（英）Scc500d使用说明书（力士乐带自由落钩）发新西兰

SCC500D Hydraulic Crawler Crane
Operation Instructions
SCC500D-O＆M
(08CC05140048)
Shanghai Sany Science & Technology Co., Ltd.

AUG. 2008
Operation Instructions for SCC500D Hydraulic Crawler Crane
Preface
Dear Customers,
Hello! Shanghai Sany Science & Technology Co., Ltd. will sincerely welcome you to
become a member of the SCC series of hydraulic crawler cranes! We will provide you a
“First-class Product, First-class Quality, and First-class Service” with all my heart.
Adopted the latest foreign technologies and combined with China's own national
conditions, SCC500D hydraulic crawler cranes is a full hydraulic crawler crane with own
intellectual property rights researched and developed by Shanghai Sany Science &
Technology Co., Ltd. In order to make you a comprehensive and systemic understanding of
the structure, characteristics, performance and parameters of the SCC500D hydraulic
crawler cranes, we will provide you a series random file including operation instructions.
In order to ensure a normal operation of the machine, give full play to their best
performance and extend the service life, as well as the personal safety of you and others,
please carefully read in detail about the operation instructions, maintenance manuals and
other random files prior to any operation, moreover, always do everything according to the
requirements of the operation instructions, maintenance manuals and other random files.
Thank you again for the trust. We will adhere to the ideas of “Everything for the
customer, All resource from the innovation” to develop and improve our products. In the
meantime, any modifications for the designs and parameters will not be notified! For
questions, please contact us!
Shanghai Sany Science & Technology Co., Ltd.
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SCC500D Crawler Crane

Operation Practice
Dear Customers,
This crane is used for hook block type installation and loading &
unloading. Any operating condition such as grab, dragline, heavy
tamping, electromagnetic lifter, etc. is strictly prohibited.
Operating level of the crane is A3W.
Mechanism operating levels are respectively lifting M4, luffing M4,
swing M3 and travel M2.
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Table of Contents
Preface·······································································································1
I. Safe Operating Rules···············································································5
II. Main Technical Parameters and Dimensions············································11
Rated Load ··············································································································11
Job Scope·················································································································14
2.3 Dimensions ········································································································18
III. Operations·····························································································19
3.1 Attention Points for New Machines ···································································19
3.2 Inspection before Operation···············································································19
3.3 Configurations of the Control handle, Instrument and Button·························20
3.4 Engine Control···································································································22
3.5 Operation of the Main Lifting Mechanism·························································24
3.6 Luffing Operation of the Jib···············································································26
3.7 Swing Control and Swing Stopping ···································································27
3.8 Sub-lifting Operation ·························································································29
3.9 Travel Operation ································································································29
3.10 Telescopic Operation of Crawler······································································30
3.11 Braking and Locking of Hoisting Drum···························································33
3.12 Braking and Locking of Luffing Drum ····························································34
3.13 Swing Braking and Locking ············································································34
3.14 Travel Braking ·································································································35
3.15 Attention Points of Boom Operation ································································35
3.16 Installation Attention Points of the Lift Arm and Drop Arm of 52m Main
Operation Boom ······································································································37
3.17 Work and Operation of the Safety Device ·······················································38
3.18 Intelligentized and Humanization Design ························································42
IV. Disassembly and Assembly of the Boom ················································43
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4.1 Assembly of the Boom Base ··············································································43

4.2 Disassembly of the Basic Boom ········································································45
4.3 Assembly of Boom inserts and Jibs····································································46
V. Compositions of the Main Boom and Jibs················································47
5.1 Composition of the Main Boom·········································································47
5.2 Composition of the Jibs ·····················································································49
5.3 Installation Position of the Sub-streching Wire ··················································50
VI. Lifting of the A-frame Support ·······························································51
6.1 Dropping down Operation of the A-frame Support············································51
6.2 Hoisting Operation of the A-frame Support ·······················································52
6.3 Attention Points in the Process of A-frame Lifting ············································53
VII. Wire Cable·····························································································53
7.1 Composition of the Wire Cable··········································································53
7.2 Unfasten of the Wire Cable················································································53
7.3 Installation of the Wire Cable to Drum ······························································54
7.4 Replacement of the Wire Cable··········································································55
7.5 Examination Standards of Wire Cable Scraping ················································56
7.6 Winding Methods of the Wire Cable··································································57
7.7 Selections for the Size of Wire Cable·································································58
VIII. Structure and Hydraulic Pressure Electrical System ····························60
8.1 Structure ············································································································60
8.2 Hydraulic Pressure System ················································································60
8.3 Electrical System ·······························································································60
IX. Transportation and Hoisting ···································································66
9.1 Trailer Transportation ························································································66
9.2 Overall Dimension of Disassembled Transportation ··········································67
9.3 Transportation Plan ····························································································67
9.4 Hoisting Plan ·····································································································67
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I. Safe Operating Rules

● Neat overalls should be put on, and protection equipments (footwares, safety helmets,
etc.) should also be taken with.
● Pre-examination for cranes: check for the load moment indicators, anti-overwind device
of hook block, 78° caging device of jib, and operation should be started if all these
devices are fault-free.
● To extend the life of machines, preheating running must be carried out before operation.
Fig. 1-1
● Operations must be carried out within a radius of the rated load, or otherwise dangers
may occur if overloaded (Figure 1-2).
Fig. 1-2
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● Operations on condition that the A-frame is lowered down are prohibited. (Figure 1-3)
Fig. 1-3
● Side towing from the crane is prohibited. (Figure 1-4)
Fig. 1-4
● Handling radius should not exceed 34m on condition that the jib is very long (more than
43m). The angle of jib only can be in the range of 30~78° for all circumstances.
Fig. 1-5
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● 70% of rated load travel is allowed, the conditions of which are: hard ground, slope
within 1°, 0.5m height above ground of the weights, front direction of the boom, locked
position of the hoisting pawl. 100% of rated load is allowed in special circumstances.
Loading travel on soft ground, slope of 1° above or installed with jibs are prohibited.
Fig. 1-6
● Increase of balance weight and decrease of multiplying power operation of wire cable
are prohibited.
Fig. 1-7
● A considerable distance should be provided in the vicinity of electric wires (Table 1),
and the operation should be done according to relevant standards of electric power
department.
7
Fig. 1-8
Table 1 Minimum Distance between the Transmission Lines and Jib
Voltage of the Transmission Line (KV) ＜1 1-35 ≥60
Minimum Distance (m) 1.5 3 0.01(V-50)+3
● Machines should stop on hard ground. In case of soft ground, it should be appropriately
hardened. Operations should not close to the edge of a cliff or on a soft shoulder, and
road surface guide staff is needed.
Fig. 1-9
● Drastic operation should be avoided when dropping down the main boom. When the
wire cable lifting device is installed at the boom base, the boom tip should not leave the
ground, or otherwise, the ear board of boom base may be damaged.
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Fig. 1-10
● Crane with the same lift capacities should be used when there are two cranes working at
the same time. When operation, the crane should at a low-speed and make the weight
leveled, meanwhile, swing lock should also be made.
Fig. 1-11
● Before the driver leaving the cab, they should put the heavy load onto the ground, put
every the handle (pole) at the meso-position, make all the pawl devices locked, and shut
down the engine. When the driver will leave the cab for a short time, they should
release all the switches (ON state).
Fig. 1-12
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● When using wire cable coupling sleeve, anti-loosing treatment should be made on the
end of wire cable by twine retainers.
Fig. 1-13
● Routine inspections and maintenances should be carried out on flat ground. If it must be
repaired on the slope, the machine should be fixed and swing locked.
Fig. 1-14
● In case of great windy weather, operation should be carefully carried out. As

circumstances permit, short arm should be used. When the wind speed have reached
13.8m/s (equivalent to 6 wind level), operations should be stopped.
● For body equipped with two balance weights, forward climbing and retreating of
crawlers are prohibited.
● Generally, if the maximum or minimum temperature is only a few days in a year, then
the allowed the temperature of crane should be between -25 ° C +40 ° C
● Operations should be carried out in a relatively high/low humidity of the air.
● Full load operation can be carried out at the altitude of 1,000 meters; No dangerous is
existed when operating at an altitude of 2,000 meters.
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● The following level of noise may occur in the vicinity of upper structure operator's seat:
85 db – engine’s maximum number of turns is 2200r/min when there is without loading.
II. Main Technical Parameters and Dimensions

