Zoomlion Heavy Industry Science & Technology Co.,Ltd.

Address: Quantang Industrial Park, No. 1636, 2nd Yuanda Road, Changsha, Hunan Province, China Postcode: 410131
Website: http://www.zoomlion.com Email: Sos-service@zoomlion.com

Copyright © 2015 Zoomlion Heavy Industry Science&Technology Co., Ltd. All rights reserved
ZTC800R532 Truck Crane
Operator’s Manual

Edition 1 March 2018

 Operator’s Manual for Truck Crane

To Users
Zoomlion appreciates your selection of ZOOMLION truck crane for your application.

No one should operate the crane unless they read and understand the information in this manual.

This manual contains the instructions and data on the safety and operation of the truck crane.
Follow the operation procedures to make sure that your machine operates at MAXIMUM
EFFICIENCY. The operator must keep this manual in the cab of the crane.

If there is anything in the manual that is not clear or you do not understand, please contact our
service technician. We (Zoomlion) are NOT responsible for damages from an operator who does not
obey the instructions in the OPERATOR’S MANUAL.

The OPERATOR’S MANUAL is an important part of the crane. If the crane becomes the property of
a different person, make sure that the manual stays in the cab of the crane.

The data (data, specifications, illustrations) in this manual is for cranes in production at the time of
this manuals publication. We reserve the right to make changes to this manual at any time, without
obligation.

The manual has been translated to be best of our knowledge. Zoomlion assumes no liability for
translation errors. The Chinese version of the OPERATOR’S MANUAL is solely applicable for
factual accuracy.

Thank you!

Mobile Crane Branch Company of Zoomlion Heavy Industry Science and Technology Co., Ltd.

Copyright
Under the copyright laws, this manual may not be copied, photocopied, reproduced, translated, or reduced to any electronic
medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science
and Technology Co., Ltd.
Copyright © 20XX, Zoomlion Heavy Industry Science and Technology Co., Ltd.
All rights reserved.

I
 Operator’s Manual for Truck Crane

Safety Instructions
DANGER, WARNING, CAUTION and NOTICE labels are on signs and decals, and as you read this
manual to show important instructions. In this manual, the labels follow the paragraph or item they
apply to. The markers are as follows:

Refers to a dangerous situation which, if you do not prevent, will cause

DANGER death or injury.

Refers to a possible dangerous situation which, if you do not prevent,

WARNING could cause death or injury.

Refers to a possible dangerous situation which, if you do not prevent, may

CAUTION cause light or moderate injury.

Refers to a situation which, if you do not prevent, may cause property or

NOTICE
equipment damage.

II
 Operator’s Manual for Truck Crane

Contents

To Users ........................................................................................................................................ I

Safety Instructions ....................................................................................................................... II

Chapter 1 Description of Crane

1.1 Models and name plates .............................................................................................. 1-1

1.1.1 Models ............................................................................................................. 1-1
1.1.2 Name plates..................................................................................................... 1-1
1.1.3 Name plates installation locations..................................................................... 1-2
1.1.4 Vehicle identification number (VIN) and its locations ......................................... 1-2
1.1.5 Engine code, name plate and their locations..................................................... 1-3
1.2 Crane components and product description ................................................................. 1-4
1.2.1 Crane components ........................................................................................... 1-4
1.2.2 Product description .......................................................................................... 1-6
1.2.3 Boom ............................................................................................................... 1-8
1.3 Technical data.............................................................................................................. 1-9
1.3.1 Overall view ..................................................................................................... 1-9
1.3.2 Protection devices .......................................................................................... 1-10
1.3.3 Technical data .................................................................................................1-11
1.3.4 Work parameters............................................................................................ 1-14
1.3.5 Lifting capacity tables ..................................................................................... 1-15
1.3.6 Lifting height chart .......................................................................................... 1-30
1.3.7 Working areas ................................................................................................ 1-32

Chapter 2 Safety Guidelines

2.1 Safety instructions and safety signs ............................................................................. 2-1

2.1.1 Safety instructions ............................................................................................ 2-1
2.1.2 Safety signs ..................................................................................................... 2-1
2.2 Planning crane operation ............................................................................................. 2-4
2.3 Break-in instructions .................................................................................................... 2-5
2.4 General safety technical guidelines .............................................................................. 2-6
2.4.1 Requirements of the crane operator, rigger and signalman ............................... 2-6
2.4.2 Selecting an operating site ............................................................................... 2-8
2.4.3 Supporting ..................................................................................................... 2-10
2.4.4 Working conditions ..........................................................................................2-11

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 Operator’s Manual for Truck Crane

2.4.5 Points for attention for safe operation ............................................................. 2-15

2.5 Hand signals.............................................................................................................. 2-18

Chapter 3 Operation – Crane Chassis

3.1 Driver’s cab ................................................................................................................. 3-1

3.1.1 Overview.......................................................................................................... 3-1
3.1.2 Steering wheel assy. ........................................................................................ 3-3
3.1.3 Instrument assy. ............................................................................................... 3-8
3.1.4 Reversing radar system ................................................................................. 3-21
3.1.5 Air horn button ............................................................................................... 3-24
3.1.6 Foot pedal (R): Engine control ........................................................................ 3-24
3.1.7 Foot pedal (M): Service brake ........................................................................ 3-24
3.1.8 Foot pedal (L): Clutch..................................................................................... 3-24
3.1.9 Center console ............................................................................................... 3-25
3.1.10 Crane lighting ............................................................................................... 3-31
3.1.11 Door, driver's cab.......................................................................................... 3-32
3.1.12 Seats in driver's cab ..................................................................................... 3-34
3.1.13 Attachments ................................................................................................. 3-35
3.2 Before starting up the vehicle ..................................................................................... 3-36
3.2.1 Prerequisites .................................................................................................. 3-36
3.2.2 General checks before setting off ................................................................... 3-36
3.2.3 General checks at vehicle start up .................................................................. 3-37
3.3 Driving the crane........................................................................................................ 3-38
3.3.1 Starting and stopping the engine .................................................................... 3-38
3.3.2 Transmission operation .................................................................................. 3-40
3.3.3 Clutch operation ............................................................................................. 3-41
3.3.4 Steering operation .......................................................................................... 3-42
3.3.5 Brake operation.............................................................................................. 3-42
3.3.6 PTO operation................................................................................................ 3-44
3.3.7 Towing ........................................................................................................... 3-46
3.4 Points for attention ..................................................................................................... 3-47
3.4.1 Road driving................................................................................................... 3-47
3.4.2 Crane movements in off-road conditions......................................................... 3-48
3.4.3 Park the vehicle ............................................................................................. 3-48
3.4.4 Emergency stop on the roadway .................................................................... 3-48

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 Operator’s Manual for Truck Crane

Chapter 4 Operation – Crane Superstructure

4.1 Operator’s cab ............................................................................................................. 4-1

4.1.1 Overall view ..................................................................................................... 4-1
4.1.2 Switch panel..................................................................................................... 4-2
4.1.3 Auxiliary switch panel ....................................................................................... 4-5
4.1.4 Control boxes ................................................................................................... 4-8
4.1.5 Operator's seat............................................................................................... 4-13
4.1.6 Engine control pedal....................................................................................... 4-14
4.2 Computer system....................................................................................................... 4-15
4.3 Starting up the crane .................................................................................................. 4-16
4.3.1 Checks before starting up............................................................................... 4-16
4.3.2 Starting and stopping the engine .................................................................... 4-17
4.4 Safety devices ........................................................................................................... 4-18
4.4.1 Level gauge ................................................................................................... 4-18
4.4.2 Angle indicator ............................................................................................... 4-18
4.4.3 Hoisting limit switch ........................................................................................ 4-19
4.4.4 Lowering limit switch ...................................................................................... 4-21
4.4.5 Hydraulic safety devices................................................................................. 4-22
4.4.6 Emergency stop button .................................................................................. 4-23
4.5 Crane operation ......................................................................................................... 4-24
4.5.1 Preparations for crane operation .................................................................... 4-24
4.5.2 Outrigger........................................................................................................ 4-25
4.5.3 Derricking....................................................................................................... 4-32
4.5.4 Telescoping .................................................................................................... 4-35
4.5.5 Lifting / lowering ............................................................................................. 4-38
4.5.6 Slewing .......................................................................................................... 4-43
4.5.7 Simultaneous crane movements..................................................................... 4-45
4.5.8 Rope reeving.................................................................................................. 4-51

Chapter 5 Equipment

5.1 Safety technical guidelines for assembly ...................................................................... 5-1

5.2 Jib ............................................................................................................................... 5-2
5.2.1 General ............................................................................................................ 5-2
5.2.2 Assembly ......................................................................................................... 5-2
5.2.3 Angle settings .................................................................................................. 5-9
5.2.4 Disassembly................................................................................................... 5-10
5.2.5 Reeving in the auxiliary hoist rope ...................................................................5-11

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 Operator’s Manual for Truck Crane

5.2.6 Connection of hoisting limit switch ...................................................................5-11

5.3 Rooster sheave ......................................................................................................... 5-14
5.3.1 Assembly ....................................................................................................... 5-14
5.3.2 Disassembly .................................................................................................. 5-15
5.3.3 Connection of hoisting limit switch .................................................................. 5-15

Chapter 6 Additional Equipment

6.1 Air conditioning in driver's cab ...................................................................................... 6-1

6.1.1 Operating methods........................................................................................... 6-1
6.2 GPS terminal ............................................................................................................... 6-4
6.2.1 Digital display ................................................................................................... 6-5
6.2.2 Emergency unlocking ....................................................................................... 6-5
6.2.3 Control lights – GPS terminal state ................................................................... 6-6
6.3 Air conditioning in operator's cab ................................................................................. 6-7
6.3.1 Air conditioning ................................................................................................ 6-7
6.3.2 Cab heater ....................................................................................................... 6-9

Chapter 7 Transportation and Storage

7.1 Transportation.............................................................................................................. 7-1

7.2 Storage ........................................................................................................................ 7-2

VI ZTC800R532 Truck Crane

Truck Crane Operator’S Manual

Chapter 1 Description of Crane

 Operator’s Manual for Truck Crane

Chapter 1 Description of Crane

Description of Crane
1.1 Models and name plates
1.1.1 Models
Model in engineering industry: ZTC800R
Chassis model: ZLJ5461JQZR3

1.1.2 Name plates

For name plate of crane, refer to Figure 1-1.
For name plate of chassis, refer to Figure 1-2.

80000

Figure 1-1 Name plate of crane

Figure 1-2 Name plate of chassis

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 Operator’s Manual for Truck Crane

1.1.3 Name plates installation locations

Description of Crane

The name plate of crane is installed on the left side of operator’s cab.
The name plate of chassis is installed on the right longitudinal beam of chassis frame.
For exact locations, please refer to Figures 1-3 and 1-4.

0 0
20 1
30
40

50
60
80 70

Crane name plate

Figure 1-3 Crane name plate location

Chassis name plate VIN

Figure 1-4 Chassis name plate location

1.1.4 Vehicle identification number (VIN) and its locations

The VIN of ZTC800R is L5E6H5D3××A××××××, and is stamped in the crane name plate,
chassis name plate and right longitudinal beam of chassis frame.
The exact location is shown in Figure 1-4.

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 Operator’s Manual for Truck Crane

Description of Crane
1.1.5 Engine code, name plate and their locations
WP10.375E33 engine
The engine code is stamped on the right part of engine near the gear chamber.
The engine name plate is installed on the left part of engine.
The exact locations are shown in Figures 1-5 and 1-6.
Note: Have the above engine data available when communicating with us.

Engine code

Figure 1-5 Engine code location

Engine name plate

Figure 1-6 Engine name plate location

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 Operator’s Manual for Truck Crane

1.2 Crane components and product description

Description of Crane

1.2.1 Crane components

1.2.1.1 Crane chassis

17

16

15

14

13
1
12
2

3
4 11

5
6

8
9
10

Figure 1-7 Main components of crane chassis

Pos. Description Pos. Description

1 Clutch 10 Rear outrigger box

2 Exhaust system 11 Spare tire

3 Front axle 12 Chassis frame assy.
4 Engine housing 13 Propeller shaft

5 Front outrigger box 14 Platform

6 Guard rail 15 Air intake system
7 Intermediate axle 16 Boarding
8 Rear axle 17 Driver’s cab
9 Toolbox

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 Operator’s Manual for Truck Crane

Description of Crane
1.2.1.2 Complete vehicle

6
5

4 7
3

2 8

9
1
10

11

12

13
14
15

Figure 1-8 Main components of complete vehicle

Pos. Description Pos. Description

1 Jib 9 Slewing gear

2 Main boom 10 Derricking gear

3 Length indicator 11 Main hook

4 Angle indicator 12 Sliding beam

5 Auxiliary winch 13 Auxiliary hook

6 Main winch 14 Special purpose chassis

7 Fixed counterweight 15 The 5th outrigger

8 Operator’s cab

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 Operator’s Manual for Truck Crane
Description of Crane

1.2.2 Product description

1.2.2.1 Crane chassis

Driver's cab The low-mounted full-width sheet steel cab offers a comfortable and
functional working environment.
The control elements and displays are ergonomically arranged. Thus a safe
and fatigue free working is assured.
The cab has the following features:
– Front-mounted instrument console
– Hydraulically-cushioned seat with upper backrest
– Sun visor and power windows
– Cab heater and A/C
– Height and position adjustable steering wheel.

Chassis frame Distortion-resistant and load-bearing box structure welded from high-tensile
steel

Engine Special purpose high-pressure common-rail electronic fuel injection diesel

engine for construction machinery

Clutch Dry type single-plate pull-type clutch

Transmission 10-speed mechanical transmission with contrate gear output

Transmissions are with a synchronizer.

Suspension Front axle with longitudinal leaf spring suspension, and rear axle with leaf
spring + balance beam + thrust rod suspension. The rubber suspension is
available for options.

Wheels Special wheel rim and inflated tires

Steering Including integral circulating ball-type power steering gear, steering pump
and steering drive mechanism

Brakes It consists of service brake (driving brake), parking brake (emergency brake)
and auxiliary brake.
Service brake: dual-circuit compressed air brake acting on all wheel hubs
Parking brake: spring-loaded brake acting on wheel hubs of intermediate
and rear axles
Auxiliary brake: engine exhaust brake

Propeller shaft Styre series open-type propeller shaft assy. with contrate gear connected

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 Operator’s Manual for Truck Crane

1.2.2.2 Crane superstructure

Description of Crane
Operator's cab The sheet steel cab offers a comfortable and functional working
environment.
The cab can be tilted backwards for 20° during operation.
The cab has the following features:
– Adjustable seat with headrest
– Pilot-operated control levers
– Windshield wiper and washer system.

Main boom and 5-section (1 basic boom, 4 telescopic sections) main boom
telescoping system Low-alloy and high-tensile steel provides the boom with excellent
bending resistance.
The built-in slide blocks with compensation technology applied have
the guidance capability and lifting capacity improved.
The main boom can be telescoped in and out by means of two
telescoping cylinders with synchronous boom extension / retraction
wire ropes.

Derricking gear A front-mounted oil cylinder with balance valve

Hoist gear Consisting of hydraulic motor, winch reducer, hoisting limit switch,
lowering limit switch and hoist rope

Slewing gear Consisting of hydraulic motor, slewing reducer and slewing bearing

Hydraulic system Open-type, hydraulic proportional control, with proportional

speed-regulating function
Driven by one variable plunger pump and two gear pumps

Load moment limiter It is composed of mentor, pressure sensor, length sensor and angle
sensor.

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 Operator’s Manual for Truck Crane
Description of Crane

1.2.3 Boom
It includes main boom and jib.
Main boom includes 1 basic boom and 4 telescopic sections.
Main boom length: 12.1 m – 47.0 m
Jib length: 9.5 m, 16.0 m
When the fully extended main boom is fitted with jib (3 offsets: 0°, 15° and 30°), the boom
length is L = 47.0 m + 9.5 m = 56.5 m or L = 47.0 m + 16.0 m = 63.0 m.

