load for long time, to maintain or safety transport, and the main, aux.
hoist devices have been set with pawl drum locking device, the structure is shown as
below:
10-2/6
Fig 10.2
Table 10.2
No. Name Remark
A Pawl locking position
B Pawl disengage position
¾ Before main, aux. hoisting winch starts to operate, press the right control box switch
main hoisting pawl switch (18.10.12), aux. hoisting pawl switch (18.10.7) down as
shown in Fig 3.2.3.2a, make the switch to the position that open the lock, and main/aux.
drum pawl disengage under B status, to enter into normal working status.
¾ When the system stops working, put above switches to locking position, and main/aux.
drum pawl locking is under A status, then pawls will be locked.
10.3 Maintenance of caliper brake
The environmental temperature for using caliper brake is -40℃-- +50℃, and the flammable,
explosive, corrosive gas cannot exit in surrounding working environment, the relative
humidity of air cannot be more than 90%.
10-3/6
10.3.1 Precautions
Take following inspections before installing the brake:
1. Check the brake if damage during transportation.
2. Check the brake installation frame
a. The installation surface should be clean and with no grease.
b. The center of installation surface should be superposition with the center of brake center.
3. Check the brake disc
a. The plane of brake disc’s both ends is less than 0.1mm.
b. The end flop of brake disc end is less than 0.2mm.
10.3.2 Installation
1. Put the two half brake on the installation frame.
2. Keep the brake at suitable position, put the fixed bolt to its installation hole. (note: the min.
grade of linking bolt must be equal to 10.9 grade)
3. Tighten the nut, don’t forget to add anti-loosen washer, tighten it by moment spanner.
4. Connect the hydraulic pipeline, the exhaust port stays the opposite of pressure hole, if the
if installation is permitted, and please try to make the exhaust port to up.
10.3.3 Adjustment
1. After installing the brake on the installation frame, and need to be filled and purify the
hydraulic cylinder.
2. Remove the protective cap of exhaust joint, connect the exhaust hose with locked nut and
exhaust joint, and the other end enters into other containers,
3. Get the pressure oil through brake.
4. After purify the hydraulic cylinder and exhaust the gas, remove the exhaust hose with
locked nut, and install the protective cap to exhaust joint again.
5. After exhaust, continuously brake some times, to match the friction piece, and make the
brake moment reach rated value.
10.3.4 Maintenance
Check and make sure the brake is under non-pressure status.
1. Replacement of friction piece
1.1 Check and make sure the piston is on the “loose brake” position. (confirm and make
10-4/6
sure the friction piece is also on the “loose brake” position); when the friction piece cannot
be assembled/disassemble caused by the limit of brake installation position, and dismantle
the brake from its brake frame. (note: the brake and hydraulic station is disconnected)
1.2. After loosing the nut, and dismantle the stay rod, then loose the bolt and press plate,
and dismantle them (as shown below)
1.3 Remove the friction mat, and replace it with new one.
1.4 Install the stay rod and nut, reposition the press plate and install the bolt
1.5 Adjust the spring’s compression position (as shown below)
1.6 Re-adjust the brake after replacement.
2. Replacement of oil seal parts (operate by professional personnel)
2.1 Remove the brake from brake frame (brake and hydraulic station is disconnected)
2.2 Remove the friction piece.
2.3 Dismantle the piston from the shell body.
2.4 Replace the seal device’s each piston.
2.5 Re-install the piston, check and make sure they are on the correct position of shell body.
2.6 Re-install the friction piece and its attachments,
2.7 Install the press plate and tighten, after completion, adjust the position of spring
compression. (as shown below)
2.8 Re-install the brake to the brake frame, and adjust the brake.
10.3.5 Maintenance
1. Check the thickness of friction piece periodically, when the friction material only left
1-2mm, replace the friction piece in time, to avoid brake disc damages due to friction
materials abrasion totally.
2. Check each linking bolt periodically, to avoid loosen and safety accidents happen.
3. Check the oil pipe joints periodically, to avoid leakage.
10.3.6 Fault analyses
1. Brake moment is not enough, brake no action or action slow.
2. Check both sides baffle plates if interfere with the friction piece.
b. Check the stay rod of friction piece if deformation or improperly installed, in order to
interfere with the installation hole.
10-5/6
2. Brake oil leakage
a. Joint oil leakage, re-connector or tighten the joint.
b. Oil leakage behind the friction piece, check or replace the oil seal.
If above steps cannot reach the expected requirements, please contact our after-sales.
10.3.7 Overall and installation diagram as shown below:
10-6/6

FWX85 Operation Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FWX85 Operation Manual

Uploaded by

Copyright:

Available Formats

FWX85M

Hydraulic Crawler Crane

FUWA HEAVY INDUSTRY CO.,LTD.

FUWA Heavy Industry Co.,Ltd

which is the integration of our centuries’ manufacturing experiences and foreign

safe operation and improvement of working efficiency.

z When ordering the parts, please refers to “Parts Manual.”

z Please obey local regulations when using this machine.

z Operate, check and maintain carefully, keep safety first always.

safety operations in this manual.

z If the crane needs to reconstruct, contact us immediately.

our company will be free to repair during the guarantee period.

selecting the parts.

within these instructions.

FUWA Heavy Industry Co.,Ltd.

Add: No.2 ShuangYang Road, Shuncheng District, Fushun Liaoning, China

If any unclear, please tell us the serial No. of crane firstly.

1.3 Crane’s direction

1. Working environment temperature is -20～+40℃, comparative humidity is less than 85%. It is

allowed to reach 100% when the time is short.

2. The machine can work normally under altitude 1000m.

speed) is more than above.

4. Ground is firm and flat, ground inclination is ≦1%.

Working level is A1; working conditions:

Hoist: M5 Derricking: M2 Slew: M2 Travel: M1

as “danger”, “warning”, “caution”, its meaning is as follows.

Icons symbol Meanings

Indicates an imminently hazardous situation which, if not

avoided , will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided

could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury.

5.Time limit of use

z Hoist quantities is about 5-10 times every day.

Note: above data only for reference.

¾ Signs need to be clean, and to be put in marked position.

Meanings Paste position

1. Read the operation manual carefully

2. Pay attention to locking safety devices.

3. Attention to electrical wire, to keep safe

4.Avoid finger injury when opening

5.Statement by the provisions of

operation to prevent tipping

6.Please shut down the engine

and pull the key out before the

7. Ensure to lock the cylinder

device.(this sign is used for

telescopic crawler crane)

when assemble or disassemble

the boom pins.

9. No standing under boom

10. Beware of falling off from high.

11. Be careful the high pressure

12. Pay attention to hot surface.

13. Avoid finger injury when

opening or closing the door.

14. Do not make your hands into

extrusion area of spare parts in

case accidents happened.

caused by jack up.

16. Operate slowly.

18. Please keep safe distance with

the crane in order to avoided