Table 2.1 Main Technical Parameter of the Complete Appliance
Technical Parameters Unit Numerical Value
Length of boom m 13～52
Luffing angle of boom 30～78
Wire speed of main drum lifting, dropping

m/min 0～110
down
Wire speed of sub-drum lifting, dropping High speed of 103, low

m/min
down speed of 62
Wire speed of boom lifting m/min 73
Wire speed of boom dropping down m/min 73
Upper swing speed of table (no load) r/min 3.2
Travel speed km/h 0～1.39
Climbing capability (equipped with boom

% 40
base, cab back towards)
Rated output power of engine kw/r/min 124/2000
Gross mass (equipped with boom base, 50t

t 49
hook block )
Ground specific pressure MPa 0.061
Mass of balance weight t 16.5
Rated Load
⑴See table 2.2 for rated load of SCC500D (without jib).
Description:
① The rated load shown in Table 2.2 refers to the value when the machine is on a hard
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soil ground, weights are slowly and steady lifted, non-travel hoisting. However, the
rated load is always within 78% of tipping load.
② Quality of hook block is included in the rated load. The actual weight is the rated load
deducted with the weight of cargo slings such as the hook block, etc. (quality of the
50t hook block is 478kg, quality of the 15t hook block is 282kg, quality of the 30t
hook block is 370kg).
③ When jib and lengthened jib are installed, the rated total load includes the mass of
main hook block and sub hook block as well as the value in table below. So, the actual
weight of crane is the value of table 2.2 deducted with the value in table below and the
quality of main hook as well as sub hook block, however, it can’t work if the remained
value is less than 0.8t.
Length of Jib Lengthened

6.10 9.15 12.20 15.25
(m) Jib
Deducted Mass
0.70 0.85 1.00 1.15 0.20
(t)
④ The length of main boom that can be equipped with jib is 22-43m.
⑤ When loading, the crawler support must be in expansion state.
⑥ Relationship of the multiplying factor of wire cable and maximum rated load as well as
the mass of hook block is shown as in Table 2.3.
⑦ The rated load of SCC500D cranes with jibs are shown as in Table 2.4.
Table 2.2 Rated Load Table of Main boom Unit: t
Length of Main Boom (m)

Range(m)
13 16 19 22 25 28 31 34 37 40 43 46 49 52
3.7 55
4 46.00
12
4.5 39.06 39.02
5 32.77 32.72 32.62
5.5 28.19 28.13 28.03 27.94
6 24.7 24.64 24.54 24.44 24.37
7 19.74 19.69 19.57 19.47 19.4 19.3 19.2
8 16.39 16.33 16.21 16.11 16.03 15.93 15.83 15.7 15.65
9 13.97 13.91 13.79 13.68 13.6 13.5 13.4 13.3 13.21 13.11 13.03
10 12.14 12.08 11.96 11.85 11.77 11.67 11.56 11.5 11.37 11.27 11.19 11.08 11
12 9.56 9.5 9.37 9.27 9.18 9.08 8.97 8.86 8.78 8.67 8.58 8.48 8.39 8.29
14 7.77 7.64 7.53 7.44 7.34 7.22 7.12 7.03 6.92 6.84 6.73 6.64 6.53
16 6.39 6.28 6.2 6.09 5.97 5.86 5.78 5.67 5.58 5.47 5.39 5.27
18 5.34 5.26 5.15 5.03 4.92 4.84 4.72 4.64 4.52 4.44 4.33
20 4.52 4.41 4.3 4.19 4.1 3.99 3.9 3.79 3.7 3.59
22 3.94 3.82 3.71 3.6 3.51 3.4 3.31 3.2 3.09 2.94
24 3.34 3.23 3.12 3.03 2.91 2.81 2.66 2.55 2.4
26 2.82 2.71 2.62 2.47 2.36 2.21 2.1 1.95
28 2.35 2.24 2.09 1.98 1.83 1.72 1.57
30 2.03 1.91 1.76 1.65 1.5 1.39 1.24
32 1.63 1.48 1.36 1.22 1.1 0.95
34 1.23 1.12 0.97 0.85 0.7
Note: ⑴ Values included in the table do not include the additional loads such as the wind load, inertial
load, impact load, etc. When the wind speed is more than 6 levels, work must be stopped.
⑵ In order to prevent overloading due to misjudge of the quality of parts, when the quality is
not clear, please do lifting by short jib section in possible ranges, or by small ranges.
Furthermore, elastic deformation because of lifting weights should be considered.
⑶ When the lengthened boom (without jib) associated with 5t hook block is used, the rated load
of the lengthened boom (i.e., 5t hook block) is 5t!
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Table 2.3 Relationship of the Multiplying Factor of Wire Cable and Maximum Rated Load as well
as the Mass of Hook Block

The
Lifting mass The maximum rated load（t）
capacity of the
of hook hook
（t） block 9times 8times 7times 6times 5times 4times 3times 2times 1times
（t）
50 0.478 55.0 44.8 39.9 34.2 28.5 22.8 17.1 11.4 5.7
30 0.370 30.0 28.5 22.8 17.1 11.4 5.7
15 0.282 15.0 11.4 5.7
5 0.171 5.0
Job Scope
(1) Lifting height curve with jib installed.
14
Fig. 2-1 Lifting Height Curve with Jib Installed
15
(2) Lifting height curve of SCC500D Hydraulic Crawler Crane (without jib)
Fig. 2-2 Lifting Height Curve without Jib Installed
16
(3) Lifting range curve of SCC500D Hydraulic Crawler Crane (without jib)
Fig. 2-3 Lifting Range Curve
17
2.3 Dimensions
Fig. 2-4 The Main Dimension of SCC500D Hydraulic Crawler Crane
18
III. Operations
3.1 Attention Points for New Machines
⑴ The first 50~100 hours for new machines is the running-in stage. During this period, impulsive load
of engine should be avoided.
⑵ Pay attention to check whether the engines, hydraulic systems, operation equipments and other
components are in normal operations
3.2 Inspection before Operation

The following Examinations should be carried out prior to each operation:
● Check whether the anti-overwind device of hook block, 78° caging device of jib are in
normal operations. Check whether the end pin shaft of arm is lubricated.
● Check whether there is any wear, corrosion and fracture on wire ropes.
● Check whether the instruments, alarm lights and other monitoring devices in cab are in
normal operations. Check whether the clutch, brake and each locking device are in
normal operations.
● Check for oil mass of the hydraulic tank; Check for oil mass and drainage of the fuel
tank; Check for oil mass of the engine; Check for water volume and whether there is
any leakage
● Check whether there is any loose on bolts, nuts at key positions
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3.3 Configurations of the Control handle, Instrument and Button
Fig. 3-1 Plan View of the Cab
6 5 4 3 2 1
7 8 9 10 11 12 13 14
1.control release /restraint release indicator 2. stop/start waiting indicator
3.water-in-fuel/engine indicator 4.diagnosis switch 5.error code shift 6.Slewing slow
7.pawl switch of main drum 8.control release 9.swing pin release
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10.swing brake cancelling 11.head light 12.swing alarm lamp
13．Windscreen wiper Ⅰ 14.Windscreen wiper II

aux. winch/swing
air-conditioner panel Release limitation switch emergency stop
manipulative handle
Swing braking release
ACK button
horn button
whirling main winch/luffing

ignition
buzzer lighter accelerator manipulative handle
horn button
Fig. 3-2 Layout Plan of Each Switch

Table 3-1 Functional Description of Each Wane Switch
Name of Wane Position of Switch 0 Position of Switch 1
Switch
Wane Switch Each wane switch is dark Each wane switch is bright, to provide
Lighting nightwork lighting.
Limitation Jib angle changes in the range of The angle change of jib is unrestricted
Release 30-78°, and each anti-overwind (primarily for lifting arm); and each
device of hook block is available. anti-overwind device of hook block is
invalid. Lights with the same symbol on
the “Release Indicator” switch turn on.
Control Release Servo control is available. All pilot handle and foot valve is
ineffective. Lights with the same symbol
on the “Release Indicator” switch turn on.
Main Drum Main Drum Pawl locked, main Main Drum can do action
Pawl Open drum can’t do action
21
Caution Light The caution light on The caution light on
Free track-slip When sub-drum swing control When sub-drum swing control handle is in
handle is in meso-position, the meso-position, the upper structure can
swing braking is in effective, swing.
namely, the upper structure can’t
swing.
Headlamp light Lights out Lights on
Note: self-locking function are provided on the limitation release switch, therefore, when
switching between the two positions, please press the self-locking device on the wane to achieve
switching operation.
Self lock device
Fig. 3-3 self lock device
3.4 Engine Control