Jib length (two jib sections): 16.0 m

Jib length (one jib

Main boom length (fully sections): 9.5 m
extended): 47.0 m

Main boom length (fully

retracted): 12.1 m

Figure 1-9 Boom lengths

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 Operator’s Manual for Truck Crane

1.3 Technical data

Description of Crane
1.3.1 Overall view
Unit: Metric mm
0
20 10
30
40

60 50
80 70
3850

19.5°
15°

（2211） 2692 1450 4500 1350 2092 205

14500

R4200

7800（全伸）
5180（半伸）
R1
006
5
R11
914

R15
052
6050

2290 2063
2800

Figure 1-10 Overall view

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 Operator’s Manual for Truck Crane

1.3.2 Protection devices

Description of Crane

Unit: Metric mm
Left guard rail
(Material: Q235-A and glassfiber reinforced plastics, connection type: bolt)

A
A

552
548

533
473

473

473

473
725 720 720
710 785 3335 985
1686

Right guard rail

(Material: Q235-A and glassfiber reinforced plastics, connection type: bolt)
548
533

473
473

473

720 720 725

1325 2995 1135 710

Rear guard rail

(Material: HG785, connection type: welding)

A-A
100
1108

30
552

424

2490

Front, rear, left and right guard rails of special purpose chassis for truck crane

Figure 1-11 Protection devices

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 Operator’s Manual for Truck Crane

1.3.3 Technical data

Description of Crane
Table 1-1 Technical data

Item Value Remarks

Max. rated lifting capacity kg 80000

Max. load moment of basic

kN.m 2646
boom
Max. load moment of main
kN.m 1288
boom (fully extended)
Max. lifting height of basic
m 13.4
boom
Max. lifting height of main The deflection of main
m 47.7
boom (fully extended) boom and jib is not
Work
taken into
performance Max. lifting height of jib m 63.8
consideration.
Max. hoist rope speed Unloaded, drum 4th
m/min. 125
(main winch) layer
Max. hoist rope speed Unloaded, drum 2nd
m/min. 110
(auxiliary winch) layer

Boom derricking up time s 55

Boom telescoping out time s 120

Slewing speed r/min. 0 – 1.7

Max. driving speed km/h 85

Max. gradeability % 46

Turning diameter m ≤ 24
Min. ground clearance mm 305

Comply with GB3847-2005 /

Driving Limits for exhaust pollutants
related GB17691-2005
and smoke
standards (National Stage III)
Fuel consumption per
L 45
hundred kilometers

Front / rear overhang angle ° 19.5 / 15

Brake distance m ≤ 10 Initial speed: 30 km/h

Table 1-1 (continued)

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 Operator’s Manual for Truck Crane
Description of Crane

Item Value Remarks

Deadweight in driving
kg 46000
condition
Complete vehicle kerb
Mass kg 45805
mass
Front axle load kg 20000
Rear axle load kg 26000

Overall dimensions
mm 14500 × 2800 × 3850
(L × W × H )

Outrigger spread (L) m 6.05

Fully extended: 7.8,
Outrigger spread (W) m intermediately
extended: 5.18
Main boom length m 12.1 – 47.0
Boom angle ° -2 – 80
Dimensions
Jib length m 9.5, 16
Offset ° 0, 15, 30
Front / rear overhang mm 2692 / 2092
Number of axles 4
Wheelbase mm 1450 + 4500 + 1350
Front mm 2290 / 2290
Treads
Rear mm 2063 / 2063
Tail slewing radius mm 4200
7.5°(Zoomlion axle)
Kingpin inclination angle °
Wheel 5°(Hande axle)
alignment Wheel caster angle ° 2
Wheel camber angle ° 1
Model WP10.375E33
6-cylinder in line,
Type turbo-charged,
inter-cooling
Engine
Fuel type Light diesel oil
Displacement ml 9726
Rated power / RPM kW/r/min 276 / 1900
Max. torque / RPM N.m/r/min 1650 / (1200-1600)

Table 1-1 (continued)

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 Operator’s Manual for Truck Crane

Item Value Remarks

Description of Crane
Model 10JSD160TB
Mechanical stepped
Type
speed change
Mechanical manual
Operating method
operation
10 forward and 2 reverse
Transmission Number of speeds
speeds
Forward speeds:
12.74,9.43,6.67,4.83,3.5
Speed ratio 3,2.64,1.95,1.38,1.00,0.
73, reverse
speed:13.73,2.84
Steering type Steering wheel

Outer diameter of
mm 480
steering wheel
Steering column Universal coupling

Steering Model PY-ZJ120C-Z/Y-01

system Steering Integral circulating
gear Type ball-type hydraulic power
steering gear

Steering Model QC25/15-WP10N1

pump Type Gear pump

Drive type 8×4

Drive axle
Speed ratio 6.72

Number of leaf springs (front) 12 / 12 / 10 Optional: 12 / 12 / —

Cab capacity 3

Fuel tank capacity L 300

Hydraulic oil tank capacity L 980

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 Operator’s Manual for Truck Crane
Description of Crane

1.3.4 Work parameters

1.3.4.1 Max. support strength per outrigger

When the crane is working within the rated lifting capacities, the max. support strength per
outrigger is 77 tons.

1.3.4.2 Hook
Table 1-2 Hook configurations

Model Number of pulleys Max. reeving Weight Remarks

Straight shank with
60 tons 6 12 550 kg single hook
(standard configuration)
Straight shank with
6 tons 0 1 150 kg single hook
(standard configuration)

1.3.4.3 Rope specification

Table 1-3 Rope specification

Stan d ard
Type of rope Sp eci fi cati o n L en g th
co d e
4V×48S+5FC-20.0-1870-
Main hoist rope GB 8918-2006 220000 mm
left-hand ordinary lay
4V×48S+5FC-20.0-1870-
Auxiliary hoist rope GB 8918-2006 140000 mm
left-hand ordinary lay

1.3.4.4 Standard rope reevings

Table 1-4 Standard rope reevings for various boom lengths

Boom length (m) 12.1 16.5 21.0 27.5 34.0 40.5 47.0 Remarks
Cylinder I
Reeving 12 10 8 6 5 4 3
extended: 100%
Boom length (m) 12.1 16.5 23.0 29.5 36.0 42.5 Remarks
Cylinder I
Reeving 12 10 6 6 4 3
extended: 50%
Boom length (m) 12.1 18.6 25.1 31.6 38.1 Remarks
Cylinder I
Reeving 12 6 5 4 3
extended: 0%

CAUTION
(1) If rope reevings are less than the value listed in the above table during lifting,
examine the load on single wire rope to make sure that it is no more than the max.
permissible lifting capacity of single wire rope.
(2) Max. permissible lifting capacity of single wire rope is 6000 kg.

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 Operator’s Manual for Truck Crane

1.3.5 Lifting capacity tables

Description of Crane
This crane is provided with several lifting capacity tables. The operator should select proper
rated lifting load referring to resp. lifting capacity tables according to actual working conditions.
For the working conditions marked with asterisk over sides and rear, the crane must uses 70 t
hook.

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 Operator’s Manual for Truck Crane
Description of Crane

Table 1-5 Lifting capacity table

Unit: kg
Main boom (m)
Radius Outriggers and telescoping cylinder I fully extended, over sides and rear, 5 t
(m) fixing counterweight
12.1 16.5 21.0 27.5 34.0 40.5 47.0
3.0 80000* 55000
3.5 67000* 53000 43500
4.0 57000 52000 43500
4.5 54000 49000 42000 31000
5.0 50000 46000 41000 31000
5.5 47000 44000 39000 30000
6.0 43000 41000 37000 29000 23000
7.0 33000 32500 32000 27000 22000
8.0 25000 24500 24000 24500 21000 16500
9.0 19500 19000 18500 20500 19500 15500
10.0 15000 14500 16500 17200 14500 11500
11.0 12500 12000 13500 14500 13500 11000
12.0 10500 10000 11500 12500 12500 10500
14.0 7000 8500 9200 10000 9300
16.0 5000 6200 7000 7600 8000
18.0 4700 5400 6000 6300
20.0 3500 4200 4700 5100
22.0 2500 3200 3700 4100
24.0 2400 3000 3300
26.0 1800 2300 2600
28.0 1200 1700 2100
30.0 1200 1600
32.0 1000 1200
34.0 1000
I 0 4.4 8.9 8.9 8.9 8.9 8.9
II 0 0 0 6.5 13.0 19.5 26
Reeving 12 10 8 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Description of Crane
Table 1-6 Lifting capacity table

Unit: kg
Main boom (m)
Radius Outriggers fully extended and telescoping cylinder I intermediately extended,
(m) over sides and rear, 5 t fixing counterweight
12.1 16.5 23.0 29.5 36.0 42.5
3.0 80000* 55000
3.5 67000* 53000 31000
4.0 57000 52000 31000
4.5 54000 49000 31000
5.0 50000 46000 31000 23000
5.5 47000 44000 30000 23000
6.0 43000 41000 29000 23000
7.0 33000 32500 27000 22000 16500
8.0 25000 24500 26500 21000 16500 12000
9.0 19500 19000 21000 19500 15500 11500
10.0 15000 17000 18000 14500 11500
11.0 12500 14200 15200 13500 11000
12.0 10500 12000 13000 12500 10500
14.0 8800 9700 10200 9300
16.0 6600 7500 8000 8100
18.0 5000 5800 6300 6700
20.0 4600 5000 5400
22.0 3600 4100 4400
24.0 2800 3300 3600
26.0 2600 3000
28.0 2100 2400
30.0 1600 1900
32.0 1500
34.0 1200
36.0
I 0 4.4 4.4 4.4 4.4 4.4
II 0 0 6.5 13.0 19.5 26
Reeving 12 10 6 6 4 3
Hook 60 tons

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Table 1-7 Lifting capacity table

Description of Crane

Unit: kg
Main boom (m)
Radius Outriggers fully extended and telescoping cylinder I fully retracted, over sides
(m) and rear, 5 t fixing counterweight
12.1 18.6 25.1 31.6 38.1
3.0 80000* 31000
3.5 67000* 31000
4.0 57000 31000 23000
4.5 54000 31000 23000
5.0 50000 31000 23000
5.5 47000 30000 23000 16500
6.0 43000 29000 23000 16500
7.0 33000 27000 22000 16000 12500
8.0 25000 26500 21000 14500 12000
9.0 19500 21700 19500 13500 11500
10.0 17800 18000 12500 11500
11.0 15000 16000 11500 10500
12.0 12700 13500 10700 9700
14.0 9500 10200 9300 8400
16.0 8000 8200 7300
18.0 6400 6800 6400
20.0 5100 5500 5800
22.0 4500 4900
24.0 3700 4000
26.0 3100 3400
28.0 2800
30.0 2300
32.0 1900
34.0
36.0
I 0 0 0 0 0
II 0 6.5 13.0 19.5 26
Reeving 12 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-8 Lifting capacity table

Description of Crane
Unit: kg
Main boom (m)
Radius Outriggers intermediately extended and telescoping cylinder I fully extended,
(m) over sides and rear, 5 t fixing counterweight
12.1 16.5 21.0 27.5 34.0 40.5 47.0
3.0 62000* 52000
3.5 52000 48000 42000
4.0 45000 43000 40000
4.5 40000 38000 37000 31000
5.0 38000 36000 34000 31000
5.5 30500 30000 29000 30000
6.0 25000 24500 24000 25000 23000
7.0 18000 17500 17000 19000 19500
8.0 13500 13000 12500 14500 15500 16500
9.0 10500 10000 9600 11300 12000 13000
10.0 8000 7600 9000 9900 10500 11500
11.0 6200 5800 7300 8100 8700 9300
12.0 5000 4600 6000 6700 7300 7800
14.0 2700 4000 4700 5200 5700
16.0 1300 2500 3200 3700 4200
18.0 1500 2200 2700 3100
20.0 1300 1800 2200
22.0 1100 1600
24.0 1000
26.0
28.0
30.0
I 0 4.4 8.9 8.9 8.9 8.9 8.9
II 0 0 0 6.5 13.0 19.5 26
Reeving 12 10 8 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-9 Lifting capacity table

Description of Crane

Unit: kg
Main boom (m)
Radius Outriggers and telescoping cylinder I intermediately extended, over sides and
(m) rear, 5 t fixing counterweight
12.1 16.5 23.0 29.5 36.0 42.5
3.0 62000* 52000
3.5 52000 48000 31000
4.0 45000 43000 31000
4.5 40000 38000 31000
5.0 38000 36000 31000 23000
5.5 30500 30000 30000 23000
6.0 25000 24500 26000 23000
7.0 18000 17500 19500 20500 16500
8.0 13500 13000 15000 16000 16000 12000
9.0 10500 10000 11800 12700 13500 11500
10.0 8000 9500 10400 11000 11500
11.0 6200 7700 8600 9200 9600
12.0 5000 6400 7200 7700 8100
14.0 4200 5100 5600 6000
16.0 3000 3700 4100 4500
18.0 1900 2600 3000 3400
20.0 1800 2200 2500
22.0 1100 1500 1900
24.0 1000 1300
26.0 1000
28.0
30.0
I 0 4.4 4.4 4.4 4.4 4.4
II 0 0 6.5 13.0 19.5 26
Reeving 12 10 6 6 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-10 Lifting capacity table

Description of Crane
Unit: kg
Main boom (m)
Radius Outriggers intermediately extended and telescoping cylinder I fully retracted,
(m) over sides and rear, 5 t fixing counterweight
12.1 18.6 25.1 31.6 38.1
3.0 62000* 31000
3.5 52000 31000
4.0 45000 31000 23000
4.5 40000 31000 23000
5.0 38000 31000 23000
5.5 30500 30000 23000 16500
6.0 25000 27500 23000 16500
7.0 18000 20000 21500 16500 12500
8.0 13500 15500 16500 14500 12000
9.0 10500 12500 13500 13000 11500
10.0 10200 11000 11500 11500
11.0 8400 9200 9700 10500
12.0 7000 7700 8300 8600
14.0 5000 5700 6100 6500
16.0 4200 4600 4900
18.0 3100 3500 3800
20.0 2300 2600 2900
22.0 2000 2300
24.0 1500 1600
26.0 1000 1300
28.0 1000
30.0
I 0 0 0 0 0
II 0 6.5 13.0 19.5 26
Reeving 12 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-11 Lifting capacity table

Description of Crane

Unit: kg
Main boom + jib
Boom Outriggers fully extended, over sides and rear, 5 t fixing counterweight
angle 47.0 m + 9.5 m 47.0 m + 16.0 m
(°)
0° 15° 30° 0° 15° 30°
80 5500 3500 3000 3500 2200 1500
78 5000 3500 3000 3500 2000 1500
76 5000 3300 2800 3200 2000 1500
74 4800 3300 2800 2800 2000 1500
72 4300 3100 2800 2800 1800 1400
70 4000 3000 2700 2600 1600 1400
68 3800 3000 2600 2400 1600 1400
66 3400 2900 2500 2300 1500 1400
64 2900 2600 2400 2200 1500 1300
62 2500 2300 2100 1900 1500 1300
60 2100 1900 1800 1700 1400 1300
58 1700 1600 1500 1400 1200 1100
56 1400 1300 1200 1100 1000 900
54 1200 1100 1000 900
52 1000 900
Reeving 1
Hook 6 tons

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Description of Crane
Table 1-12 Lifting capacity table

Unit: kg
Main boom (m)
Radius Outriggers and telescoping cylinder I fully extended, over sides and rear, 5 t
(m) fixing counterweight + 3 t movable counterweight
12.1 16.5 21.0 27.5 34.0 40.5 47.0
3.0 80000* 55000
3.5 67000* 53000 43500
4.0 57000 52000 43500
4.5 54000 49000 42000 31000
5.0 50000 46000 41000 31000
5.5 48000 44000 39000 30000
6.0 45000 41000 37000 29000 23000
7.0 37000 36500 33000 27000 22000
8.0 28000 27000 27500 24500 21000 16500
9.0 22000 21500 21500 22000 19500 15500
10.0 17000 17300 18800 17200 14500 11500
11.0 14000 14300 15500 16000 13500 11000
12.0 12000 11800 13200 14000 12500 10500
14.0 8500 9600 10300 10600 9300
16.0 6200 7300 8000 8600 8100
18.0 5600 6300 6900 7300
20.0 4300 5100 5500 6000
22.0 3300 4000 4500 4800
24.0 3100 3600 4000
26.0 2400 2900 3200
28.0 1800 2300 2600
30.0 1800 2100
32.0 1400 1700
34.0 1300
36.0 1000
I 0 4.4 8.9 8.9 8.9 8.9 8.9
II 0 0 0 6.5 13.0 19.5 26
Reeving 12 10 8 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-13 Lifting capacity table