⑴ Operating Mechanism of Engine
Position of hand throttle is as shown in Fig. 3-3, and that of foot throttle is shown in Fig.
3-5.
OFF - Engine in tail-off state
ON - Engine in operation state
ST - Engine in starting-up state
Fig. 3-4 Start Switch
22
Left-traveling
brake pedal for left-traveling
main drum control rod foot accelerator
pedal
right-traveling pedal right-traveling control rod
Fig. 3-5 Travel Control Foot Treadle and Foot Throttle
⑵ Engine Starting-up:
① When engine starting, each control lever and main drum luffing control handle,
sub-drum swing control handle should be put in the meso-position. Each switching push
button and handle is in OFF state.
② The ignition lock should be put in ON position at first, then honking (see Fig. 3-3 for
the position of horn button, with a button on left and right handle respectively) to
inform the people around, and the control lever of engine throttle should be put in
medium-speed position.
③ Turn the ignition lock to ST position, and start engine. Put the throttle at idle speed
immediately after engine starting-up, and immediately open the ignition lock, thus to
make it automatically back up to the ON position, namely, the working state.
④ Recheck the fuel supply system if the engine can’t be started up by continuous three
times. No smoke during starting indicate that no fuel have been transported by that
time.
⑤ When engine starting, the time can’t be more than 15 seconds, so as not to damage the
starter. Every starting time interval should not less than 2 minutes.
⑥ Within 15 seconds after starting-up, engine oil pressure should be displayed on
23
electronic monitor. When starting a cold engine, please increase the speed of engine
slowly which can give a fully lubrication to bearing and make a stable oil pressure.
⑦ Give an idle speed for 3~5 minutes before loading operation. Make sure not to give
prolonged idling operation, thus to avoid engine damage.
⑶ Engine Stopping
Make the engine operate five minutes without being loaded. Then turn the ignition to
OFF position
3.5 Operation of the Main Lifting Mechanism

3.5.1 Dropping down Operation of the Idler hook
(1) Make the main drum luffing control handle in the meso-position, stamp down the main
drum brake pedal (see Figure 3-7).
the brake pedal for the main drum

Fig. 3-7
(2) Press the pawl switch of main drum button to ON position(see Figure 3-8), to let the
clutch out of gear. After dropping down operation of the idler hook, put the button at
OFF (automatically reset upon loosing hand), and make the locking device well
locked.
24
auxiliary
control box
pawl switch of
main drum
Fig. 3-8
(3) When the main drum brake pedal is completely stamped, disk brake begins to work,
and the hook block can’t do any action. Idler hook dropping operation can be done
only need to slowly raise the main drum brake pedal. The dropping speed shall be
decided according to the loosing speed from foot pedal and the raise angle of that.
Note:
① Excessive speed of the idler hook should be avoided!
② Position of the hook block should be always observed, and the hook block must
not be dropped on the ground by free fall!
When the lifting mechanism is in the process of dropping, clutch switch being at OFF
is strictly forbidden! Besides, the main drum lifting control handle must be put in
meso-position, or otherwise, making the clutch access to an instantaneous work is very
dangerous!
③ The machine can also carry a small weight to drop by free fall. It can be
calculated by multiplying factors as per 200kg of each wire cable.
Multiplying 1 2 3 4 5 6 7 8 9
Factor
Mass of Load 200 400 600 800 1000 1200 1400 1600 1800
(kg)
3.5.2 Lifting and Step-down Operation of Main drum

See Fig. 3-9 for main drum operation. Make the main drum clutch handle at OFF
25
(natural position), and open the main drum pawl switch on the sub-control box to make the
main drum pawl out of gear. If the drum is too tight to declutch, the user can put the main
pawl switch at declutch position in the first, and then make an inching motion to the handle,
finally, the pawl can be released.
When the main drum/luffing control handle on right arm rest box is in the
meso-position, the main drum will give braking; when the handle is pushed forward from
meso-position, the main hook block drops down; when the handle is pulled backward from
meso-position, the main hook block goes up.
horn button
Lowering of hook
Boom boom
lowering main winch/luffing
lifting boom manipulative handle
lowering
lifting of hook
right handrail box
igniton lock
Fig. 3-9
Note: lifting and dropping operation should not hurry!At the beginning and final stages,
the movement of main drum luffing control handle should be slow, so as not to form a
major impulse inertia.
3.6 Luffing Operation of the Jib

When there is a need for jib lifting, the lock of luffing drum must be relieved at first;
if the lock is so tight that can’t be relieved, the user can make a inching motion to the main
drum/luffing control handle, to lift arm support slightly, then, the pawl can be relieved.
See Fig. 3-9 for each operating condition of the main drum luffing control handle.
When the main drum luffing control handle is in the meso-position, the luffing drum will
give braking; when the handle is pulled close to one side of seat, the jib goes up and jib
26
angle increase; when the handle is pushed to the side away from seat, the jib drop down and
jib angle decrease.
Note:
⑴ Luffing operation should not hurry! At the beginning and final stages, the movement of
main drum luffing control handle should be slow, so as not to form a major impulse inertia.
⑵ If the crane will be in standby stage, please check whether the pawl is in place, and
whether it can block the ratchet.
3.7 Swing Control and Swing Stopping

3.7.1 Swing Control
Honking (with a button on left and right handle respectively) to inform swing before
operation, and then open the warning lights button on control box (Figure 3-2), at this time,
the alarm lights button turn on.
Free track-slip function is provided in this car. It means that when sub-drum swing
control handle is in meso-position, the upper structure will give no braking, but can make
track-slip freely. When the centers of gravity of load and arm support are out of the same
plane due to inaccurate judgment, the upper structure can be put straight automatically
through free track-slip, to prevent vibration after the load is slinging up.
Whether there is a free track-slip function shall be controlled by the swing braking
release switch on right arm rest box. When the free track-slip switch (see Figure 3-2) is at
ON, a free track-slip function is provided; When the free track-slip function switch is at
OFF, there is no free track-slip function, at this state, the upper structure give braking when
the sub-drum swing control handle is in meso-position.
See Fig. 3-10 for each operating condition of the sub-drum swing control handle.
When the sub-drum swing control handle is pulled close to one side of seat, the turn table
turns clockwise; when the handle is pushed to the side away from seat, the turn table turns
counterclockwise. After all the swing are finished, the warning lights button on
sub-operating box should be turned off to release the OFF state by swing braking (see Fig
27
3-11).
3.7.2 Stopping of Swing Control
When the free track-slip function is out of use, the sub-drum swing control handle is in
meso-position, and the upper structure give braking.
After using the free track-slip function, when sub-drum swing control handle is in
meso-position, the upper structure can’t make braking. Because of too big operating range,
or uneven ground, or excessive wind, it may occur that the handle is in meso-position but
the upper structure can not stop swing. At this time, the user can turn in opposite direction
of handle by a little (actual degree can be decided according to one’s experience). By this
reverse oil pressure to stop the rotation of upper structure can avoid impactions.
Lowering
下降 of hook
aux. winch/swing Anticlockwise

逆时针转 Clockwise
顺时针转
manipulative handle rotation rotation
提升
Lifting of hook
left handrail box
Fig. 3-10
swing pin release swing

locking
handle
Fig. 3-11
Note:
28
⑴ In case of field tilt, strong winds, standby of machine or transportation process, and the
driving pin switch must be turn at OFF, and aiming at stop groove block (see 3.11).
⑵ Swing operation should not hurry! At the beginning and final stages, the movement of
sub-drum swing control handle should be slow, so as not to form a major impulse inertia.
3.8 Sub-lifting Operation

See Fig. 3-10 for each sub-lifting operating. When the sub-drum swing control handle
is in the meso-position, the sub-drum brake will give braking; when the handle is pulled
forward, the sub-hook block drop down; when the handle is pushed backward, the sub-hook
block goes up.
confluence button
aux. winch/swing
manipulative handle
Fig. 3-12
Note:
(1) Cocurrent flow can be used in the lifting and dropping operation, thus to accelerate the
speed of sub-hook. However, in other conditions the button switches on the control handle
should not be pressed!
(2) Sub-lifting operation should not hurry! At the beginning and final stages, the
movement of sub-drum swing control handle should be slow, so as not to form a major
impulse inertia.
3.9 Travel Operation

Left crawler shall be driven by left travel control lever, and crawler shall be driven by
right travel control lever (see Fig. 3-13). Both the left and right control levers must be used
at the same time when the machine is going forward or backward. When turning, control
one crawler to move, or control both two crawlers to move (one go forward and another go
29
backward).
left-traveling left-traveling
brake pedal of pedal control rod
main drum foot accelerator
move forward
move backward
right-traveling
right-traveling control rod
pedal Fig. 3-13
Note:
⑴ Turning operation should not hurry! At the beginning and final stages, the movement of
travel control handle should be slow, so as not to form a major impulse inertia.
⑵ In case of long distance traveling, the travel engine should be placed at rear part and
given a medium speed.
3.10 Telescopic Operation of Crawler

To meet the both states of operation and transportation, a telescopic crawler frame is
provided for the main frame of crane.
Note: balance weight and arm support should not be installed during telescopic
operation of crawler frame, in order to avoid rollover risk!
⑴ The mainframe should be stopped at a harder level ground to make the body leveled;
besides, the turn table should be rotated to the side of crawler (see Fig. 3-14).
Fig. 3-14
30
⑵ Before telescopic operation of crawler, the canted tie plate (4 parts) which is located at
the connection between crawler frame and base to adjust the space should be removed.
track frame
base
Tapered cushion plate
Fig. 3-15
⑶ When extend the crawler frame, user should spin out the lengthened beam and well
connect the fixed pin at first (total 4 parts), then pulling out the telescopic transform control
lever and four fixed pins.
connect fixed pin

Turn out
extension beam
Fig. 3-16
fixed pin connecting plate
base
Telescopic
shifting rod
Fig. 3-17
① Push the left travel control lever forward, and extend the right crawler frame at a
suitable position, and well lock the fixed pins then make the left travel lever at a neutral
position.
31
② Make a 180 degrees rotation to turn table, push the left travel control lever forward, and
extend the left crawler frame at a suitable position, and well lock the fixed pins then
pull the left travel lever at a neutral position.
left-traveling control rod

left-traveling pedal
expanding
neutral
draw back
Fig. 3-18
③ Make canted tie plate fixed by using of bolts, and make sure a minimum space of
2-3mm between the crawler frame and canted tie plate.
bolt
Tapered cushion plate
base
track frame
Fig. 3-19
④ Finally check whether the pins are well fixed and completely extended.
⑷ When contraction, the canted tie plate which is located at the connection between
crawler frame and base should be removed, then the telescopic transform control lever
and four fixed pins should be pulled out.
① Push the left travel control lever backward, and contract the right crawler, and well lock
the right fixed pins. Then make the left travel lever at a neutral position.
② Make a 180° rotation to turn table, push the left travel control lever backward, and
contract the left crawler, and then pull the left travel lever at a neutral position.
③ Press the crawler telescopic transform control lever back to original position, and check
whether the pins are well fixed.
32
④ Remove the fixed pin of lengthened beam and well stored. Spin in the lengthened beam
and make ear board well fixed.
⑤ After contraction, keep the removed canted tie plate in a proper place.
detach fixed pin

base
detach fixed pin
turn back
turn back extension
extension beam
beam Telescopic
shifting
fix lug plate rod
fix lug plate properly
properly
Fig. 3-20
Note:
① Telescopic operations of crawler are not allowed during crawler crane operations.
3.11 Braking and Locking of Hoisting Drum

When the main drum luffing control handle is in meso-position, the main drum is in
braking lock state.
To ensure the safety during operation, a pawl is provided to lock the winding drum in
this machine. (See Fig. 3-2 for the pawl switch) When the switch is at ON, the pawl oil
cylinder of main drum will be filled with oil, then pawl open; when the switch is at OFF,
there is no pressure oil in pawl oil cylinder of main drum, at this time, the ratchet is locked
by pawl, so the drum is unable to make any action.
main drum
pawl locking of
main drum
Fig. 3-21
33
3.12 Braking and Locking of Luffing Drum

When the main drum luffing control handle is in meso-position, the luffing drum is in
braking lock state. When the handle is not in meso-position, the braking lock of luffing
drum is released, and arm lifting and dropping can be achieved.
To ensure the safety during long time loading and traveling, maintenance and
transportation, a pawl is provided to lock the winding drum in this machine. Pawl oil
cylinder of main drum should be controlled by the hydraulic control valve. When the main
drum luffing control handle has any action, under the valve control action of pressure oil,
the pawl oil cylinder of main drum will be filled with oil, then pawl open; when the main
drum luffing control handle is in meso-position, there is no pressure oil in pawl oil cylinder
of main drum, at this time, the ratchet is locked by pawl, so the drum is unable to make any
action.
amplitude-ch
anging drum
pawl locking
Fig. 3-22
Note: Operators must check whether the winding drum is locked by pawl locking
device before they off shift.
3.13 Swing Braking and Locking

When the free track-slip function is out of use, the sub-drum swing control handle is in
meso-position, the swing brake is in braking state (i.e. normally closed braking). When the
free track-slip function is provided, and the handle is in meso-position, the upper structure
will give no braking.
When works are finished or in transportation, or the machine is on tilt ground or
traveling with load, in order to achieve swing lock of the upper structure, locking devices
34
are provided. It can be realized through the swing lock handle on the sub-operating box.
releasing
swing locking pin
Swing locking Upper swing platform
locking
handle swing roll disk
Lower traveling frame
Fig. 3-23
3.14 Travel Braking

Travel brake is a automatic brake. When the travel control lever is in meso-position,
brake work. When the engine is stopped, no servo pressure exists. Even if the control lever
locates in other places, the brake is also in braking condition.
left-traveling control rod right-traveling control rod
(neutral position) (neutral position)
Left-traveling Motor right-traveling motor
Note: When the machine is stopped on the slope, the driver must add wedge to
main oil circuit main oil circuit
crawler if they are to leave the cab.
Fig 3-24 Travel braking device
3.15 Attention Points of Boom Operation
⑴ When the crane is undertaking lifting arm, dropping arm and loading rotary, the
operation must be carried out slowly.
⑵ When use the main boom and install the jib, the boom must face forward and the travel
engine must be placed at the rear. Then lifting or dropping operations of boom can be
achieved.
⑶ On condition that a 52m main boom or a 43m main boom additional with a 15.25m jib
35
lifting arm is provided, the boom must face forward and the travel engine must be placed at
the rear. Limitations functions should be released before starting lifting, which can be
realized by pressing the limitation release switch, when the switch is at ON state. Then turn
it at OFF after finishing arm lifting. Limitation release should also be performed before arm
dropping, which make the switch at ON state. Then turn it at OFF after finishing arm
dropping.
⑷ On condition that a 52m main boom or a 43m main boom additional with a 15.25m jib
lifting arm is provided, 5-6 square timbers should be placed under the front crawlers where
the body has installed with boom supports. The put width and height of that are about
70mm. Then the body should be driven forward to slowly climb up the board by about
100mm (see figure below). Then, two or three pieces of wood should be placed in front of
the both side of crawlers, the direction of which is perpendicular to the direction of the
wood. Make the body move ahead again by about 50mm. Halt and ready to lift arm.
Steps of dropping arm are the same as above.
set wood plate for second time
Fig. 3-25
first time set wood
plate properly
⑸ When jib operations, the rated total load of main hook is the weight based on the length
of jib deducted with the weight in table below, that is to say, the actual load is the original
weight deducted with the weight in table below and the weight of main hook as well as
auxiliary hooks.
Length of Jib (m) 6.10 9.15 12.2 15.25
Deduct (kg) 700 850 1000 1150
36
Closing to transmission lines of jib is very dangerous; therefore, distance between the jib
and transmission lines shall not exceed the values shown as in following table:
Voltage of the Transmission Line (KV) ＜1 1-35 ≥60
Minimum Distance (m) 1.5 3 0.01(V-50)+3
In actual operation, operation distance between jibs and transmission lines can be
determined according to the number of electro-purotron (see table below).
Number of electro-purotron
17～24 10～14 5～8 2～4
(Nr.)
Distance between Jibs and