Description of Crane

Unit: kg
Main boom (m)
Radius Outriggers fully extended and telescoping cylinder I intermediately extended,
(m) over sides and rear, 5 t fixing counterweight + 3 t movable counterweight
12.1 16.5 23.0 29.5 36.0 42.5
3.0 80000* 55000
3.5 67000* 53000 31000
4.0 57000 52000 31000
4.5 54000 49000 31000
5.0 50000 46000 31000 23000
5.5 48000 44000 30000 23000
6.0 45000 41000 29000 23000
7.0 37000 36500 27000 22000 16500
8.0 28000 27000 26000 21000 16500 12000
9.0 22000 21500 23500 19500 15500 11500
10.0 17000 19300 19000 14500 11500
11.0 14000 16200 17100 13500 11000
12.0 12000 13700 14600 12500 10500
14.0 10200 11000 10600 9300
16.0 7800 8600 9100 8100
18.0 6000 6800 7300 7300
20.0 5400 5900 6300
22.0 4400 4800 5200
24.0 3500 4000 4300
26.0 3200 3600
28.0 2600 2900
30.0 2100 2400
32.0 2000
34.0 1600
36.0
I 0 4.4 4.4 4.4 4.4 4.4
II 0 0 6.5 13.0 19.5 26
Reeving 12 10 6 6 4 3
Hook 60 tons

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Table 1-14 Lifting capacity table

Description of Crane
Unit: kg
Main boom (m)
Radius Outriggers fully extended and telescoping cylinder I fully retracted, over sides
(m) and rear, 5 t fixing counterweight + 3 t movable counterweight
12.1 18.6 25.1 31.6 38.1
3.0 80000* 31000
3.5 67000* 31000
4.0 57000 31000 23000
4.5 54000 31000 23000
5.0 50000 31000 23000
5.5 48000 30000 23000 16500
6.0 45000 29000 23000 16500
7.0 37000 27000 22000 16000 12500
8.0 28000 26000 21000 14500 12000
9.0 22000 24000 19500 13500 11500
10.0 20000 18000 12500 11500
11.0 16800 17100 11500 10500
12.0 14300 15200 10700 9700
14.0 10800 11600 9300 8400
16.0 9100 8200 7300
18.0 7300 7300 6400
20.0 6000 6400 5800
22.0 5300 5200
24.0 4400 4600
26.0 3700 4000
28.0 3300
30.0 2800
32.0 2300
34.0
36.0
I 0 0 0 0 0
II 0 6.5 13.0 19.5 26
Reeving 12 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-15 Lifting capacity table

Description of Crane

Unit: kg
Main boom (m)
Radius Outriggers intermediately extended and telescoping cylinder I fully extended,
(m) over sides and rear, 5 t fixing counterweight + 3 t movable counterweight
12.1 16.5 21.0 27.5 34.0 40.5 47.0
3.0 62000* 52000
3.5 52000 48000 42000
4.0 45000 43000 40000
4.5 40000 38000 37000 31000
5.0 38000 36000 34000 31000
5.5 34000 33500 31500 30000
6.0 28000 27500 25000 26000 23000
7.0 21000 20000 19500 21000 21500
8.0 16000 15500 15000 16700 17500 16500
9.0 12000 12000 11500 13200 14200 15000
10.0 9500 9300 10700 11500 12200 11500
11.0 7700 7500 8700 9500 10200 10500
12.0 6200 6000 7200 8000 8600 9000
14.0 3800 5000 5700 6200 6600
16.0 2300 3400 4100 4600 5000
18.0 2300 3000 3400 3800
20.0 1400 2000 2500 2800
22.0 1300 1800 2100
24.0 1200 1500
26.0 1000
28.0
30.0
I 0 4.4 8.9 8.9 8.9 8.9 8.9
II 0 0 0 6.5 13.0 19.5 26
Reeving 12 10 8 6 5 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-16 Lifting capacity table

Description of Crane
Unit: kg
Main boom (m)
Radius Outriggers and telescoping cylinder I intermediately extended, over sides and
(m) rear, 5 t fixing counterweight + 3 t movable counterweight
12.1 16.5 23.0 29.5 36.0 42.5
3.0 62000* 52000
3.5 52000 48000 31000
4.0 45000 43000 31000
4.5 40000 38000 31000
5.0 38000 36000 31000 23000
5.5 34000 33500 30000 23000
6.0 28000 27500 26000 23000
7.0 21000 20000 22000 22500 16500
8.0 16000 15500 17200 18200 16000 12000
9.0 12000 12000 13700 14600 15000 11500
10.0 9500 11200 12000 12600 11500
11.0 7700 9200 10000 10500 11000
12.0 6200 7700 8500 9000 9500
14.0 5500 6200 6700 7100
16.0 3800 4600 5000 5400
18.0 2600 3300 3800 4100
20.0 2400 2900 3200
22.0 1600 2100 2400
24.0 1500 1800
26.0 1000 1300
28.0 1000
30.0
I 0 4.4 4.4 4.4 4.4 4.4
II 0 0 6.5 13.0 19.5 26
Reeving 12 10 6 6 4 3
Hook 60 tons

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 Operator’s Manual for Truck Crane

Table 1-17 Lifting capacity table

Description of Crane

Unit: kg
Main boom (m)
Radius Outriggers intermediately extended and telescoping cylinder I fully retracted,
(m) over sides and rear, 5 t fixing counterweight + 3 t movable counterweight
12.1 18.6 25.1 31.6 38.1
3.0 62000* 31000
3.5 52000 31000
4.0 45000 31000 23000
4.5 40000 31000 23000
5.0 38000 31000 23000
5.5 34000 30000 23000 16500
6.0 28000 29000 23000 16500
7.0 21000 23000 22500 16500 12500
8.0 16000 18000 19000 14500 12000
9.0 12000 14500 15300 13200 11500
10.0 11800 12600 12300 11500
11.0 9800 10500 11000 10500
12.0 8300 9000 9600 9300
14.0 6000 6700 7200 7500
16.0 5100 5500 5800
18.0 3900 4300 4500
20.0 2900 3300 3600
22.0 2600 2800
24.0 2000 2200
26.0 1400 1700
28.0 1300
30.0 1000
I 0 0 0 0 0
II 0 6.5 13.0 19.5 26
Reeving 12 6 5 4 3
Hook 60 tons

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Description of Crane
Table 1-18 Lifting capacity table

Unit: kg
Main boom + jib
Boom Outriggers fully extended, over sides and rear, 5 t fixing counterweight + 3 t
movable counterweight
angle
(°) 47.0 m + 9.5 m 47.0 m + 16.0 m
0° 15° 30° 0° 15° 30°
80 5500 3500 3000 3500 2200 1500
78 5000 3500 3000 3500 2000 1500
76 5000 3300 2800 3200 2000 1500
74 4800 3300 2800 2800 2000 1500
72 4300 3100 2800 2800 1800 1400
70 4000 3000 2700 2600 1600 1400
68 3800 3000 2600 2400 1600 1400
66 3600 2900 2500 2100 1500 1400
64 3300 2700 2400 2000 1500 1300
62 2900 2500 2300 1900 1500 1300
60 2500 2300 2100 1800 1400 1300
58 2200 2100 1900 1700 1400 1200
56 1900 1800 1700 1500 1300 1200
54 1600 1500 1400 1200 1100 1000
52 1300 1200 1100 1000 950 900
50 1100 1000 950 900
48 1000
Reeving 1
Hook 6 tons

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 Operator’s Manual for Truck Crane
Description of Crane

1.3.6 Lifting height chart

68

47.0+16 64

60
47.0+9.5
56

80°
0° 52
75° 15°
47.0 30°
70°
65° 48

60° 0°
15°
30° 44
55°
52°
Boom 50°
length (m) 40
48°
Lifting
36 height
(m)

32

28

21.0 24

16.5 20

16
12.1

12

4 8 12 16 20 24 28 32 36 40

Working radius (m)

Figure 1-12 Lifting height chart

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Description of Crane
CAUTION
(1) The sliding beams of outriggers must be extended (to a uniform length on both
sides) to the extent stated in the lifting capacity table. All wheels must be raised
clear of the ground.
(2) When you set up the 5th outrigger, the values in the lifting capacity tables are
suitable for 360° full range operation. Extend the 5th outrigger when you lift a load
over front.
(3) The values given in the lifting capacity tables are the max. permissible lifting
capacities under various OMs and specified operating conditions. The values as
given in the tables include the mass of the hook (main hook: 550 kg, auxiliary hook:
150 kg) and slings.

Actual lifting capacity of

Rated lifting the crane + Mass of the hook and slings
capacity =

(4) The working radius is the horizontal gravity center distance of the hook block from
the rotational axis of the crane superstructure measured at the ground. The radius
stated is valid under load conditions.
(5) Use next lower rated capacity when working at radius between the figures on the
rated lifting capacity table.
For example:
If the crane is working with 19 m long main boom at 4.8 m working radius, the lifting
capacity found in the lifting capacity table of bigger values – 21 m long main boom
and 5.0 m working radius – should be referred to. That is to say, the lifting capacity
41000 kg should be referred to.
(6) If the jib is mounted on the main boom head during main boom operation, the
possible load is reduced further corresponding weight of the jib (2000 kg).

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Description of Crane

(7) The max. lifting capacity for the rooster sheave is 6000 kg. If the rated lifting
capacity found in the lifting capacity table is less than 6000 kg according to the
actual working conditions, the lifting capacity found in the table should be referred
to.
For example:
The rated lifting capacity is 6000 kg when the crane is working with 26.4 m long
main boom under 6 m working radius.
The rated lifting capacity is 2900 kg if the crane is working with 39 m long main
boom under 26 m working radius.
(8) During operation, do not lift a load with both main hook and auxiliary hook
simultaneously.

WARNING
If the main boom is more than 30 m long, derrick the boom according to the lifting height
chart, even if the crane is without a load. Otherwise, the crane may topple.

1.3.7 Working areas

Over front Over sides and rear

Figure 1-13 Working areas

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Truck Crane Operator’S Manual

Chapter 2 Safety Guidelines

 Operator’s Manual for Truck Crane

Chapter 2 Safety Guidelines

2.1起Safety instructions and safety signs

重
2.1.1
机 Safety instructions
说
a)
明 Be sure to comply with all valid national and regional traffic regulations when driving the
crane on roads!

Safety Guidelines
b) No person is allowed to stay in operator’s cab during driving.
c) The crane must be made to comply with the relevant local traffic regulations, before it is
driven on public streets, roads and other places. Make sure the weights, axle loads and
dimensions are within the permits specified in the vehicle license.
d) The relevant persons should be trained to ensure safe operation. Initial commissioning
and starting must only be undertaken by a competent person who has read and fully
understands the information provided in the Operator's Manual.
e) Comply with the safety signs on the crane to avoid serious injuries or casualties.
f) All the assembly, commissioning, operation, maintenance and service of crane should only
be carried out by specialized personnel.

DANGER
Do not allow the hook block to impair the driver’s field of vision when you drive the
crane on public roads!

2.1.2 Safety signs

CAUTION
(1) Some safety signs indicating potential great danger are only stuck on the vehicle
body. Do not move the decals at random.
(2) Other potential danger is mentioned in this Operator’s Manual. Pay much attention
to it.
(3) Examine the safety signs on the potentially dangerous parts at a regular interval.
Replace all missing or damaged safety signs to make sure that the decals show and
are in good condition.

a) Read the operator’s manual

注 意
This decal is only stuck on the CAUTION
操作前请仔细阅读操作手册
right pane in operator’s cab. 操作中应遵守安全规程
和操作手册
Caution: Carefully read the
Operator’s Manual before operation.
Obey the instructions in this manual and
the safety regulations during operation.

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 Operator’s Manual for Truck Crane

b) Do not telescope the boom with

警 告
WARNING
a suspended load.
This decal is only stuck on the
严禁带载伸缩
right pane in the operator’s cab.
Do Not Telescope
With Suspended Loads
Safety Guidelines

c) Exit
This decal is only stuck on the
front windshield in the operator’s
cab.

d) No standing under the boom.

This decal is stuck on the sides
of boom.

e) Be careful in the working radius. 危 险

DANGER
注 意
CAUTION

与移动中的机构
This decal is stuck on the sides 保持安全距离

Keep clear of
moving machine.
of fixed counterweight.

f) Fire extinguisher
It is on the side of driver’s cab
near the fender.

g) Keep clear of moving outriggers.

危 险
This decal is stuck on the sliding DANG ER

beam. 当心支腿

Keep Clear Of
Moving Outriggers

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 Operator’s Manual for Truck Crane

h) Always lock the door when not in

警 告
use. WARNING

起 This decal is stuck on the lower

重 right corner of left hood.
机
说
明

Safety Guidelines
i) No step
警 告
This decal is on the roof of left WARNING

hood. 禁止踩踏
No access to this area
此处踩踏会损害设备
Otherwise, the equipment
will be damaged.

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 Operator’s Manual for Truck Crane

2.2 Planning crane operation

In addition to a perfectly working crane and a well-trained crew, crane operation planning is an
important principle of safe crane operation.
The crane operator must obtain or receive the necessary information in a timely fashion before
driving to the work site. In particular:
Safety Guidelines

a) Natural environment of work site

b) Work site and travel distance
c) Route
d) Height and width clearance measurements
e) Electric transmission lines
f) Space restrictions at the work site
g) Movement restrictions caused by buildings
h) Weight and dimensions of the loads to be lifted and the required lifting height and working
radius
i) Geological conditions or ground bearing capacity at the work site.
Basing on the above information, the crane operator must assemble the equipment required to
operate the crane:
a) Load hook / hook block
b) Load handling device
c) Jib
d) Underlay materials for outrigger pads.

WARNING
Crane operation may not be possible or improvisation can result if a crane operator
does not have all the required data.

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2.3 Break-in instructions

The purpose of crane break-in is to improve its adaptability to the environment. Proper break-in
起
operation can extend crane service life, increase work reliability and save energy consumption.
重
机
Pay attention to the following items during the break-in period:
说
a) During initial crane operation (less than 100 operating hours), you must follow the below
明
instructions:

Safety Guidelines
– The work load and work speed must not be too high.
– The maximum lifting capacity should not be larger than 80% of the rated one.
– Do not operate the crane at a speed that is more than the maximum limits.
b) Do not drive the crane at a driving speed higher than 55 km/h and with the engine speed
higher than 1800 r/min within the first 600 km. Drive the vehicle on even road.
c) Increase the driving speed or engine RPM gradually after the first 600 km and 2000 km.
d) When the vehicle is driving for the first 2500 km – 3000 km, replace the engine oil.
e) Do start and stop the vehicle slowly and gently. Shift the transmission frequently to break
in it at every gear position.
f) Break in the brake linings:
To achieve optimum braking performance, all new brake linings must be broken in by
activating the brakes. Activate the brakes by pumping them at low to high speed. Hard
braking is not permitted. In general, the break-in distance depends on the type of vehicle,
but a minimum of 500 km is recommended. During this phase, the maximum temperature
of brake hub or braking lining may not exceed 200°C.

DANGER
Risk of accident!
The risk of accident increases when new brake linings are subjected to one or more
braking operations over extended periods of time or if the vehicle is forced to a stop by
hard braking from maximum speed several times.
Hard braking and continuous braking are not permitted!