7 5 4 3
Transmission Lines (m)
3.16 Installation Attention Points of the Lift Arm and Drop Arm of 52m Main
Operation Boom
1. Connection of the basic jib section and the longest main boom: ① Connect the upper
two pins at first, then connect the lower two pins by luffing. ② Remove the luffing
sheave support from basic arms, then connect it to the stretching wire of main boom.
Note: reverse steps for disassembly are required, any omission or modification is not
allowed. That is to say, the luffing sheave support must be removed from the
stretching wire of main boom, and connected to basic jib section firstly, then the lower
two pins of basic jib section can be removed. The upper two pins should be removed
after the main boom is placed on the ground.
2. Safety Inspection:
① Welding state of arm support connector. ② Whether there is any bending, crack,
local pit on the main stem, web member. ③ Whether the split pin shafts are complete
(main boom and stretching wire). ④ Whether there is any welding or knocking or
touching defect on the yoke plate. ⑤ Whether there is any defect, crack or bell mouth
37
on the heart-shaped ring and aluminum sleeve of stretching wire. Whether there is any
flattening, broken wire, hard bending, loose. ⑥ Not any sundries (tools, boards, spare
parts, etc.) is allowed to leave on the main boom. ⑦ Examination of the A-frame
support. ⑧ Luffing winching inspection.
3. Hook block is not allowed to part from the ground before lifting arm by 30° (enough
lifting rope length has been provided before lifting arms).
4. Driving wheel is at the rear part.
5. The pilot wheel should press above the 50-80mm height of square timbers which are
vertical in groups (Body positive angle should be guaranteed).
6. For the first lifting, put down the arms just as it having been part from the ground.
(misalignments arising from the alignment process between the body and main boom
should be eliminated)
7. For the secondary lifting, stop just as the arm is at a horizontal plane; Do assessment for
the stability of brakes, booms and the whole body, then put it down.
8. For the third lifting, it should be smooth, uniform in speed, more than 30° at a time, and
with no intermediate stop.
9. The hook block should be put down on the ground when drop arm is less than 30° in
angle, and with no intermediate stop. Limitation release switch should be at ON during
lifting and dropping. Return the limitation release switch at OFF in time after finishing
lifting and dropping.
10. Two tires should be placed on the ground below the connection of top jib section and
9m arm to prevent accident.
11. No one is permitted to stand nearby the booms.
12. Pay attention to the wind direction and force.
Arm angle between 65° to 70° for the travel state of 52m arm is preferred.
3.17 Work and Operation of the Safety Device

Safety devices in this crane include load moment indicators, angle caging device of jib,
38
anti-overwind device of hook block and other kinds of brakes or locking devices. In case of
in danger, the load moment indicators and anti-overwind device will startup the automatic
alarm function, and lift the crane, automatically stop the luffing movements to eliminate
dangers.
Electronic Monitor. Torque Limiter
3.17.1 Anti-overloading Device - Load Moment Indicator

The function of load moment indicator is shown as in figure below: when the crane is
in normal operation, the load moment indicator can automatically detect the loaded quality
and angle of jibs, and can also display its rated load and actual load, working radius, angle
of jibs.
Load measure Angle measure
lifting luffing
Automatic stop
Can operate
Fig. 3-26
39
When the actual load is below 90% of the rated load, “Normal” lights on; when the
actual load has reached 90% of the rated load, “90%” lights on, meanwhile, the buzzer on
the mainframe of load moment indicator start to call discontinuously to give an early
warning; when the actual load has reached 100% of the rated load, “100%” lights on.
meanwhile, the buzzer on the mainframe of load moment indicator begin to give
accelerated call warning; when the actual load has reached 105% of the rated load, “105%”
lights on, meanwhile, the buzzer on the mainframe of load moment indicator start to give a
long call warning, and relay start to work, then the lifting and working radius increasing
operation will automatically stop.
Note: in case of soft or uneven ground, when the actual load has reached more than
90% of the rated load, any swing operation is strictly forbidden to prevent dangerous!
See Operation Instructions of the Load Moment Indicator for detailed descriptions and
adjustment of the load moment indicator.
3.17.2 Anti-overwind Device of Hook block
See as the figure below: the inching motion switch is energized when the hook block is in
natural vertical laying. When the hook block has moved to a certain height, the weight
dropper can be supported; then, the inching motion switch will be reset by spring, and the
switch contact open, meanwhile, the buzzer on associate control console give call warning.
At this time, control solenoid valve is energized and the solenoid valve oil way is cut off,
thus the outlet oil way of control valve is cut off. Therefore, hook block operation has to be
automatically stopped, till then only the dropping operation is available, thereby overwind
of hook block is prevented. In normal operations, the inching motion switch on the top of
jib is switched on. Distance between weight dropper and inching motion switch is shown as
in the table below.
Category of Operating Device L Size micro-move switch
Main Boom ≥3.0mm above

heavy hammer
Jib ≥2.5mm above
40
Fig. 3-27
3.17.3 Caging Device of the Jib

The caging device of jib is shown as in figure below. When the elevation of boom is
less than 78°, the inching switch on the bottom of boom is switched on, at this time; the
luffing action of boom is in normal state.
When the elevation of boom is more than 78°, the inching switch on the bottom of
boom is switched on, and its contact open, besides, control relay begin to work, and the
buzzer as well as electromagnetic valve are energized, so buzzer give call warnings and the
outlet oil way of luffing control valve is cut off by solenoid valve, thus the boom is in
automatic standby state. At this point, even if additional movement is made to the luffing
handle, the boom is still in automatic standby state. Therefore, safety protection function is
achieved. However, the boom can be lowered down at this time. When devices are failed to
meet abovementioned requirements, they can be adjusted to meet the requirements of state.
When the dropping angle of boom is less than 30°, this control will be limited, in order
to prevent the crane to operate in small angles, the protection function shall be controlled
by the load moment indicator automatically. If the user wants to disassemble or adjust the
arm length on the ground, they can press the limitation release switch on the sub-operating
box, to make this switch at ON state. Since the limitation release switch is not an automatic
type, and the safety control function of the load moment indicator and the safety
anti-overwind function of hook block have also been released. Therefore, the limitation
release switch should avoid prolonged release state, so if the user wants to reset to normal
safe working state, they can press the limitation release switch to OFF state.
41
limiting position switch

main boom
Fig. 3-28
Note:① Before running, make sure that the abovementioned actions of devices are in
normal operations.
② When install a crane, the limitation release switch should be in open state.
③ When normal operating, the limitation release switch should not be in ON state.
3.17.4 Control Release
When the driver want to leave the cab for a short time, but do not want to shut down
the engine, in order to prevent any misoperation due to the contact of body and any control
handle, the control function can be released by control release switch, at this time, all
control handles is out of function.
The control release button on sub-operating box is often closed at OFF state. When
pressed the button at ON state, servo pressure will be cut off automatically by the hydraulic
system (the coming oil of servo pump will directly back to the oil tank), therefore, all
movements of handle will be out of function.
Note: when the machine is in normal operation, the release switch should not at ON
state. Please do not press this button at ON state (release), otherwise special circumstances
exist.
3.18 Intelligentized and Humanization Design

This machine has equipped with electronic monitoring devices and other intelligent
devices. Electronic monitoring devices can monitor engine speed of, display the oil
pressure, water temperature, hydraulic oil temperature and status of engine, battery voltage,
cumulative working hours of engine, switch state of overwind alarm and rain blade, work
lights and headlight switches, etc.
See Operation Instructions of the Electronic Monitor for detailed descriptions of each
display state and using method of switches.
To provide a good working environment for drivers, heating & air-conditioning is
42
provided in this machine. Therefore, cab temperature can be freely adjusted according to
seasonal temperature changes. Control panel of the air-conditioning is on the left arm rest
box. See Operation Instructions of the Air-conditioning for detailed descriptions of the
wind speed and temperature control.
control panel of air conditioner left handrail box

Fig. 3-29
Convenience for refueling: electrical fueller can be used for fuel refueling. The electrical
fueller is placed in the vicinity of engines。
Prevention: To prevent fire accidents, this machine has equipped with fire extinguishers.
The fire extinguishers are placed in the driver's cab.
IV. Disassembly and Assembly of the Boom

4.1 Assembly of the Boom Base
⑴ Lift the jib base to the horizontal connection position of mainframe (without balance
weight), then move slowly to fit close to the pin hole at bottom, finally, insert the pins
and make them secured by locking pin.
back stop mast

root pin hole of lower boom
Fig. 4-1
⑵ Lift the boom tip to the horizontal connection position of boom base, and move slowly
to make both pin holes of boom bases fit close to each others. Then insert pin shafts and
43
make them secured by locking pin.
top pin hole of lower boom root pin hole of lower boom
upper boom
Fig. 4-2
⑶ Connect the luffing sheaves to boom tip by 6.35m main boom stretching wire, and
remove the two central pin shafts of A-frame support. Slowly wind up the luffing wire
cable to raise the A-frame, install the two central pin shafts to tight the wire cable. Install
the sway rod to the ear board of the front support of A-frame, and slowly rise up the
boom support through slow speed running.
Fig. 4-3
⑷ Upper and lower balance weights should be installed after installation of the boom
supports.
counterweight
installed
44
Fig. 4-4
4.2 Disassembly of the Basic Boom

⑴ Operation field for boom bases should be flat, and should be leveled by tie plate or other
objects. First, remove the upper and lower balance weights, and then lay down A-frame.
Make the crane in normal travel direction, namely, the boom must be in the side of track
driving wheel. At this time, the crane is in disassembly state.
then lowering A-shape frame
first detaching
counterweight
Fig. 4-5
⑵ Relax the luffing wire cable, and connect the luffing sheaves to the ear board of jib base,
and then make them secured by locking pin.
connect amplitude-changing
sheave group with lug plate of
lower boom
pull-rope of main boom

Fig. 4-6 and conducting wire
⑶ Remove the main boom stretching wire and anti-overwind device wire. Underlay the
table support for jib base, and remove the lower connecting pins first and then remove the
upper connecting pin. Disassembly for upper boom is over.
upper connection pin pull-rope of main boom

and conducting wire
upper boom
lower connection pin
45
Fig. 4-7
4.3 Assembly of Boom inserts and Jibs

⑴ Connect an appropriate length of boom inserts to form a boom in necessary, and connect
the main boom stretching wires with the same length. Make the jib base close to boom
supports, and make both the upper and lower connecting pin holes fit close to each others.
Then insert connecting pin. The upper two pin shafts should be connected at first and the
lower two pin shafts should be connected later. All of them should be secured by locking
pins.
then connect lower
first connect
pin shaft
upper pin shaft
pull-rope of main boom
Fig. 4-8
⑵ Make the luffing sheaves and main boom stretching wire well connected. Luffing down
and make the luffing sheaves completely lay on the boom support. Removed the two
connecting pins between luffing sheaves and jib base, and make them separate from each
others. Note: before ending of this process, the boom support must not leave the ground,
in order to avoid damage to boom supports!
Fig. 4-8
⑶ When jibs assembling, put the well installed jibs and masts on the sleeper, the favorable
height of which should be the connecting level of jibs and main boom. Connect appropriate
length of jibs to form a jib supports and jib stretching wires.
46
Fig.4-9
⑷ Make the jib supports close to the body with main boom installed (including balance
weight, boom support with appropriate length), and connect the boom tip and jib by pin
shafts, then connect the jib stretching wire to the supporting bracket on the upper side of
main boom through jib mast. Finally, install the lifting wire cable of jibs, anti-overwind
device of hook block, load moment indicators and weight dropper.
Fig. 4-10
⑸ Upon completion of the above operations, lift the hook block and make the jib leave
from ground. Check whether the safe turn angle of jib is at 10° or 30°, if not, the jib
should be dropped down to re-determine a length of tightened wire cable to ensure a safe
installation angle.
V. Compositions of the Main Boom and Jibs

5.1 Composition of the Main Boom
The boom base length of the machine is 13m (with boom base of 6.5m, boom tip of
6.5m), in addition, there are 3m, 6m and 9m mid-booms sections. Proper connecting
method should be in accordance with the requirement in this section. The length of main
boom is between that of boom base (13m) and maximum (52m). Free lengthening can be
realized by adding boom inserts in necessary. Leaving factory standard boom sections are:
boom base 13m (with boom base of 6.5m, boom tip of 6.5m), 3m*1, 6m*3 and 9m*2. Its
47
composition is as follows:
Fig. 5-1 Connection Form of the Main Boom (Without Jib) and Main Stretching Wire
48
Fig. 5-2 Connection Form of the Main Boom (With Jib) and Main Stretching Wire
Note: (1) In the above figures, “◆” refers to the optimized combinations.
(2) The 13m~43m combination form of main boom in figure 5-1 can also been used for the
installation of jibs.
Length of the Main Stretching:
S/N in Figures A B C D
Length of Wire
6.35 3.0 6.0 9.0
Cable (m)
5.2 Composition of the Jibs

Jibs of this machine can be installed on the main boom with length of 22, 25, 28, 31,
34, 37, 40 and 43m. The length of jib base is 6.1 meters, with 3 mid-jib sections and 3.05m
49
in length per each. The lengths of jibs that can be used for combination respectively are:
6.10, 9.15, 12.20, 15.25 m.
5.3 Installation Position of the Sub-streching Wire

A: 13.4m
Aux.guy rope (lower)
Installation Angle D: 1.9m
B: 5.84m
Sub-stretching
Wire (upper) C: 14.14m
tightened sheave at upper part of auxiliary boom
balancing pulley
Pulley at auxiliary boom end
balancing pulley
tightened steel rope at

lower part of auxiliary
boom
steel rope for auxiliary drum
aux.drum
Fig. 5-3 Installation Drawing of the Aux.guy rope
Table 5.1 Installation Table of the Aux.guy rope
Aux.guy rope (upper) Aux.guy rope (lower)
Installation Angle of 10° and 30° 10° 30°
Jib
6.10 C A A+D
9.15 B+C A A+D
12.20 B+C+B A A+D
15.25 B+C+B+B A A+D
Note: it is the wire cable through balance sheaves.
Note: 1. If the aux.guy rope wasn’t properly installed, the installation angle of jib
50
may exceed the specified value which may lead to overload and damages to jibs,
therefore, proper installation is needed.
2. When installing the lengthened boom, please use boom with length less than
49m length, or otherwise, dangers may occur due to overloading!
3. When lengthened boom is used, please deduct the value in table with the mass
of lengthened booms, hook blocks and cargo slings, which is about 350kg.
VI. Lifting of the A-frame Support

A telescopic type of A-frame support is adopted in this crane, during operation, the
A-frame support must be risen up. When transporting or going through the electrical lines,
A-frame support can be lowered down.
Note: ① If the operation is carried out in the process of lowering down A-frame
support, damages may be made to the luffing wire cable and main stretching
wire, thus to lead an accident! Therefore, operations during this time should be
strictly prohibited.
② When the length of boom is more than 19m, even if going under the
electrical wire, lines, lowering down the A-frame is not allowed.
6.1 Dropping down Operation of the A-frame Support

(1) Put down the boom and underlay with sleeper.
Fig. 6-1
(2) Give a slow speed running to engine, relax the luffing wire cable and pull out the pin
from A position.
51
Fig. 6-2
Note: luffing wire cable should not be relaxed too loose, in order to not make
damages to the A-frame upper structure due to fast drop upon pulling out the pins.
⑶ Slowly relax the luffing wire cable, let the upper structure of A-frame support drop
down by free fall, till touch bottom.
⑷ Insert the pin to the hole at position B.
Fig. 6-3
6.2 Hoisting Operation of the A-frame Support

(1) Put the jib on the sleeper.
Fig. 6-4
(2) Pull out the pin from position B (Figure 6-3).
52
(3) Give a slow speed running to engine, slowly raise the luffing wire cable of jib, at the
same time, the A-frame will risen up with the wire till touch top.
(4) Insert the pin to the hole at position A. (Figure 6-2). Lifting of A-frame support is over.
6.3 Attention Points in the Process of A-frame Lifting