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 Operator’s Manual for Truck Crane

2.4 General safety technical guidelines

2.4.1 Requirements of the crane operator, rigger and signalman
The primary responsibility of crane operator, rigger and signalman is to control, operate, adjust
the crane and conduct the operation in a manner that is safe for both themselves and others.
Many crane accidents are caused by incorrect crane operation.
Safety Guidelines

The main operating errors, which are made again and again while operating or driving a crane,
are as follows:
a) Not paying careful attention while working, for example:
1) Slewing too quickly
2) Quick braking of the load
3) Diagonal pulling when the load is still on the ground
4) Loose wire rope formations.
b) Overloading.
c) Crashing into bridges, roofs or high voltage wiring due to insufficient vertical clearance.
d) Unsuitable operation when lifting a load with several cranes at the same time.
About 20% of crane damages are caused by improper maintenance:
a) Insufficient lubricating oil, lubricating grease or antifreeze
b) Broken wire rope, worn parts
c) Limit switches or load moment limiter not operating properly
d) Brake or transmission failure
e) Hydraulic defects (for example: cracked hoses)
f) Loose bolts.

DANGER
In the interest of both yourself and others, make sure you understand how your crane
operates and familiarize yourself with all the risks associated with the work to be done.

2.4.1.1 General qualifications for operator

a) The person who has been trained with the safety knowledge about the crane operation
b) Healthy and agile
c) Eyesight (remedied eyesight included) is above 0.7, no color blindness.
d) Hearing is qualified.
e) Know about the possible fatalness existing in the working area.
f) The ability to estimate and monitor load is enough.
g) Be able to estimate and monitor the distance, height, clearance and load correctly.
h) Be familiar with the Operator’s Manual for the crane, and know the working principle, lifting
performance, structural performance and the function and adjusting method of the safety
devices as well as master the operation essentials and maintenance skills.

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i) Be familiar with safety rules, safety signals and symbols.

j) Be qualified with the work in hearing, eyesight and reaction ability. Have the requisite

起 physical to operate the crane safely. Be able to estimate the distance, height and
重 clearance correctly.
机
k) Know how to administer first aid and know how to use a fire extinguisher. Know how to
说
明 survive in an emergency.
Make sure that only the personnel who are qualified and authorized are allowed to operate the

Safety Guidelines
crane.

NOTICE
(1) The operator should examine the brakes, hook block, wire rope and safety devices
before operation. Correct the malfunction.
(2) The operator must focus his attention on his work during operation and is forbidden
to chat with others. Generally speaking, operator can only follow the signal sent out
by appointed persons. However, for a stop signal, the operator should obey it at all
times, no matter who send it out. He should refuse to follow signal which violates
operation regulations. Stop the crane immediately if somebody is found climbing
the crane.
(3) Operator who is in low spirits or poor health is not allowed to operate the crane. Do
not drink before operation.

2.4.1.2 General qualifications for rigger

The rigger is responsible for ensuring that the load is slung or released safely and carefully and
decides which hook and load handling device to be used in accordance with work plan. The
rigger is also responsible for the safety of the crane.
Qualifications for rigger:
a) With crane operation certificate.
b) Be qualified with the work in hearing, eyesight and reaction ability.
c) Be able to estimate and monitor the distance, height, clearance and load correctly.
d) Have been trained in the skill of handling load.
e) Be able to choose the proper hook and load handling device according to conditions of the
load.
f) Have been trained in hand signals for operation and is familiar to use them.
g) Be able to safely use audio equipment (such as interphone) to send out oral order exactly
and clearly.
h) Make sure that only authorized personnel are allowed to carry out the work.

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 Operator’s Manual for Truck Crane

2.4.1.3 General qualifications for signalman

The signalman is to transfer signal from the rigger to operator. He can substitute for the rigger
to conduct the crane operation, but such work can only be done by one person at any time.
Qualifications for signalman:
a) Be qualified with the work in hearing, eyesight and reaction ability.
b) Be able to estimate the distance, height and clearance correctly.
Safety Guidelines

c) Have been trained in hand signals for operating and is familiar to use them.
d) Be able to safely use audio equipment (such as interphone) to send out oral order exactly
and clearly.
e) Make sure that only authorized personnel are allowed to carry out the work.

2.4.2 Selecting an operating site

It is very important to choose an appropriate location for crane operation in order to minimize
safety risks.
When selecting the placement location of the crane, observe the following:
a) Crane operations can be carried out within the necessary radius (working radius and
counterweight slewing radius).
b) Support the crane and other things only on ground with sufficient load bearing capacity.
c) The ground pressure should comply with the permitted and expected value under the
crane with a required lifting load.

2.4.2.1 Slopes and ditches

The crane may not be set up too close to slopes or ditches. Maintain adequate safety
clearances in accordance with the type of soil. The formulas for calculating the safety clearance
are as follows:
For non-cohesive and soft cohesive ground:
A2
A 2 = 2T (1)
A1
For stiff or semi-solid cohesive ground:
A1 = T (2)
T refers to the depth of ditch.
T

DANGER
If the safety distance cannot be maintained, fill and level up the slope and ditch.
Otherwise the crane may topple!

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2.4.2.2 Permissible ground pressure of outrigger

When the crane is supported on outriggers for a lift operation, the outriggers transmit significant
起
forces to the ground. In certain cases, a single outrigger has to transmit almost the entire
重
weight of the crane, plus the load weight, to the ground. The ground must be able to safely
机
absorb this pressure every time. If the outrigger pad area is inadequate, then it must be
说
明
supported from below according to the load bearing capacity of the ground.

Safety Guidelines
The formula for calculating the required support area is as follows:
Support area = maximum crane support force / load bearing capacity of the ground
The pressure strength of a variety of ground types are shown in Table 2-1, and it is for
reference only.

Table 2-1 Load bearing capacity of the ground

Ser.
Soil type Load bearing capacity (kg/cm2)
No.
A Back-filled, naturally compacted ground 0–1

Natural, clearly undisturbed ground:

1. Mud, peat, marshy soil 0

2. Non-cohesive ground, sufficient compactly
layered soil
Fine to medium grained sand 1.5
Coarse-grained sand to gravel 2.0
3. Cohesive ground:
Sludgy 0
B
Soft 0.4
Firm 1.0
Semi-compact 2.0
Hard 4.0
4. Rock with few fissures, in healthy,
unweathered condition and in a favorable
location:
In cohesive layer order 15
In massive or column-style shape 30
Artificially compacted ground:

1. Asphalt 5 – 15
C
2. Concrete
Concrete group B I 50 – 250
Concrete group B II 350 – 550

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 Operator’s Manual for Truck Crane

Note:
If there is anything about the load bearing capacity of the ground at the placement site that you
do not understand, use a special detecting instrument to do a soil test.

CAUTION
Only strong materials may be used for the outrigger pad bases such as properly
Safety Guidelines

dimensioned wooden timbers.

In order to make sure that the pressure is evenly distributed over the base surface, the
outrigger pads must be positioned in the center of the support base.

2.4.3 Supporting
a) Before operation, all wheels must be raised clear of the ground.
b) Before you extend the vertical cylinder, extend the sliding beams to the specified positions.
c) Extend all the sliding beams according to the data in the lifting capacity table and secure
them by pins.
d) Before operation, level the crane. Under any working conditions, the inclination angle α of
the crane must not be more than 0.6°. Refer to Figure 2-1.

Figure 2-1 Inclination angle of crane

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DANGER
If the crane is positioned at an incline and the boom is turned towards the downslope,
起
then the radius is increased as a result. It is possible that the crane can topple in
重
extreme cases.
机
说
After the crane is supported, examine the following safety measures:
明
a) The placement location has been selected in such a way that the crane can be operated

Safety Guidelines
with the least possible radius.
b) The load bearing capacity of the ground is adequate.
c) There is a sufficient safe distance to slopes or ditches.
d) All outriggers have been extended to the specified position.
e) The outriggers are secured with pins.
f) The outrigger pads are secured.
g) The crane has been leveled.
h) All tires do not touch the ground.
i) There are no live electrical wires within the working range of the crane.
j) There are no obstacles which will hinder the required crane movements.

2.4.4 Working conditions

2.4.4.1 Temperature
Do not operate the crane if the temperature at the job-site is not in the proper range from -20°C
to 40°C.

NOTICE
Pay attention to the ambient temperature in the job-site.

2.4.4.2 Wind load

Before operation, measure the wind speed with the anemometer on boom head. At the same
time, judge the instantaneous wind speed according to physical phenomenon. The maximum
wind force during crane operation is Beaufort 5. That is to say, the wind speed is 14.1 m/s and
the wind pressure is 125 N/m2.

2.4.4.2.1 Wind speed

During operation, the instantaneous wind speed should be taken as the actual one. Wind speed
during crane operation should not exceed 14.1 m/s.
The wind speed during crane operation (3 s instantaneous wind speed) = average value of
wind speed for 10 minutes of 10 m above the ground × conversion coefficient 1.5.
For the beaufort and wind speed in weather forecast, please refer to Table 2-2.

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Table 2-2 Wind speed

Instantaneous
Average wind
Beaufort Description wind speed Effect of the wind on the land
speed (m/s)
(m/s)

0 Calm 0 – 0.2 0 – 0.3 No wind, smoke rises vertically

Slight air Wind direction shown by smoke
Safety Guidelines

1 0.3 – 1.5 0.5 – 2.3

(draft) drift but not by wind vanes
Light Wind felt on face, leaves rustle,
2 1.6 – 3.3 2.4 – 5.0
breeze vanes move by wind
Gentle Leaves and small twigs in constant
3 3.4 – 5.4 5.1 – 8.1
breeze motion, wind extends light flag
Moderate Dust swirls up, small branches
4 5.5 – 7.9 8.3 – 11.9
breeze move
Fresh
5 8.0 – 10.7 12 – 16.1 Small trees in leaf begin to sway
breeze
Large branches in motion, difficult
Strong
6 10.8 – 13.8 16.2 – 20.7 to use umbrellas, whistling heard
breeze
in telegraph wires
Whole trees in motion, difficult to
7 Stiff wind 13.9 – 17.1 20.9 – 25.7
walk against the wind
Gale force Breaks twigs off trees, impedes
8 17.2 – 20.7 25.8 – 31.1
wind progress
Slight structural damage (roof tiles
9 Gale 20.8 – 24.4 31.2 – 36.6 and chimney covers, etc. blown
off)
Severe Trees uprooted, considerable
10 24.5 – 28.4 36.8 – 42.6
gale damage occurs
Violent Extensive, widespread storm
11 28.5 – 32.6 42.8 – 48.9
storm damage
12 Hurricane > 32.7 > 49.1 Major destruction

2.4.4.2.2 Wind pressure

Crane operation is affected by wind speed. The higher the height above the ground is, the
stronger the wind speed is, and the higher the wind pressure is.
Wind pressure = ground wind pressure × height changing coefficient of wind pressure
The equation of wind pressure and wind speed: p=0.625ν s 2. (p represents wind pressure, unit:
N/m2, ν s represents average instantaneous wind speed, unit: m/s)
K h represents height changing coefficient of wind pressure.

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Take the ground wind speed of 14.1 m/s as an example. For the wind pressure and wind speed
of different heights, please refer to Table 2-3.

起 Table 2-3 Wind speeds for different heights above ground

重
机 above
Height
≤ 10 10 – 20 20 – 30 30 – 40 40 – 50 50 – 60 60 – 70 70 – 80
说
ground (m)
明
Kh 1 1.13 1.32 1.46 1.57 1.67 1.75 1.83

Safety Guidelines
Wind speed
14.1 15.03 16.25 17.09 17.72 20.02 20.49 20.96
ν s (m/s)
Height above
80 – 90 90 – 100 100 – 110 110 – 120 120 – 130 130 – 140 140 – 150
ground (m)

Kh 1.90 1.96 2.02 2.08 2.13 2.18 2.23

Wind speed
21.35 21.69 22.02 22.34 22.61 22.87 23.13
ν s (m/s)

WARNING
If the instantaneous wind speed is greater than the permissible value of 14.1 m/s
(beaufort 5), while the crane is in operation, do the tasks that follow:
(1) Stop the work (safely lower the load).
(2) Retract the boom.
(3) Correctly stow the boom.

2.4.4.3 Height above sea level

During crane operation, height above sea level should not be higher than 2000 m.
If the height above sea level of job-site is between 2000 m and 4000 m, activate the highland
mode switch in order to reduce a highland influence on the crane. For the details, please refer
to 3.1.8.1 in Chapter 3.
If the height above sea level of job-site is above 4000 m, have the crane made to order in
advance.
The technical data of this crane such as gradeability and fuel consumption etc. are applied to
the job-site of which the height above sea level is below 2000 m.

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NOTICE
The higher the height above sea level is, the lower the air pressure is, and the less the
oxygen content is.
The height above sea level is higher than 2000 m, the following crane performance will
be affected:
Safety Guidelines

– Gradeability is reduced.
– Fuel consumption is increased.
– The boiling temperature of engine coolant decreases.
– Exhaust system emits black smoke.

2.4.4.4 Direct sunshine

A temperature difference occurs between the side facing the sun and the side facing away from
the sun in cranes with telescopic booms. This causes telescopic boom side distortion, which
can reduce the load-bearing capacity of the telescopic boom.

DANGER
Risk of accident because of component overloading!
(1) If the telescopic boom has become distorted because of one-sided sunlight, this
can cause component overloading and therefore accidents.
(2) When a telescopic boom extension such as a jib is being used, the equipment and
the work site must be visually inspected before picking up the load in order to
ensure that the boom is not showing signs of side deformation because the sun
shining on one side. According to the condition of the work site, adjust the
operation posture of crane. Turn crane directly towards the sun or behind the sun
so that both sides of the boom are brought to about the same temperature,
therefore preventing side deformation!

2.4.4.5 Other Conditions

a) During crane operation, if the visibility is less than 200 m, do the tasks that follow:
1) Stop the work (safely lower the load).
2) Retract the boom.
3) Correctly stow the boom.
b) During crane operation, stop working in case of thunderbolt or rainstorm. At the same time,
take action to prevent lightning and thunderbolt to ensure personnel safety.

WARNING
During crane operation, stop working in case of thunderbolt or rainstorm. At the

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same time, fully retract and correctly stow the boom.

c) Strong electromagnetic fields are likely to be present if the construction site is close to a
起 transmitter. Under this condition, be sure to consult a high frequency specialist or contact
重
the local franchiser or the manufacturer.
机
说
明 DANGER

Safety Guidelines
Electromagnetic field can pose direct or indirect danger, such as harmful effect on
human organs due to radiation and make spark or electric arc, to persons,
equipment and objects.

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 Operator’s Manual for Truck Crane

2.4.5 Points for attention for safe operation

a) Personnel must stay away from the area
below the boom.
Safety Guidelines

b) Do not let personnel on the slewing table

while you operate the crane.

c) Do not move personnel on the load or

other equipment used to lift.

d) Do not move a load above personnel.

e) Support the crane on outriggers before

operation.

f) Do not lift a load that is above the capacity

of the crane.

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g) The crane, with extended outriggers, must

be on the ground with a slope α of less

起 than 0.6° during operation.

重
机
说
α
明

Safety Guidelines
h) Do not pull load at an angle and do not lift
a load that is not in balance.

i) Do not try to lift a load that is buried or

frozen on the ground.

j) When the load is off the ground, the

operator must stay in the cab.

k) Do not telescope the boom with a

suspended load.

l) Do not pick-and-carry a load.

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 Operator’s Manual for Truck Crane

m) When the job-site is near live power lines,

you must keep a safe distance. Make sure
that you comply with the related
regulations.
Safety Guidelines

n) Personnel must stay away from the reach of the boom.

o) Stop the crane in an emergency.
p) When the load is off the ground, do not adjust the hoist gear brake.
q) Keep no less than 3 wraps of wire rope on the drum.
r) Before crane operation, adjust the slings (rope or chain) to make the hook block on the
upright position of load gravity center.
s) Prevent the load or lifting equipment from collision with crane.
t) During crane operation, stop working in case of thunderbolt or rainstorm. At the same time,
take action to prevent lightning and thunderbolt to ensure personnel safety.
u) Before you start or stop the crane operation, make sure the movable parts and movable
load in danger zone will not interrupt any persons and objects.
v) When the actual lifting load reaches 90% of the rated one, the warning light will light up
and the buzzer will sound the alarm. When this occurs, be careful as you continue to lift.
w) The operation should be stable and gentle. Do not carry out any jerky movements with the
joysticks. Avoid any sudden acceleration or braking or conversion operation.