● Lifting operation of A-frame support must be carried out when the boom tip is installed,
If only the boom base is installed, other auxiliary lifting equipments should be used.
Lifting A-frame support using jib is forbidden when it is blocked, in order to avoid
damage to jibs
● Hard beating should be avoided when installing and removing the pins at position A
and B. The installation and removing of pins can be realized only need giving an
appropriate vibration to the luffing wire cable. The pins should be well tightened after
being inserted.
VII. Wire Cable

7.1 Composition of the Wire Cable
Composition of wire cable can be represented by number of strands and the single line
of that, e.g. 6 stock and 29 single lines per each is called as 6*29. Hemp core and steel core
are usually the two kinds of wire cable. Generally, the former is widely used; however, the
latter is widely used in construction machines.
steel rope
rope core
steel rope with

single wire steel rope with steel core
Fig. 7-1 Composition of the Wire Cable Fig. 7-2 Wire Core
7.2 Unfasten of the Wire Cable

The following unfasten method should be used for wire cables. Incorrect way will
cause a rope disorder, resulting loosing or twisting, and influence the life of wire cable.
Therefore, attentions should be given.
53
correct release binding method Wrong release binging method
Fig. 7-3 Unfasten Method for Wire Cables
7.3 Installation of the Wire Cable to Drum

The following order Steel drums to install, according to:
(1) When the wire cable is wounded on the drum, excessive length of the wire cable
end from the outlet of drum should be avoided.
(2) When the wire cable is wounded on the drum, the gap between wire cables should
eliminated with a hammer or crowbar to make them evenly arranged.
tighten
tighten
tighten
correct set-in wrong set-in set-in from

aside slightly
Fig. Winding Methods of the Wire Cable to Drum
(3) When the winding layer of wire cable restarts, make sure that the gap between wire
cable and edge of drum should not too big.
(4) When winding the wire cables, a certain tension should be given to them, and do
winding while tightening.
(5) Disorder of wire cables should be absolutely avoided, which is one of the reasons that
causes the early broken.
(6) Rewinding should be done after a certain time of new wire cables, or otherwise,
disorder of windings may occur.
54
(7) When the wire cable is put in the wiring sleeve, twine retainer should be used to secure
the wire cables according to Figure 7-5.
Fig. 7-5
7.4 Replacement of the Wire Cable

Depending on different running conditions, the life of wire cable is different, therefore,
regular examination should be given to them. They should absolutely not be used if any
defect exists. For dynamic load wire cable which is used for lifting and static load wire
cable which is used for hoisting, the same stringent examinations should be carried out for
them, or otherwise, any broken may lead to serious accident. Replacement time for wire
cables should be determined based on the conditions such as broken, wear, corrosion and
etc. For any of the following circumstances, they should not be used:
(1) Between the length of lays, singular line (except for filling line) has more than 10% of
the fractures
(2) Reduction of diameter has exceeded 7% of the nominal diameter.
(3) Kinking.
(4) Serious relax and corrosion.
Fig. 7-6
In addition, a considerable vibration load is acting on the wire cables; therefore,

special attention should be paid to the wire cable which may be broken due to over fatigue.
55
Although the examination for replacement period must be taken under the abovementioned
conditions, the internal broken wires can’t be seen from surface according to different
operating conditions. The wire cables should be replaced with new ones after working for
2000 hours.
7.5 Examination Standards of Wire Cable Scraping

⑴ Once the number of broken wire cables has reached the values listed in Table 7.1, it is
scrapped.
Table 7.1 Number of Broken Wire Cables (GB6067-85)
Number of Broken Wire Cables in A Pitch
Structure of Wire Cable (GB1102-74)
Number of Wire Cable 6W (19) Wire Cable 6 * (19) Wire Cable 6 * (37)
Broken Wires
Non-spinning Lang lay Non-spinning Lang lay
Safety Factor
Less than 6 12 6 22 11
6-7 14 7 26 13
More than 7 16 8 30 15
Note: ① The number of broken wire in table refers to fine steel wire cables. Thick wire
cable is equivalent to 1.7 times of fine wire cables.
② A pitch refers to the axial distance for a cycle per strand wire cable.
⑵ When the wire cable has corrosion or wear, the number of scraped wire cables in Table
7.1 should be reduced according to Table 7.2, and scraped according to the reduced
number.
Table 7.2 Reduction Coefficient
Surface wear and corrosion extent 10 15 20 25 30-40 大于 40
Reduction coefficient 85 75 70 60 50 0
56
⑶ Number of scraped wire cable which is used for lifting heated metal or dangerous goods
should be determined by taking half of the number of general cranes, including the
reduction of surface wear and corrosion.
guiding pulley
top sheave
steel rope of main drum

8 7 6 5
nine times
main drum 4 3 22 1
7.6 Winding Methods of the Wire Cable

⑴ Winding methods for main drum lifting:
Fig. 7-7 Winding Drawing of Lifting Wire Cables
57
⑵ Winding methods for sub-drum lifting installed with jibs.
tightened sheave at jib top
sheave
balance sheave at jib top
sheave at support bar
tightened steel rope at

jib base
steel rope of
auxiliary drum
auxiliary drum
Fig. 7-8 Winding Method of Lifting Wire Cables with Jibs
⑶ Winding methods for luffing wire cable.
Pulley of tightened device
sheave of tightened device

of A-shape frame
shaft of
A-shape frame
Pulley of A-shape frame

Amplitude-changing drum
Fig. 7-9 Winding Method of Luffing Wire Cable
7.7 Selections for the Size of Wire Cable

Table 7.3 and 7.4 should be taken as the references.
58
Specifications for wire cable and the length of wire cable in above table refer to the
calibration value before leaving factory, when replacement for wire cables, please select
according to Table 7.4.
The length of wire cable needed in Table 7.4 refers to the length when it is at the
minimum working range and the hook block is 1m above the ground. When underground lift
is needed, length of wire cables should be determined by taking into account of lift depth.
Table 7.3 Specifications for Wire Cable
Specifications for Wire Diameter Length

Using Mechanism
Cable (mm) (m)
Lifting (for main

20NAT6*29FI+IWR1870 20 171
hook)
Lifting (for sub-

20NAT6*29FI+IWR1870 20 121
hook)
Luffing 16NAT6*29FI+IWR1870 16 142
Note: level of intensity of wire cable should not less than 1870Mpa.
Table 7.4 Table of Wire Cable Length for Cranes
Unit: m
Multiplying Factor of the Wire Cable
Length of Main
9 8 7 6 5 4 3 2 1
Boom (m)
13 (Main Hook) 154 139 125 109 94 79 64 49 33
16 (Main Hook) 170 154 138 121 105 89 72 56 39
19 (Main Hook) — — 170 150 129 108 87 66 45
22 (Main Hook) — — — 168 144 120 96 72 48
25 (Main
— — — — 165 138 111 84 57/85
Hook/Sub-hook)
59
28 (Main
— — — — 170 143 116 89 62/88
Hook/Sub-hook)
31 (Main
— — — — — 168 135 102 69/97
Hook/Sub-hook)
34 (Main
— — — — — — 147 111 75/103
Hook/Sub-hook)
37 (Main
— — — — — — 159 120 81/109
Hook/Sub-hook)
40 (Main
— — — — — — 170 128 87/115
Hook/Sub-hook)
43 (Main
— — — — — — — 138 93/120
Hook/Sub-hook)
46 (Main Hook) — — — — — — — 147 99
49 (Main Hook) — — — — — — — 157 105
52 (Main Hook) — — — — — — — 164 111
VIII. Structure and Hydraulic Pressure Electrical System

8.1 Structure
The main structures of crane include: operation equipment, turntable, travel device,
power-driven equipment and hydraulic system. SCC500D structure sketch plan is shown
as in Fig. 8-1.
8.2 Hydraulic Pressure System

Overall hydraulic pressure drive is adopted in this machine. Schematic diagram of the
hydraulic system is shown as in Fig. 8-2.
8.3 Electrical System

Voltage of DC24V is provided in this vehicle, which is made up of two batteries in
series. It is mainly used to start the engine, electrical control wiring and lighting equipment.
60
The generator will provided power for batteries, and supply power for electricity equipment
at the same time. Single line system is adopted in the entire vehicle, and negative earthing
way is used in power supply. See Fig. 8-4 for electrical diagram. See Operation Instructions
for detailed descriptions of the Air-conditioning.
Luffing
steel rope of Amplitude-changi
Upper boom Main pull rope
main drum ng sheave group steel wire
A-shape frame
rope
hydraulic oil tank
counterweight
main working
devices
hydraulic pump
cab
Hook block
Engine
traveling device
radiator
battery
swing device fuel tank
track frame
Fig. 8-1-1 Sketch Map of System Structure
61
Fig. 8-1-2 Sketch Diagram of System Structure
S/N Name and Chart no. S/N Name and Chart no.
1 Crawler travel device QUY55-1000 13 Hood QUY50-4900 0000 00
0000 10
2 Turn table QUY50-1200 0000 00 14 A-frame support QUY50-5100 0000 10
3 Power-driven equipment QUY50-1500 15 Balance weight QUY50-5300 0000 10
0000 00
4 Swing mechanism QUY50-1800 0000 16 Main operation equipment QUY50-5500
10 0000 10
62
5 Main lifting mechanism QUY50-2100 17 Stretching wire device of main boom
0000 00 QUY50-5800 0000 00
6 Sub- lifting mechanism QUY50-2400 18 Lengthened arm QUY50-6100 0000 00
0000 00
7 Luffing mechanism QUY50-2700 0000
00
8 Hydraulic system QUY50-3000 0000 00
9 Travel hydraulic system QUY55-3400
0000 00
10 Servo System QUY50-3600 0000 00
11 Electric equipment QUY50-4000 0000
00
12 Cab QUY50-4700 0000 00
63
Fig. 8-2 Sketch Diagram of Hydraulic System
64
Fig. 8-3 Sketch Diagram of Electrical System
65
IX. Transportation and Hoisting

9.1 Trailer Transportation
(1) Attention Points for Trailer Transportation
① When road transport, rules of traffic management departments should be complied with.
② The height of barriers on the way should be investigated.
③ Crawlers should be drawn back and the A-frame support should be put down.
④ When transfer the body to trailer, a 20° sloped bedplate can be used for trailer’s inverse
climbing (with cab in the rear part). Meanwhile, swing locking devices should be provided
and bundled by wire cables.
⑤ After the main frame is installed with trailer, swing locking devices should be provided,
and chocks should be installed in the front and back of crawlers, to prevent moving around,
moreover, they should be bundled by wire cables.
⑵ Parts for Loading:
180mm square timber, 3.5m in length, 4 pieces will be used as the main beam of sloped
bedplate.
300mm square timber, 0.5m in length, 6 pieces will be used as the middle supporting of
sloped bedplate.
(3) Climbing state when transportation: when boom is installed, the angle of jib should be
less than 30°. When forward climbing, the cab should be in the front; when backward
climbing, the cab should be at rear part. The largest climbing angle is 20°, as shown in
Figure 9-1.
Fig.9-1
66
9.2 Overall Dimension of Disassembled Transportation

When disassembled transportation, the following parts can be removed: jib and
balanced weight.
9.3 Transportation Plan

Description: (1) the quality of main frame of SCC500D hydraulic crawler cranes is 29t
(excluding balanced weight and boom support).
(2) When transportation, a 40t (12.5m in length, height of truck is 1m) flat bed truck must be
used for transportation. Machines should be disassembled according to this drawing. Before
transportation, machines should be firmly tied by No. 8 (Φ6) wire, and secured by
underlaying wood at loosing positions.
(3) Anti-corrosion treatment should be done for surface leaking working parts, and plastic
foil and wood should be used to seal the tie bar of A-frame.
(4) This transportation only can go through 3 class tunnels.
9.4 Hoisting Plan

Wire cables are not allowed to touch the machine shed. When hanging the wire cables,
the corner position should be well underplayed to prevent damages to wire cables.
Weight of Main Frame: G=29000kg
Central Coordinate Value: (286，25，954)
Table 9.1 Table for Disassembly Transport Quality and Overall Dimensions
Quality
Name of Parts Length(mm) Width(mm) Height(mm) Remark
(kg)
Excluding
Body Main frame 29000 5720 3300 3260 balance
weight
Balance weight 635 (Except for

9000 3120 1340
(lower) ear plate)
67
Balance weight 625 (Except for

7500 3120 1340
(upper) ear plate)
Boom base 1168 6650 1400 1540
Boom tip 1082 6880 1400 1400
Main drum wire

288 171m
cable
Luffing wire cable 162 142m
Sub drum wire

203 121m
cable
3m boom insert 305 3100 1400 1400
Operating 6m boom insert 575 6100 1400 1400
Equipments 9m boom insert 845 9100 1400 1400
of Cranes Horizontal jib

110 3350 600 550
base
Horizontal jib tip 144 3250 700 550
Middle jib 76 3110 600 550
Jib support 119 3200 550 560
50t Hook block 478 1527 570 392
30t Hook block 370 1546 570 340 Optional
15t Hook block 282 1495 570 311
5t Hook block 171 772 298 298
68
Fig. 9-3 Hoisting Plan
69

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（英）Scc500d使用说明书（力士乐带自由落钩）发新西兰

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SCC500D Hydraulic Crawler Crane

Shanghai Sany Science & Technology Co., Ltd.

Shanghai Sany Science & Technology Co., Ltd.

SCC500D Crawler Crane

unloading. Any operating condition such as grab, dragline, heavy

tamping, electromagnetic lifter, etc. is strictly prohibited.

Operating level of the crane is A3W.

Mechanism operating levels are respectively lifting M4, luffing M4,

swing M3 and travel M2.

4.1 Assembly of the Boom Base ··············································································43

I. Safe Operating Rules

● Side towing from the crane is prohibited. (Figure 1-4)

Table 1 Minimum Distance between the Transmission Lines and Jib

Voltage of the Transmission Line (KV) ＜1 1-35 ≥60

Minimum Distance (m) 1.5 3 0.01(V-50)+3

● In case of great windy weather, operation should be carefully carried out. As

II. Main Technical Parameters and Dimensions

Technical Parameters Unit Numerical Value

Length of boom m 13～52

Luffing angle of boom 30～78

Wire speed of main drum lifting, dropping

Wire speed of sub-drum lifting, dropping High speed of 103, low

Wire speed of boom lifting m/min 73

Wire speed of boom dropping down m/min 73

Upper swing speed of table (no load) r/min 3.2

Travel speed km/h 0～1.39

Climbing capability (equipped with boom

Rated output power of engine kw/r/min 124/2000

Gross mass (equipped with boom base, 50t

Ground specific pressure MPa 0.061

Mass of balance weight t 16.5

Length of Jib Lengthened

Table 2.2 Rated Load Table of Main boom Unit: t

Length of Main Boom (m)

4.5 39.06 39.02

5 32.77 32.72 32.62

5.5 28.19 28.13 28.03 27.94

6 24.7 24.64 24.54 24.44 24.37

7 19.74 19.69 19.57 19.47 19.4 19.3 19.2

8 16.39 16.33 16.21 16.11 16.03 15.93 15.83 15.7 15.65

24 3.34 3.23 3.12 3.03 2.91 2.81 2.66 2.55 2.4

26 2.82 2.71 2.62 2.47 2.36 2.21 2.1 1.95

28 2.35 2.24 2.09 1.98 1.83 1.72 1.57

30 2.03 1.91 1.76 1.65 1.5 1.39 1.24

32 1.63 1.48 1.36 1.22 1.1 0.95

34 1.23 1.12 0.97 0.85 0.7

Furthermore, elastic deformation because of lifting weights should be considered.

of the lengthened boom (i.e., 5t hook block) is 5t!

as the Mass of Hook Block

Fig. 2-1 Lifting Height Curve with Jib Installed

Fig. 2-2 Lifting Height Curve without Jib Installed

Fig. 2-3 Lifting Range Curve

Fig. 2-4 The Main Dimension of SCC500D Hydraulic Crawler Crane

3.2 Inspection before Operation

3.3 Configurations of the Control handle, Instrument and Button

Fig. 3-1 Plan View of the Cab

1.control release /restraint release indicator 2. stop/start waiting indicator

3.water-in-fuel/engine indicator 4.diagnosis switch 5.error code shift 6.Slewing slow

7.pawl switch of main drum 8.control release 9.swing pin release

10.swing brake cancelling 11.head light 12.swing alarm lamp

13．Windscreen wiper Ⅰ 14.Windscreen wiper II

Swing braking release

whirling main winch/luffing