DANGER
Stop the operation or do not start to lift a load, if one of the items that follow occurs:
(1) An overload or if the weight of the load is unknown.
(2) The load lift moves out of position, the rigging becomes too loose or the load is out
of balance.
(3) The protective material between the edges of load and wire rope is missing.
(4) The light level at the job-site goes below a safe work condition.
(5) Equipment malfunction or damage to the crane that decreases the safe operation of
the crane, such as failure of brake and safety devices or damage to wire rope.

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2.5 Hand signals

起
a) Start
重 Hold the right arm stretched vertically
机
upwards. The palm faces forwards.
说
明

Safety Guidelines
b) Use main winch
Tap fist on head, then use regular
signal.

c) Use auxiliary winch

Tap elbow with one hand, then use
regular signal.

d) Lift the load

With forearm vertical, extended fingers
pointing up, move hand in small
horizontal circle.

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e) Lower the load

With arm extended downward with a
30° angle to the body, forefinger
pointing down, move hand in small
horizontal circle.
Safety Guidelines

f) Lift the load slowly

With forearm vertical, palm of the hand
facing upwards, wave hand up
repeatedly.

g) Rotate
Turn left: With right forearm vertical, the
palm of the hand facing outwards, lower
the forearm sideways horizontally,
fingers pointing in the direction of
rotation.
Turn right: With left forearm vertical, the
palm of the hand facing outwards, lower
the forearm sideways horizontally,
fingers pointing in the direction of
rotation.

h) Lower the load slowly

With arm extended downwards with a
30° angle to the body, palm of the hand
facing downwards, wave hand down
repeatedly.

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i) Rotate slowly
Turn left: With right forearm vertical, the

起 palm of the hand facing outwards, move

重 forearm horizontally and repeatedly,
机 fingers pointing in the direction of
说
明 rotation.
Turn right: With left forearm vertical, the

Safety Guidelines
palm of the hand facing outwards, move
forearm horizontally and repeatedly,
fingers pointing in the direction of
rotation.

j) Indicate load lowering position

Extend the fingers to point at the
position the load should fall on.

k) Raise boom
Arm extended, finger closed, thumb
pointing upward.

l) Lower boom
Arm extended, finger closed, thumb
pointing downward.

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m) Raise boom slowly

Forearm extends in front of body with
palm facing downwards, another hand
moves up and down with thumb
pointing upwards.
Safety Guidelines

n) Lower boom slowly

Forearm extends in front of body with
palm facing upwards, another hand
moves up and down with thumb
pointing downwards.

o) Extend boom
Both fists in front of body with thumbs
pointing outwards.

p) Retract boom
Both fists in front of body with thumbs
pointing toward each other.

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q) Stop
Arm extended, palm down, and move

起 the arm back and forth horizontally.

重
机
说
明

Safety Guidelines
r) Emergency stop
Both arms extended, palms down,
move arms back and forth horizontally.

s) End a movement
Cross your hands in front of your
forehead.

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Chapter 3 Operation – Crane Chassis

 Operator’s Manual for Truck Crane

Chapter 3 Operation – Crane Chassis

3.1起Driver’s cab
重
3.1.1
机 Overview
说
明

Operation
–

Figure 3-1 Cab exterior Crane Chassis

Pos. Description Pos. Description

1 Wire rope holder 6 Front combination signals

2 Rotating beacon a 7 Side turn signal

3 Corner marker light 8 Door handle

4 Mirror (R) 9 Mirror (L)

5 Front windshield wiper 10 Handrail

The part marked with “a” is optional.

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 Operator’s Manual for Truck Crane

起
重
机
说
明
Operation

–
Crane Chassis

Figure 3-2 Cab interior

Pos. Description Pos. Description

1 Instrument console 8 Sun visor

2 Steering wheel assy. 9 Toolbox

3 Oil reservoir, clutch 10 Central electric control box

4 Air horn switch 11 Center console

5 Foot pedal (L): Clutch 12 Co-driver’s seat

6 Foot pedal (M): Service brake 13 Sleeper berth

7 Foot pedal (R): Engine control 14 Driver’s seat

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 Operator’s Manual for Truck Crane

3.1.2 Steering wheel assy.

See Figure 3-3.
起
重
机
说 3 5
明

6
1 4

Operation
Figure 3-3 Steering wheel assy.
–

Crane Chassis
Pos. Description Pos. Description

1 Ignition starter switch 4 Left-hand steering column switch

2 Steering wheel adjustment handle 5 Electric horn buttons

3 Steering wheel 6 Right-hand steering column switch

3.1.2.1 Steering wheel adjustment handle

The position and height of the steering wheel can be adjusted to suit the driver.
You can adjust the steering wheel height and position when you pull the adjustment handle
upwards.

CAUTION
1) DO NOT adjust the steering wheel while you move the crane. This can kill you.
2) Pull the handle downwards to lock the steering wheel after adjustment.

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3.1.2.2 Left-hand steering column switch

See Figure 3-4.
起
重
机
说
1
明 R
L
5
4 2
OFF

3
Operation

Figure 3-4 Left-hand steering column switch

–
Crane Chassis

a) Turn signal activation (left / right)

Jog steering column switch forwards (in direction 1): activate turn signal (right).
Jog steering column switch backwards (in direction 3): activate turn signal (left).
b) Switch between the low beam and high beam and operate the headlamp flasher
Jog the switch upwards (in direction 2) to turn on the high beam and headlamp.
Jog the switch upwards and downwards continuously to operate headlamp flasher.
No matter what working conditions other lamps are in, once the headlamp flasher is on,
the headlamp will light up.
c) Hazard light switch
Press the “ ” marking (in radial direction 4) at the end of steering column switch to
activate the left and right turn signals simultaneously in order to realize danger warning
function. Press it again to reset.
d) Switch on lighting
Rotate the end of the steering column switch to the position to activate the front
width lamp, rear width lamp, corner marker light, license plate lamp, operating instrument
lamp and side marker light.
Rotate the end of the steering column switch to the position to activate the high beam
or low beam.
e) Switch on high beam
Jog steering column switch leftwards (in direction 5): activate high beam.

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3.1.2.3 Right-hand steering column switch

See Figure 3-5.
起
重
机
说
MIST
明 1
OFF
INT ON
LO OFF 2
HI PULL

Operation
Figure 3-5 Right-hand steering column switch
–

Crane Chassis
a) Activate the windshield wiper
Jog steering column switch forwards (in direction 1, MIST): activate the windshield wiper
and automatically reset.
Jog steering column switch backwards (in direction 3): realize 4 stages of windshield
wiper.
HI: High speed
LO: Low speed
INT: Intermittent
OFF: Off
b) Activate the windshield wiper washer system
Jog steering column switch (in direction 2). The washer and wiper begin to work. They will
not stop working until the button is released.

CAUTION
Do not operate the wipers on hot sunny days unless you use spray the window with
wiper fluid. When the temperature is below freezing, make sure that the wiper
blades are not stuck to the window before you set the wipers to ON.

c) Activate the engine exhaust brake

Rotate the end of the steering column switch to position “ON” to activate the engine
exhaust brake.
Rotate the end of the steering column switch to position “OFF” to deactivate the engine
exhaust brake.

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 Operator’s Manual for Truck Crane

CAUTION
起You can depress the engine control pedal or clutch pedal to deactivate the engine
重
exhaust brake temporarily. The engine exhaust brake will continue its work after you
机
说release the pedal.
明When the engine RPM is below 800 rpm, the engine exhaust brake will be
deactivated automatically. The engine exhaust brake is deactivated when ABS
system works.

3.1.2.4 Electric horn buttons

They are in the central area of the steering wheel. Press either of the two buttons on the left or
Operation

right side of the central area to activate the electric horn.

3.1.2.5 Ignition starter switch

–
Crane Chassis

The 4 positions of the switch (in clockwise sequence) are as follows:

LOCK All circuits are OFF. You can plug in or pull out the key.
ACC The battery begins to supply electricity and parts of the electrical system begin to
work.
ON The entire electrical system of chassis is electrified.
START A temporary position, use it to operate the starter. The key will return to position
“ON” automatically after you release the key when the engine starts.

CAUTION
You cannot remove the key from the ignition until the switch is in the position LOCK.

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3.1.2.6 Power windows

a) Controls beside driver
起 Swich, left door window
重
Press it forwards:
机 Switch, left door window
说 Door windows manually rise.
明 Press it backwards:
There are two shifts.
Shift 1: door windows manually
descend.
Shift 2: door windows automatically
descend. Switch, right door window

Operation
Switch, right door window
Press it forwards:
–
Door windows manually rise.

Crane Chassis
Press it backwards:
Door windows manually descend.
b) Controls beside co-driver
Plug
Switc, right door window
Press it forwards:
Door windows manually rise.
Press it backwards:
Door windows manually descend.

Switch, right door window

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 Operator’s Manual for Truck Crane

3.1.3 Instrument assy.

起
重
机
说
明
Operation

–
Crane Chassis

Figure 3-6 Instrument assy.

Pos. Description Pos. Description

1 Water thermometer 5 Main interface

2 Fuel gauge 6 Odometer

3 Tachometer 7 Barometer 1

4 Display unit 8 Barometer 2

3.1.3.1 Instrument
1 Tachometer
Displays engine speed (RPM).

2 Fuel gauge
Displays the fuel reserves.

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3 Water thermometer
Displays the engine coolant
temperature in degrees Celsius
起
重 (C°).
机
说
明 WARNING
Do not stop the engine
immediately when the engine
coolant temperature is above
the maximum limit. If you stop
the engine, the coolant

Operation
temperature decreases
suddenly and damage to the
engine occurs. Operate the –

Crane Chassis
engine at a RPM immediately
above idle to help decrease
the coolant temperature.

4 Odometer
Displays the speed of the crane
in kilometers per hour (km/h)

5 Barometer 1
Displays the pressure of brake
system of front axle.

6 Barometer 2
Displays the pressure of brake
system of rear axle.

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 Operator’s Manual for Truck Crane

3.1.3.2 Display unit

1 2 3 4 5 6 7 8 9 10 11
起
重
机
说
明

12 13 14 15 16 17 18 19 20

Figure 3-7 Display unit

Operation

Pos. Description Pos. Description

–
Crane Chassis

Control light Control light

1 11
Vehicle direction of travel left Vehicle direction of travel right
Control light Control light
2 12
Rear fog light PTO engaged
Control light Warning light
3 13
Low beam Engine oil pressure low
Control light Warning light
4 14
High beam Water in fuel
Control light Warning light
5 15
Lighting Engine error code displayed
Warning light Control light
6 16
ABS defects Diesel engine preheating system
Warning light Control light
7 17
ABS error code displayed GPS state(standby)
Control light Control light
8 18
Parking brake closed Longitudinal differential lock
Control light Warning light
9 19
Transversal differential lock Engine coolant level low
Warning light Warning light
10 20
Charging monitoring OBD(standby)

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 Operator’s Manual for Truck Crane

1 Control light
Vehicle direction of travel left
Illuminates:
起
重 The vehicle is to turn left.
机
说
明
2 Control light
Rear fog light
Illuminates:
The rear fog light is ON.

Operation
3 Control light
Low beam –

Crane Chassis
Illuminates:
The low beam is ON.

4 Control light
High beam
Illuminates:
The high beam or headlamp flasher is ON.

5 Control light
Lighting
Illuminates:
The left-hand steering column switch is rotated to
the position.
The front width lamp, rear width lamp, corner
marker light, license plate lamp, operating
instrument lamp and side marker light
are also ON.

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 Operator’s Manual for Truck Crane

6 Warning light
ABS defects
Illuminates:
起
重WABCO ABS system fails.
机Extinguishes:
说
The ABS system manufactured by Changchun
明
Yiqi Hongding Auto Co., Ltd. is installed.

7 Warning light
ABS error code displayed
Illuminates:
Switch on the ABS fault diagnosis switch to read
Operation

the flash code.

–
8 Control light
Crane Chassis

Parking brake closed

Illuminates:
Parking brake is closed.
Do not start the vehicle until the parking brake is
released and the control light extinguishes.
9 Control light
Transversal differential lock
Illuminates:
The button “Longitudinal and transversal
differential locks” is switched on and the
transversal differential is locked.
10 Warning light
Charging monitoring
Illuminates:
The ignition starter switch is in position ON.
Extinguishes after engine starts:
The generator begins to charge the battery.

NOTICE
If the warning light illuminates during engine
running, it means that the generator is
defective. Stop to examine at once!

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11 Control light
Vehicle direction of travel right
Illuminates:
起
重 The vehicle is to turn right.
机
说
明
12 Control light
PTO engaged
Illuminates:
The PTO is engaged.

Operation
13 Warning light
Engine oil pressure low –

Crane Chassis
Illuminates:
Ignition starter switch is in position ON under
normal condition.
Extinguishes:
Engine starts.

CAUTION
The warning light illuminates if the engine oil
pressure is low or the engine oil filter element
is dirty. Immediately bring the crane to a
standstill and rectify! Otherwise the engine will
be damaged seriously!

14 Warning light
Water in fuel
Illuminates:
The water level in the water diversion plate of fuel
coarse filter exceeds the normal value It is time to
drain the water.

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 Operator’s Manual for Truck Crane

15 Warning light
Engine error code displayed
Illuminates all the time:
起
重Engine defects.
机Bring the vehicle to a standstill and rectify it.
说
Read the error code in terms of operating
明
instructions on the instrument.
16 Control light
Diesel engine preheating system
Illuminates:
The engine is being preheated.
Note:
Operation

The preheating system works automatically and is

– controlled by the air intake temperature of the
Crane Chassis

engine.

17 Control light
GPS state
(standby)

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18 Control light
Longitudinal differential lock
Illuminates:
起
重 The button “Longitudinal and transversal
机 differential locks” is switched on and the
说
longitudinal differential is locked.
明
19 Warning light
Engine coolant level low
Illuminates:
Engine coolant level in expansion tank is lower
than the set value.

Operation
NOTICE
–
Do not try to add water in the coolant if the

Crane Chassis
engine is hot. Otherwise, the coolant
temperature decreases suddenly and damage
to the engine occurs.

20 Warning light
OBD
(standby)

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3.1.3.3 Main interface of instruments assy.

起
重
机
说
明
Operation

–
Crane Chassis

Figure 3-8 Main interface

3.1.3.3.1 Control lights

1 2 3 4 5 6 7 8

1 2 3

ECO ECO ECO

9 10 11 12 13 14 15 16

Figure 3-9 Control lights

Pos. Description Pos. Description

Control light Warning light
1 9
Low pressure 1 Air filter soiled
Control light Warning light
2 10
Low pressure 2 Left door opened
Control light Warning light
3 11
Low pressure 3 Right door opened

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Warning light Warning light

4 12
Engine coolant temperature high Left and right doors opened
Warning light Warning light
起
5 13
重 Fuel level low Chassis maintenance
机 Warning light Control light
说
6 14
明 AdBlue level low Engine power mode
Warning light Control light
7 15
Power source voltage low Engine economic mode
Control light Control light
8 16
Engine exhaust brake Engine fuel–efficient mode

1 Control light

Operation
Low pressure 1
Illuminates:
1 –

Crane Chassis
The pressure of service brake of
front axle is lower than the set
value (0.5 MPa).
2 Control light
Low pressure 2
Illuminates:
The pressure of service brake of 2
rear axle is lower than the set
value (0.5 MPa).
3 Control light
Low pressure 1

3
Illuminates:
The pressure of parking brake is
lower than the set value (0.5
MPa).
4 Warning light
Engine coolant temperature
high
Illuminates:
Engine coolant temperature is
higher than the set value (96 ℃
).

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5 Warning light
Fuel level low
Illuminates:
起
重 The fuel level is lower than the
机 set value (10%).
说
明
6 Warning light
AdBlue level low
Illuminates:
The AdBlue level is lower than
the set value (10%).
Operation

7 Warning light
– Power source voltage low
Crane Chassis

Illuminates:
The power source voltage is
lower than the set value (23V).

8 Control light
Engine exhaust brake
Illuminates:
The Engine exhaust brake
works.

9 Warning light
Air filter soiled
Illuminates:
The air filter is soiled.

10 Warning light
Left door opened
Illuminates:
The left door is opened.

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11 Warning light
Right door opened
Illuminates:
起
重 The right door is opened.
机
说
明
12 Warning light
Left and right doors opened
Illuminates:
The left and right doors are
opened.

Operation
13 Warning light
Chassis maintenance –

Crane Chassis
Illuminates:
Some parts of chassis need to
repair or service.
Confirm the parts to be repaired
or serviced via the instrument.
Operate the “Confirmation “on
the instrument after
maintenance.
14 Control light
Engine running mode
Illuminates:

ECO
After the ECO mode button is
pressed, the engine
automatically runs a matching
running mode according to
current vehicle speed and road
condition etc.
There are three running modes.
Red: power mode
Yellow: economic mode
Green: fuel-efficient mode.

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 Operator’s Manual for Truck Crane

3.1.3.3.2 Other indicators

起
重
机
说
明
Operation

Figure 3-10 Other indicators

–
Crane Chassis

1 Indicator
Engine oil pressure
Displays the engine oil pressure
when the engine is running.

CAUTION
The warning light “Engine oil
pressure low” illuminates if
the engine oil pressure is low
or the engine oil filter element
is dirty. Immediately bring the
crane to a standstill and
rectify! Otherwise the engine
will be damaged seriously!

2 Indicator
Voltage
Displays the voltage of generator
during engine running or displays
the voltage of battery when the
engine stops.
3 Indicator
Mileage subtotal
Displays the circulation driving
distance per time.

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4 Indicator
Mileage total
Displays the total driving
起
重 distance of vehicle.
机
5 Indicator
说
明 Working hours
Displays the total working hours
of engine.
6 Indicator
Instantaneous fuel
consumption

Operation
Displays the instantaneous fuel
consumption of vehicle during
driving. –

Crane Chassis
3.1.4 Reversing radar system

Figure 3-11 Reversing radar system display

After you move the gear lever to the reverse gear about 1 second, the main interface of the
instrument automatically switches to radar distance display interface. When there is an
obstacle, the figure in a square box indicates the distance in a straight line from the prober to
the obstacle and the perpendicular distance of the non-prober. The unit is meter and the cross
strip shows the position of crane.
a) When the distance of obstacle is between 2.1 – 3.5 m, it is an early warning area. The
alarm sounds “BI----BI----BI” and the interface displays the distance of prober;

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b) When the distance of obstacle is between 1.2 – 2.0 m, it is a general warning area. The
alarm sounds “BI--BI--BI” and the interface displays the distance of prober;
c) When the distance of obstacle is between 0.6 – 1.1 m, it is a main warning area. The alarm
起
重sounds “BIBIBIBIBI” and the interface displays the distance of prober;
d) 机When the distance of obstacle is between 0.1 – 0.5 m, it is a dangerous area. The alarm
说
warms persistently. The distance displays “P” and it indicates that it is very close to the
明
obstacle and needs to stop the vehicle;
e) When the distance of obstacle is beyond the distance detected by the radar, no warning
sound gives out. The distance displays “-- --” and it indicates that the vehicle is far away
from the obstacle, namely more than 3.5 m or less than 0.1 m;
f) If the figure in the square box displays “X.X”, it is indicates that the data is invalid. Maybe it
is a radar equipment fault or line fault etc.
Operation

g) If you cannot receive the reverse signal within 1 second, automatically exit the reverse
– display interface and return back to the main interface.
Crane Chassis

CAUTION
(1) The reverse speed should be less than 6 km/h.
(2) When the actual distance is equal or less than 0.6 m, should stop the vehicle.
(3) When the surface of prober frozes or is stained with mud, please keep the prober
clean.
(4) Spraying paint will affect the detectivity of prober. Do not paint by yourself.
(5) The absorption of reflector will affect the detecting distance and precision. For
example, different clothing materials have different acoudtic reflectivity.
(6) The weather also has a certain influence on the detecting distance and precision,
such as the moist air, dry climate and large temperature difference.
(7) When driving on the steep slope, the lawn or the uneven road surface, it is apt to
give an alarm due to the unnecessary obstacle detected.

Figure 3-12

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(8) Pay attention to the following objects which are difficult to be detected.

– Spongy objects such as

起 cotton and sponge
重
机
说
明

– Glossy conglobate and soft

cylindrical objects.

Operation
–

Crane Chassis
– Sharp objects.

(9) Drive carefully since the prober cannot function under the following special
circumstances.

– Low-lying circumstances such

as pond and hole etc.

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– Height permitted transverse

rod piece which is higher than
the prober a certain height
起
重
机
说
明

(10) As for the vehicle installed the spare tire at the tail, there is a blind spot over rear.
The obstacle above the ground and within minimum ground clearance may cannot
be detected, so please drive carefully.
Operation

(11) The reversing radar is only a reversing auxiliary device. The driver cannot rely on
the reversing radar to detect the rear circumstance.
–
Crane Chassis

3.1.5 Air horn button

It is located on the outside of clutch pedal and on the left side of driver.
Depressed: Air horn alarms.
Released: Air horn stops alarming.

3.1.6 Foot pedal (R): Engine control

It is an electron pedal.
Depressed: the vehicle accelerates.
Released: the vehicle decelerates.

3.1.7 Foot pedal (M): Service brake

Depressed: the vehicle decelerates or stops.

3.1.8 Foot pedal (L): Clutch

Depressed: the clutch is disengaged.

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3.1.9 Center console

起
重 1
ABS
DIAG ECO

机
说
明

3
OFF AU TO A C

Operation
4

Crane Chassis
5

Figure 3-13 Center console

Pos. Description Pos. Description

1 Keyboard 4 Gear lever

2 Media player 5 Parking brake hand lever

3 Control panel, A/C and cab heater

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 Operator’s Manual for Truck Crane

3.1.9.1 Keyboard

1 2 3 4 5 6 7 8
起
重
机
说
明
ABS
DIAG ECO
Operation

–
Crane Chassis

9 10

Figure 3-14 Keyboard

Pos. Description Pos. Description

Button Button
1 6
Engine stop Highland mode
Button Button
2 7
Rear fog light ECO mode
Button Button
3 8
Longitudinal and transversal differential locks Daytime running light
Button Button (optional decode input)
4 9
Outrigger illumination switch Engine fault diagnosis
Button Button
5 10
ABS fault diagnosis Rotating beacon (optional)

1 Button Engine stop

Keep it pressed for 2 – 3 seconds:
The engine stops running.

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2 Button Rear fog light

Pressed:
The rear fog light is ON.
起
重 Note:
机 The rear fog light can be activated only when the high beam or
说
low beam is activated.
明

3 Button Longitudinal and transversal differential locks

Pressed:
The longitudinal and transversal differential locks are
activated.

Operation
CAUTION
You can operate the button only when the vehicle is –

Crane Chassis
stationary.

4 Button Outrigger illumination switch

Pressed:
The outrigger illumination is ON during travelling. It is mainly
used for worksite transition and illumination. After power
take-off, it is invalid to switch on this button. However, you can
switch on the work lamp switch on outrigger control box to light
the outrigger illumination.

5 Button ABS fault diagnosis

Pressed and hold for 1 -3 seconds:
Watch the ABS fault diagnosis warning lamp and read the
flash code after ABS system gives an alarm. And then check
the ABS fault code.

6 Button Highland mode

Pressed:
In order to prevent shutdown after power takeoff, the idle
speed of superstructure will automatically increase to the set
value 750 r/min when the vehicle works at the highland.

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 Operator’s Manual for Truck Crane

7 Button ECO mode

Pressed:
In order to save the fuel, the engine adjusts its power and
起
重 limits the vehicle speed within proper economic running range
机 in real time according to the running conditions such as
说
rotating speed, vehicle speed, torque, load and gear etc. when
明
the vehicle drives on the road.
8 Button Daytime running light
Pressed:
The daytime running light extinguishes.
When the ignition starter switch turns to position ON, the
daytime running light illuminates.
Operation

–
9 Button Engine fault diagnosis
Crane Chassis

It is used for inputting standby switch to decode urgently after

the engine automatically locks.
It is not an engine fault code diagnosis switch, and the engine
fault code can be read from the bus instrument.

10 Button Rotating beacon

It is available for options.
Pressed:
The rotating beacon illuminates.

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3.1.9.2 Media player

起
重
机
说
明

Operation
Figure 3-15 Media player

1 Button –

Crane Chassis
Power source / Mode
Pressed:
Switch on the power.
Pressed again and released:
Changeover the mode.
Pressed and held for 10
seconds:
Switch off the power.

2 Button Stop
Pressed:
Songs played by USB, SD-MMC
or audio device stop.

3 Button
Pause/ Automatic radio search
Pressed:
Pause MP3 player, or
automatically search radio
station and reserve it.

4 Button EQ
Pressed:
The EQ is activated.

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5 Button MUTE
Pressed:
The media player is mute.
起
重 Pressed again:
机 The media player returns to
说
former volume.
明
6 Button RPT
Pressed:
In the mode of MP3 player,
songs are repeated.

7 Button
Operation

Play/Search reserved radio

stations or songs
–
Crane Chassis

Pressed:
In the mode of radio player, keep
it pressed to search radio station
from high-frequency to
low-frequency.
In the mode of MP3 player, keep
it pressed to play the first 10
songs.

8 Button
Play/Search reserved radio
stations or songs
Pressed:
In the mode of radio player, keep
it pressed to search radio station
from low-frequency to
high-frequency.
In the mode of MP3 player, keep
it pressed to play the last 10
songs.
For the detailed information, please refer to the attached Operating Instructions for Media
Player.

CAUTION
Set the ignition starter switch to "ACC", when you use the media player with the
engine in the OFF position.

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3.1.9.3 Gear lever

The gear lever is installed on the right-hand side of the driver.
起Jog the gear lever leftwards, rightwards, forwards and backwards to select and changeover the
重
gear.
机
说 Parking brake hand lever
3.1.9.4
明
Pull the hand lever backwards to activate the parking brake and emergency brake.

3.1.10 Crane lighting

3.1.10.1 Front combination signals

Take the lights on the left as an example. The lights on right side are the same as the left ones.

Operation
For the details, refer to Figure 3-16.

Crane Chassis
High beam
Front corner
marker light Low beam Daytime running light Front turn signal

Figure 3-16 Front combination signals

3.1.10.2 Side turn signal

Take the signal on the left as an example. The signal on right side is the same as the left one.
For the details, refer to Figure 3-17.

Side turn signal

Figure 3-17 Side turn signal

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 Operator’s Manual for Truck Crane

3.1.10.3 Interior illumination

The interior illumination is located at
the起roof of the driver's cab, including
重
small lamp & its button and door lamp
机
& its
说 button.
明 lamp & its button:
Small
The direction of small lamp can be
adjusted by pressing its edge. The
small lamp button is a 2-handed
button.
Door lamp & its button:
Operation

The door lamp button is a 3-handed

button:
–
Center position: off
Crane Chassis

Left and right positions: on

The door lamp will light up
automatically if any door is open. If the
doors are closed well, the door lamp
will extinguish. In addition, the door
lamp can also be controlled manually.

3.1.11 Door, driver's cab

a) Open the door from outside
Hold the handle and pull it
outwards.
b) Close the door
The door will be locked
automatically when the door is Door handle Key hole
closed.

CAUTION
Do not drive the vehicle if the doors are not properly closed and locked!

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 Operator’s Manual for Truck Crane

起
重
机
说
明

Operation
Figure 3-18 Door of driver’s cab –

Crane Chassis
c) Open the door from inside
Pull the inside door switch upwards and hold the handle to push the door outwards.
d) Lock the door from inside
The locking knob is on the lower edge of door window.
Press down the locking knob to lock the door from inside.
Pull the locking knob upwards before opening the door.

CAUTION
If the door is not closed well, the locking knob cannot be pressed down.
e) Lock the door from outside
Unlock Lock
Insert vehicle key into the key
hole. Turn it clockwise to lock the
door, turn it counterclockwise to
unlock the door.

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 Operator’s Manual for Truck Crane

3.1.12 Seats in driver's cab

3.1.12.1 Seat adjustment

起
重 crane is equipped with a suspension
This
机
seat, which can be adjusted to suit any driver
说
height
明 or size before setting off.
When you adjust the stiffness of the seat,
please set the red pointer within the range
between 40 kg to 130 kg.
1. Switch, adjust backrest setting
2. Switch, adjust seat cushion angle (rear
1
Operation

section)
2
3. Switch, adjust seat cushion angle (front
3
– section)
4
Crane Chassis

4. Rotary knob, adjust stiffness 5

5. Switch, adjust horizontal setting

3.1.12.2 Putting on seat belt

Fasten and adjust the three-point seat belt to suitable position before setting off.
Insert tongue piece into belt lacer to fasten the belt.
Press the button to unfasten the belt.

CAUTION
Risk of fatal injury if seat belt is not worn!
All occupants must be belted in before setting off in the crane and during the driving.

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3.1.12.3 Sleeper berth

起
重
机
说
明

Toolbox 1 door lock handle

Operation
–
Figure 3-19 Sleeper berth

Crane Chassis
The co-driver’s seat is a connecting one and can be used for sleeper berth.
Toolbox 1 door lock handle – To lock / unlock the door plank.
 Move the handle outward and pull out the toolbox 1 door to open the door.
 Move the handle outward and push in the toolbox 1 door to close the door.

3.1.13 Attachments
a) Sun visor
The sun visor is located above front windshield inside driver's cab.
Pull the sun visor downwards to shut out the sunshine.
Push the sun visor upwards to roll it up.
b) Toolbox 2
The toolbox 2 is in the instrument console of the driver's cab, in which there are two
toolboxes in different sizes.
Press the switch to open the toolbox 2 and push down the cover to close it.
c) Cigarette lighter
Push-in the cigarette lighter for 3 to 5 sec. Pull it out to use it. After you use it, put it in its
initial position.

CAUTION
Set the ignition starter switch to "ACC", when you use the cigarette lighter with the
engine in the OFF position.

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 Operator’s Manual for Truck Crane

3.2 Before starting up the vehicle

3.2.1 Prerequisites
起
a) 重If the crane is used for the first time, make sure the crane is in proper working condition
机
说(without damage or abnormalities).
b) 明Always use the correct light diesel oil and engine oil. Make your selection on the lowest
ambient temperature where you are to do the work. For details, please refer to the
Operation and Maintenance Manual for WP 10 ** Series Diesel Engine and Operation and
Maintenance Manual for WP 12 ** Series Diesel Engine.

3.2.2 General checks before setting off

a) Do a check of the coolant level and add more if below the required level.
Operation

b) Do a check of the AdBlue level and add more if below the required level.
– c) Do a check of the fuel level and make sure that you have more than is necessary to
Crane Chassis

complete the task.

d) Make sure that the parts in the steering and brake systems are flexible, safe, and reliable.
e) Do a check of the steering fluid level and the clutch fluid level and add more if below the
required level.
f) Make sure that the parts that follow are tight:
 Bolts in universal joints for steering axles
 Leaf spring bolts
 U-bolt
 Wheel bolts.
g) Examine the leaf springs for crack.
h) Examine all tires for correct pressure.
i) Examine the items that follow for damage:
 Condition of tires
 Door locks
 Doors
 Windows
 Each crane control mechanism.
j) Examine the fittings of oil pipes, air pipes, water pipes and AdBlue pipe for leakage.
k) Examine the air reservoir for condensation (drain the water as necessary).
l) Examine the battery terminals for too much corrosion and make sure that the power wires
are tight.
m) Examine the level of the battery electrolyte (adjust as necessary).

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 Operator’s Manual for Truck Crane

n) Turn the ignition starter switch to position “ON” and examine the functions of the items that
follow:
 Instruments
起
重  Switches and buttons
机  Lighting
说
 Control lights and warning lights
明
 Wipers
 Miscellaneous displays.
o) Adjust the mirrors for clear vision to the rear.

3.2.3 General checks at vehicle start up

Examine the controls and instruments.

Operation
a) Examine the engine oil pressure gauge.
1) Idle speed: the engine oil pressure must be more than 0.1 MPa.
–

Crane Chassis
2) When engine speed is 1200 r/min, the engine oil pressure must be in the range of
0.35 – 0.55 MPa.
b) Examine the barometer.
If the brake pressure is less than 0.55 MPa, the warning light “Brake pressure low” will
illuminate. Risk of danger if start off at this time!
c) Examine the water thermometer.
The pointer must point to the green range (above 60°C).
d) Make sure that the PTO is disengaged.
e) Make sure that the parking brake is not ON.
f) Start up the vehicle slowly with low gear. Do not engage the clutch when the engine is
running at excessively high speed (above 1600 r/min).

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 Operator’s Manual for Truck Crane

3.3 Driving the crane

3.3.1 Starting
起 and stopping the engine
重
3.3.1.1机Starting the engine
说
a) 明Examine the items that follow:
1) Engine oil for correct level and make sure that it is clean
2) Coolant for correct level
3) Fuel tank for correct level
4) AdBlue tank for correct level.
b) Before starting the engine, make sure the following prerequisites are met:
1) Put the gear lever in neutral.
Operation

2) Apply the parking brake.

– 3) Turn the ignition starter switch to position “ON”.
Crane Chassis

4) Disengage the PTO (At this time, the control light “PTO engaged” does not
illuminate).
5) In winter, the engine will be preheated automatically (The control light “Diesel engine
preheating system” lights up at the same time).
6) After the control light “Diesel engine preheating system” extinguishes, depress the
engine control pedal softly and turn the ignition starter switch to position S to start the
engine.

CAUTION
(1) Turn the ignition starter switch to position S within 30 sec. after the control
light “Diesel engine preheating system” extinguishes.
(2) If you cannot start the engine in a maximum of 15 seconds, wait for 30 sec.
Then try to start the engine again to avoid engine damage.
If the engine cannot be started for three consecutive times, fix it right away.

WARNING
Depress the clutch pedal when you start the engine in order to avoid
inadvertent starting of the vehicle.

c) Preheat the engine and examine instruments for functions:

Release the engine control pedal slowly and run the engine at idle speed for several
minutes to warm up the engine. At this time, examine the instruments and control / warning
lights for functions.

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CAUTION
(1) In order to make the engine oil flow into each part of engine and raise up
起
water temperature to burn the fuel normally, it is necessary to warm up the
重
机 engine before starting.
说 (2) Do not run the engine at high speed without a load during warming up.
明
Otherwise, the engine will be damaged and its service life will be
shortened.
(3) Do not run the engine at idle speed for a long time, which may weaken
engine performance.
(4) Do not run the engine at high speed with a heavy load when the coolant
temperature is below 60°C.

Operation
(5) The engine oil pressure should not be lower than 0.1 MPa when the engine
runs at idle speed. With the engine warming up, the oil pressure is going to
–

Crane Chassis
be stable gradually.

WARNING
Do not run the engine in a place where the combustible gas exists.
The gas may be inhaled into the engine through the air intake system to make
the engine speed up even overspeed, which may cause fire, explosion and
heavy wealth losses.

3.3.1.2 Stopping the engine

a) Depress the service brake pedal slightly to decelerate the vehicle, at the same time, shift
down the transmission to gear 1.
b) When the engine decelerates to the low speed, depress the clutch pedal and the service
brake pedal at the same time to bring the vehicle to a standstill at the specified location.

CAUTION
Except in an emergency, do not depress the service brake pedal jerkily!

c) Pull the parking brake hand lever backwards to the locking position to park the vehicle and
then shift the transmission to neutral position.
d) Run the engine at idle speed for several minutes after the vehicle stops so as to cool the
engine down gradually.
e) Press down the button “Engine Stop” for 2 to 3 sec. to stop the chassis engine.
f) Turn the ignition starter switch to position “LOCK” and pull it out after the engine is stopped
about 30 seconds.
g) Do not keep the ignition starter switch in the "ON" or “ACC” position after you park the
crane. The battery drains in these conditions.

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 Operator’s Manual for Truck Crane

h) If you park the crane on a slope, you must put the chocks before and behind the wheels to
avoid accident.
i) To prevent an accident when you park the crane in the dark, you must turn on the hazard
起
重lights.
机
3.3.2 Transmission
说 operation
明
The crane is fitted with a main transmission and an auxiliary transmission.
The main transmission is mechanically and manually controlled, and the auxiliary one is
pneumatically controlled.
The gearshift air pressure should be more than 0.41 MPa.
For details, please refer to Figure 3-20.
Operation

High gear range

–
Crane Chassis

Forward
direction
Low gear range

Figure 3-20 Transmission

3.3.2.1 Gear shifting

a) Move the gear lever to the 1st gear position and set the switch “Pre-selection of high / low
gear range” into low gear range before you start the vehicle.
b) When you shift the gear, disengage the clutch completely and shift the gear lever in
position.
c) Both the high gear and low gear ranges have a neutral position, namely the neutral
position between 7th and 8th gears in high gear range and between 2nd and 3rd gears in low
gear range. Move the gear lever to the neutral position in the low gear range when you
park the crane.
d) Stop the vehicle before you move the gear lever to the reverse gear to prevent
transmission damage. When you engage the reverse gear, apply large force to overcome
resistance of the reverse lock.
e) Do not skip a gear when you move through low gear range and high gear range.
Otherwise, you will shorten the service life of synchronizer of auxiliary transmission.

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WARNING
起 You should use the switch “Pre-selection of high / low gear range” when you
重 change gear between gears 5 and 6.
机
说
f) When you drive downwards a slope, do not shift gear between high and low gear range.
明
g) When you hear an unusual noise in the transmission or it is hard to move the steering
wheel, stop the crane immediately. Correct the malfunction.
h) Do a check of the grease level of transmission after you stop the vehicle for several
minutes.

CAUTION

Operation
The temperature of transmission should be between -40°C – 120°C during
continuous working. –

Crane Chassis
When the temperature exceeds 120°C, the grease will be decomposed and service
life of transmission will be shortened.

3.3.2.2 Points for attention

Depress the clutch pedal when you shift the gears. When you downshift the gear,
accelerate at the neutral position to make the connecting parts have the same rotational
speed.

WARNING
Do not let the vehicle move forward when transmission is in neutral.

3.3.3 Clutch operation

In the drive system, clutch is a part directly connected with the engine. Its function is to
effectively engage or disengage its driving and driven parts under driver’s operation.

3.3.3.1 Points for attention

a) During driving, do not place the foot on clutch pedal if it is not used.
b) When you downshift the gear, depress the service brake pedal to decelerate the vehicle,
and then depress the clutch pedal properly to change into proper gear.

CAUTION
When you shift the gear during driving, depress the clutch pedal and then release it
rapidly. Otherwise there is a risk of increasing clutch abrasion.

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c) Do not depress the clutch pedal as possible as you can except braking at low speed.

起 CAUTION
重
Only when the compressed air pressure P is above 0.4 MPa, can the clutch be
机
说completely disengaged.
明
3.3.4 Steering operation
a) When you go into a corner, look around before you turn the steering wheel. Turn the
steering wheel after you make sure that it is safe to move. Then put the transmission in a
lower gear and apply a small quantity of pressure on the service brake.
b) The steering wheel has a mechanical limit. Do not continue to turn the wheel when at the
Operation

limit. Do not keep the wheel at the limit for more than 5 seconds.
c) If the vehicle is steered insufficiently, decrease the speed slowly while you turn the
– steering wheel in the same direction as the turn.
Crane Chassis

d) If you over-steer, release the engine control pedal or depress the service brake pedal while
you turn the wheel in the opposite direction of the turn.

CAUTION
Do not turn the steering wheel quickly in one direction unless it is an emergency.
Make your turns smoothly to keep the crane laterally stable. When you complete the
turn, lightly and immediately turn the steering wheel to the neutral position to
prevent an unstable condition.

e) Decrease the speed of the vehicle and move down the transmission gear if you have a
sharp turn.

3.3.5 Brake operation

The brake system consists of driving brake (service brake), engine exhaust brake and
emergency brake (parking brake). The emergency brake can also be selected to park the
vehicle in normal condition and on slopes.

3.3.5.1 Operation
a) Driving brake
There are several cases of braking. For details, please refer to the following instructions:
1) Normal brake during driving, release the engine control pedal ahead to slow down the
vehicle according to the actual road conditions (with regard to the road surface, traffic,
etc.), and then continuously or intermittently depress the service brake pedal to slow
down stably or stop the vehicle.

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2) Slow brake after rapid brake: when there is an accident in front, depress the service
brake pedal rapidly and then depress it again slowly. Release the pedal slowly
according to the distance away from the accident spot and shift gear in accordance
起
重 with the actual driving speed. At last, depress the engine control pedal to drive at
机 normal speed.
说
3) Cadence brake: depress the service brake pedal and release it. Repeat the operation
明
to decelerate the vehicle gradually. The operation should be very gentle.
4) Rapid brake: in a sudden emergency, release the engine control pedal immediately
and depress the service brake pedal jerkily (sometimes apply the parking brake at the
same time) to bring the vehicle to a standstill as soon as possible. As a result, the
accident will be avoided.

Operation
CAUTION
When you make many hard brake stops, the tire, brake drum and brake lining –

Crane Chassis
wear prematurely and service life of each part shortens. Use more caution
when the roads are wet or frozen.

b) Engine exhaust brake

When you drive the vehicle downwards a long slope, use the engine exhaust brake. The
vehicle decelerates via engine instead of service brake.
The engine exhaust brake has the advantages below:
 To improve driving safety.
 To ensure the brake performance and to avoid the brake failure.
Note:
When you depress the service brake pedal frequently, the brake drum will be
overheated.
How to activate the engine exhaust brake:
 Release the engine control pedal.
 Jog the right-hand steering column switch backwards.
Result:
– The engine exhaust brake is activated and the control light “Engine exhaust brake”
lights up.

CAUTION
You can depress the clutch pedal or engine control pedal to temporarily deactivate
the engine exhaust brake.

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c) Emergency brake (parking brake)

If service brake fails or cannot be applied in time during driving, pull the parking brake
hand lever backwards to the locking position to activate the emergency brake. Push the
起
重hand lever forwards to the unlocking position to deactivate the emergency brake.
机
说
明 CAUTION
(1) You can also use the emergency brake (namely parking brake) to park the
vehicle in normal condition or on slopes.
(2) Deactivate the emergency brake before driving.

3.3.5.2 Points for attention

Operation

a) After the engine control pedal is released during driving, do not step on the service brake
pedal when there is no necessity to brake the vehicle.
– b) Do not apply the emergency brake when the vehicle is driving on the narrow, frozen or
Crane Chassis

muddy road or in a rainy / snowy day. Under the conditions, such as crossing the railway,
driving under the bridge, or driving on a road with pools of water, or one side of the vehicle
is driving on frozen or muddy road, avoid applying the service brake as much as possible.
Otherwise the vehicle may be shut down suddenly.
c) After driving across a road with pools of water, depress the service brake pedal for several
times to eliminate the water on the braking shoe so as to ensure the brake performance.
d) Before you drive on a long descending gradient, shift the gear lever to low gear range.
Under this condition, the driving speed is mainly controlled by the traction resistance from
the engine and with the assistance of engine exhaust brake and service brake. Do not
move the vehicle with the transmission in neutral position.
e) When the parking brake is used as the auxiliary brake, do not pull the hand lever to its limit
position. When you park the vehicle under any conditions, pull back the parking brake
hand lever into locking position, especially parking the vehicle on a slope. Otherwise, risk
of fatal injury and accident!

3.3.6 PTO operation

3.3.6.1 Engaging PTO

See Figure 3-21.
a) Open the shutoff gate valve on the hydraulic oil tank to connect the hydraulic oil tank and
the oil lines.
b) Start the engine.
c) Examine the barometer to see if the air pressure is between 0.6 and 0.8 MPa after the
engine runs stably.
d) Depress the clutch pedal.
e) Apply the parking brake and move the gear lever to the 4th gear position.

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 Operator’s Manual for Truck Crane

f) Pull out the PTO switch to engage the PTO, and then the control light I “PTO engaged”
lights up.
g) Slowly release the clutch pedal, and the crane is ready to work.
起
重
机
说
明

Figure 3-21 Engaging the PTO

Operation
3.3.6.2 Disengaging the PTO
See Figure 3-22.
–

Crane Chassis
a) Depress the clutch pedal.
b) Press the PTO switch to deactivate the PTO, and then the control light I “PTO engaged”
extinguishes.
c) Shift the gear lever into neutral position.
d) Release the clutch pedal slowly, and then the crane is in non-working state.

Figure 3-22 Disengaging the PTO

CAUTION
(1) Depress and release the clutch pedal slowly.
(2) If the PTO and the drive device for oil pump need to be repaired or replaced, put
a warning board on the ignition starter switch. Otherwise, risk of danger may
occur!

WARNING
When the PTO is engaged, keep the gear lever in the proper gear position and apply
the parking brake.

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3.3.7 Towing
There is a towing coupling at both the front and rear ends of the crane. Obey the following
起 regulations:
towing
重
a) Attach a strong towing rope onto the tow coupling at the front under the bumper. Start
机
说slowly to avoid impact.
b) 明Start the engine of the towed vehicle to make sure that it can realize emergency brake and
steering operation. Otherwise it will be very dangerous.

WARNING
If the engine of the towed crane cannot operate, do not tow the crane.

c) Move the gear lever of the towed crane in the neutral position.
Operation

d) If the transmission of the towed crane breaks down, remove the propeller shaft.
– e) If the differential gear or the rear axle of the towed crane is defective, remove the left and
Crane Chassis

right half shafts.

CAUTION
The engine exhaust brake system will be invalid if you remove the propeller shaft or the
half shaft.

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3.4 Points for attention

3.4.1 Road driving
起
重
a) Do not skip a gear when you move through the gear cycle.
机
b) Stop the vehicle if there are unusual conditions with the items in the below list:
说
明  Steering
 Braking
 Sounds or smells
 Vibrations
 Sudden speed increase or decrease.
If you cannot find or correct the problem, send the vehicle for repair.
c) Do not operate a vehicle if a warning light illuminates. Stop the vehicle and have it

Operation
repaired.
d) Examine the following instruments for functions:
–


Crane Chassis
Barometer
 Engine oil pressure gauge
 Water thermometer, etc.
e) Put the crane in a lower gear before you move up a slope to decrease the load on the
engine and drive-line.
f) Do the items that follow before you go down a long hill slope:
 Make sure that the brake system can stop the crane before you go onto the slope.
 Put the transmission in the low gear range before you go down the slope. Activate the
engine exhaust brake.
 Prevent the engine from overrunning. Overrunning of the engine refers to the
phenomenon that the engine driven by the wheel runs at the RPM which exceeds its
rated maximum engine RPM.

CAUTION
(1) Engine is easily damaged by overrunning.
(2) Decelerate the crane before you downshift the transmission. When you
downshift from the 4th gear position, the engine RPM should be below 1500
r/min. When you downshift from the 3rd gear position, the RPM should be
below 1200 r/min. Otherwise, overrunning may occur.

g) If the engine stops because the fuel tank is empty, air can go into the fuel system. When
this occurs, you remove the air from the fuel lines.

WARNING
Do not let the vehicle move forward after the engine is OFF.

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3.4.2 Crane movements in off-road conditions

When the axles are in the mud (no traction) or on rough terrain, follow these steps:
a) 起Add transversal and longitudinal differential locks.
重
b) Shift the gear lever to the low gear range and then engage the clutch slowly. Otherwise
机
说crane service life will be shortened.
c) 明Make sure that the engine RPM is around maximum.
d) Tow the vehicle or put rigid materials, e.g. pieces of wood or iron plates, below the wheels.

3.4.3 Park the vehicle

a) When you park the vehicle, follow the instructions below:
1) In bad weather condition (rain, snow, ice) or on a slope, make sure that there is a lot
Operation

of clearance in front and to the aft of the vehicle.

2) Apply the parking brake. Always put the chocks before and behind the wheels on a
– slope.
Crane Chassis

3) Move the gear lever to the neutral position of low gear range.
b) Before you stop the engine, do the items that follow:
1) Depress the engine control pedal 2 or 3 times to increase the engine RPM. This
makes the oil flow into each part of the engine.
2) Let the engine idle while you monitor the coolant temperature.
3) Stop the engine, when the coolant temperature is in the correct range.

CAUTION
Make sure that the hazard lights illuminate when the vehicle is parked on the road at
night.

3.4.4 Emergency stop on the roadway

If the crane malfunctions on the roadway, do the items that follow:
a) Stop the crane in a safe place.
b) Set the hazard lights to ON and put the warning triangle in position.
c) Apply the parking brake if you stop because of a drive train (drive shaft, axle) failure or you
make an emergency stop on a slope. Put the chocks before and behind the wheels
d) Examine the vehicle to find the part that caused the malfunction. Be careful of the road
conditions while you move around the vehicle.
If you cannot repair the vehicle, tell the servicing and repair facility.

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Chapter 4 Operation-Crane Superstructure

 Operator’s Manual for Truck Crane

Chapter 4 Operation – Crane Superstructure

4.1 Operator’s cab

4.1.1 Overall view

2 1

9
6

Operation Superstructure
7 –

10

Figure 4-1 Cab interior

Pos. Description Pos. Description Pos. Description

1 A/C control panel 2 Auxiliary switch panel 3 Lifting capacity table

4 Display 5 Right joystick 6 Load moment limiter

7 Switch panel 8 Engine control pedal 9 Operator’s seat

10 Left joystick

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 Operator’s Manual for Truck Crane

4.1.2 Switch panel

1 2 3

POWER ENGINE ENGINE

START STOP

I II
Operation Superstructure

–
4 5 6 7

Figure 4-2 Switch panel

Pos. Description Pos. Description

Button Switch
1 5
Power source Pre-selection of telescoping cylinder I / II
Button Switch
2 6
Engine start Pre-selection of telescope / derricking
Button
3 7 Bypass key switch
Engine stop
Button
4
Emergency stop

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1 Button
Emergency stop
Pressed:
All superstructure movements are cut off.

2 Button
Power source
Pressed:
POWER
The superstructure control system is
energized.

3 Button
Engine start
ENGINE

Operation Superstructure
Pressed:
The engine starts. START
–
Released after the engine starts:
The button will return to its initial position.

4 Button
Engine stop
Pressed and held for 1 to 2 seconds: ENGINE
The engine stops. STOP

5 Switch
Pre-selection of telescoping cylinder I / II I II

Left position:
The telescoping cylinder I is operational.
Right position:
The telescoping cylinder II is operational.

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6 Switch
Pre-selection of telescope / derricking
Left position:
Activate the boom telescoping function on
the left joystick.
Right position:
Activate the derricking function on the left
joystick.

7 Bypass key switch

Dangerous crane movements will be
switched off when the items below occur:
– The main or auxiliary winch is in the
spool-up mode and the hook block
touches the hoisting limit switch weight.
– The sensor senses that the main winch
has only 3 wraps of wire rope on it.
– The sensor senses that the load weight
Operation Superstructure

is more than the load weight in the

system.
–
– Safety devices are not installed during
crane installation and commissioning.
If necessary, this switch-off can be
bypassed by turning the bypass key switch
clockwise in cab. When the maintenance
personnel repair or check out the functions
on the crane, they can turn the bypass key
switch.

WARNING
Do not use the bypass key switch when
you do usual crane operations.
Otherwise, there will be life-threatening
hazards or serious damages to property.

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4.1.3 Auxiliary switch panel

1

ECO

2 3 4 5 6 7 8 9

Figure 4-3 Auxiliary switch panel

Pos. Description Pos. Description

Control light Button
1 6
Oil cooler fan Roof window washer system
Control light Button
2 7
Cab heater Front windshield washer system
Button Button
3 8

Operation Superstructure
ECO mode Front windshield wiper
Button Button
4 9
Work lights Oil cooler –

Button
5
Work lights on boom head

1 Control light
Oil cooler fan
Illuminates:
The oil cooler fan works.

2 Control light
Cab heater
Illuminates:
The cab heater works.

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 Operator’s Manual for Truck Crane

3 Button
ECO mode
This is a 2-handed button.
OFF
The ECO system doesn’t work. The icon
“ ” on the load moment limiter display
turns red. At this time, the superstructure
accelerator pedal is valid and the engine
speed is determined by the accelerator
pedal.
1st gear
The ECO system works in fuel-efficient
mode. The icon “ ” on the load moment
limiter turns green. At this time, the
superstructure accelerator pedal is valid and
the engine speed is determined by the
accelerator pedal. But maximum engine
Operation Superstructure

speed depends on the system load.

2nd gear
– The ECO system works in economic mode.
The icon “ ” on the load moment limiter
turns yellow. At this time, the superstructure
accelerator pedal is invalid and the engine
speed changes with the system load.

4 Button
Work lights
Position 1:
Switch on the background lighting.
Position 2:
Switch on the background lighting, work
lights on the slewing table and boom.

5 Button
Work lights on boom head
Pressed:
Switch on the work lights on boom head.

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6 Button
Roof window washer system
Position 1:
The roof window wiper works.
Position 2:
The roof window wiper and washer system
work simultaneously. It can return to its
initial position automatically.

7 Button
Front windshield washer system
Pressed:
Switch on the front windshield washer
system.

8 Button
Front windshield wiper

Operation Superstructure
Pressed:
Switch on the front windshield wiper.
–

9 Button
Oil cooler
Position 1:
When the hydraulic oil temperature is higher
than 50°C, the oil cooler fan will start
automatically.
Position 2:
The oil cooler fan starts.
Position 3:
The oil cooler fan stops.

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4.1.4 Control boxes

The left control box consists of left joystick, operating illustration (left), safety lever and left
armrest.
The right control box consists of right joystick, operating illustration (right), operating console
and right armrest.
For details, please refer to Figure 4-4.

1 10
6
3

2 11
7

4 8

5 9
Operation Superstructure

Figure 4-4 Control boxes

Pos. Description Pos. Description Pos. Description

1 Left joystick 2 Left armrest 3 Safety lever

4 Left control box 5 Operating illustration, left 6 Operating console

Switch
Operating illustration,
7 Tilting operator’s 8 Right control box 9
right
cab
10 Right joystick 11 Right armrest

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4.1.4.1 Joysticks
Left joystick:
– Spool up / reel off auxiliary winch.
– Telescope in / out.
– Slew to the left / right.
Right joystick:
– Spool up / reel off main winch.
– Derrick boom up / down.
Refer to Figure 4-4.
Both the left and right joysticks are fitted with a free swing button and a horn button. Refer to
Figure 4-5. Press the buttons to activate the corresponding functions.

1 2 (2) (1)

Operation Superstructure
–

Left joystick Right joystick

Figure 4-5 Joysticks

Pos. Description Pos. Description

1 Free swing button 2 Horn

(1) Free swing button (2) Horn

DANGER
The slewing table may turn freely when the free swing button is activated. Do not
activate the free swing button when the crane is operated with a suspended load.
Otherwise, there will be life-threatening hazards or serious damages to property.

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4.1.4.2 Operating illustration of left and right joysticks

Refer to Figure 4-6.

Operating illustration, left Operating illustration, right

Figure 4-6 Operating illustration of left and right joysticks

4.1.4.3 Safety lever

Position 1:
The solenoid valve Y1 in combination control valve is deenergized, and the superstructure
Operation Superstructure

cannot work.
Position 2:
– The solenoid valve Y1 in combination control valve is energized, and the superstructure can
work.
For details, please refer to Figure 4-7.

Figure 4-7 Safety lever

WARNING
Pull the safety lever to position ① before you leave the cab.

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4.1.4.4 Operating console

It is equipped with a rotatable electrical control box and a switch panel. For details, refer to
Section 4.1.2. The electrical control box can be rotated counterclockwise around the rotating
seat to suit the operator (the maximum rotation angle is 90°).
For details, please refer to Figure 4-8.

Rotating seat

90°
Switch panel

Electrical control box

Figure 4-8 Operating console

Operation Superstructure
4.1.4.5 Switch pre-selection of operator’s cab tilting mechanism
Switch
–
Pre-selection of operator’s cab
tilting mechanism operation
Left position:
Tilting the cab downwards
Right position:
Tilting the cab upwards.
Note:
The cab can be tilted upward for
20°in a maximum.

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4.1.4.6 Armrest
The height and angle of the armrest can be adjusted to suit the operator by operating the height
adjustment knob and the angle adjustment button. Refer to Figure 4-9.
Height adjustment knob:
How to adjust the height of the armrest:
a) Loosen the knob to lift the armrest to the limit.
b) Press the armrest down with your elbow to a desired position.
c) Tighten the knob to fix the armrest.
Angle adjustment button:
It is located below the armrest. The armrest can be tilted to 17° after you activate the button.
How to adjust the angle of the armrest:
a) Press and hold the button.
b) Adjust the armrest with your hand to a desired position.
c) Release the button to fix the armrest.
Operation Superstructure

Height
adjustment
– knob

Angle adjustment button

Figure 4-9 Armrest adjustment

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4.1.5 Operator's seat

Refer to Figure 4-10.

1
2
3
4

Figure 4-10 Operator’s seat

Pos. Description Pos. Description

Hand lever, upper horizontal seat Hand lever, lower horizontal seat

Operation Superstructure
1 4
adjustment adjustment
Hand lever, seat cushion (rear Hand lever, backrest angle –
2 5
section) angle adjustment adjustment
Hand lever, seat cushion (front
3
section) angle adjustment

Hand lever, upper horizontal seat adjustment:

When you adjust the seat, pull the hand lever upwards to move the sliding rail to suit the
operator. After the seat adjustment is done, release the hand lever to lock the sliding rail.
Hand lever, seat cushion (rear section) angle adjustment:
When you adjust the seat cushion angle (rear section), pull the hand lever upwards to suit the
operator. After the adjustment is done, release the hand lever to lock the seat.
Hand lever, seat cushion (front section) angle adjustment:
When you adjust the seat cushion angle (front section), pull the hand lever upwards to suit the
operator. After the adjustment is done, release the hand lever to lock the seat.
Hand lever, lower horizontal seat adjustment:
When you adjust the seat/control box, pull the hand lever upwards to move the sliding rail to
suit the operator. After the seat adjustment is done, release the hand lever to lock the sliding
rail.
Hand lever, backrest angle adjustment:
When you adjust the backrest angle, pull the hand lever upwards to suit the operator. After the
adjustment is done, release the hand lever to lock the seat.

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4.1.6 Engine control pedal

You can depress the engine control pedal to increase the engine RPM, thus to accelerate the
slewing, derricking, telescoping and hoisting movements. When the ECO system works in
economic mode, the accelerator pedal is invalid.
Operation Superstructure

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4.2 Computer system

The load moment limiter is a computer system for controlling and monitoring mobile cranes.
The load moment limiter calculates data from the pressure sensors, length sensor, angle
sensor and other monitoring devices to judge whether the crane is in safe working conditions,
and displays the basic parameters, such as boom length, boom angle, working radius, rated
lifting capacity, engine RPM and fuel reserve etc., on the LCD.
If the actual load reaches 90% – 100% of the rated one, the warning light lights up and the
buzzer sends out slow acoustic warning. At this time, the operator should pay much attention to
the operation.
If the actual load reaches 100% of the rated one, the warning light lights up and the buzzer
sends out fast acoustic warning and all dangerous crane movements are switched off.

CAUTION
(1) The load moment limiter can prevent the crane from toppling or boom destructed
and personnel death and injuries, thus ensuring safe operation of the crane.
However, do not rely entirely on the load moment limiter. If the rated lifting capacity
displayed on the load moment limiter is different from the one shown in the lifting

Operation Superstructure
capacity table, obey the lifting capacity table.
(2) Make sure that the load moment limiter is set to the proper configuration before –
operation. It is dangerous to set the load moment limiter incorrectly. Only the
operator who is skillful at operating this crane and system can set the OM. In normal
situations, make sure that the load moment limiter is set to match the crane actual
OM.
(3) The load moment limiter should only be commissioned by service technician!

For details, please refer to operating instructions attached to the crane.

ZTC800R532 Truck Crane 4-15

 Operator’s Manual for Truck Crane

4.3 Starting up the crane

4.3.1 Checks before starting up
Make sure that the following prerequisites are met before starting up:
a) Examining the engine oil level
1) The crane has been leveled.
2) Pull out the dipstick and clean it.
3) Re-insert it into oil and pull out again.
4) Examine whether the oil level is between MIN. and MAX. marks.

NOTICE
If the oil level is lower than the MIN. mark, fill oil. Otherwise, the engine will be
damaged seriously!

b) Examining the hydraulic oil

The oil level in hydraulic oil tank must be between MIN. and MAX. marks.
Open the shutoff gate valve to connect the hydraulic oil tank with the oil line.
How to open shutoff gate valve:
Operation Superstructure

1) Pull out the handle.

–
2) Turn the handle.
Refer to Figure 4-11.

Liquid level gauge

Hydraulic oil tank

Figure 4-11 Hydraulic oil tank

c) Examining the fuel reserve

The fuel reserve is displayed on the fuel gauge. Examine the fuel reserve and add fuel if
necessary.

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 Operator’s Manual for Truck Crane

NOTICE
Deaerate the fuel system before adding fuel.
If the fuel tank has been run dry, always deaerate the whole fuel system.
Do not run the fuel tank dry!

d) Examining the coolant level

Do a check of the coolant to make sure that the engine coolant is at the correct level. Add
more if below the cold engine level.
e) Examining general conditions of crane
1) Examine lubrication status of each moving parts and make sure that all moving parts
are lubricated. Add grease to if necessary.
2) Make sure that the crane is properly supported on a level load-bearing surface, and
has been set up horizontally.
3) Make sure that the gear of the slewing bearing connection is clean.
4) Make sure that the front and rear parts of oil cooler and A/C radiator have been
cleaned and are free of blockage.
5) Make sure that there are no people or objects in the crane danger zone.

Operation Superstructure
6) Make sure that the cable / rope drums and sensors are free of snow and ice.
7) Make sure that there are no loose parts on the superstructure or the telescopic boom.
8) Make sure that the joysticks in the operator’s cab are in neutral before you engage –

the PTO.
9) Make sure that all the outrigger control levers are in neutral.
10) Make sure that the parking brake is applied.

4.3.2 Starting and stopping the engine

For starting and stopping the engine in driver’s cab, please refer to the operating instructions in
Chapter 3 Operation – crane chassis.
Starting and stopping the engine in operator’s cab should be carried out in accordance with the
following operating instructions.
a) Stopping the engine
In normal conditions, press and hold the button “Engine stop” on the control panel for 1 to
2 seconds to switch off the engine.
In an emergency, you can also press the button “Emergency stop” to switch off the engine.
b) Starting the engine
You can press the button “Engine start” to switch on the engine if the following
prerequisites are met:
1) The PTO has been engaged.
2) The transmission is in the required position.
If the button “Emergency stop” is activated in an emergency, turn the button clockwise
to remove the limitation. Otherwise, the button “Engine start” is invalid.

ZTC800R532 Truck Crane 4-17

 Operator’s Manual for Truck Crane

4.4 Safety devices

4.4.1 Level gauge
A level gauge is located on each side of the crane near the outrigger control mechanism.
After the crane is horizontally aligned, the bubble in the level gauge should be in the exact
center position.

CAUTION
When the crane is on a level area, examine the level gauge. The bubble shows in the
middle of the gauge. If not, adjust the nuts below the gauge.

4.4.2 Angle indicator

The angle indicator is installed on the lower rear part of the basic boom (on the right side of the
operator’s cab). Refer to Figure 4-12.
The operator can observe it clearly from the cab. The angle indicator, which indicates the
included angle between the main boom and the horizontal plane, should be used in
combination with the lifting capacity tables and the lifting height chart.
Operation Superstructure

–
50 40 30 20 10
60
70 0
80

50 40302010
7060 0
80

40°

Figure 4-12 Angle indicator

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 Operator’s Manual for Truck Crane

4.4.3 Hoisting limit switch

The hoisting limit switches on the main boom, jib and rooster sheave are intended to prevent
the hook block from colliding with the rope pulley.
When the distance detected between the hook block and the pulley is less than the safety one,
the hoisting limit switch is triggered and buzzer sounds. The crane movements “Spool winches
up”, “Derrick down” and “Telescope out” are switched off. At this time, only the crane
movements “Reel off winches”, “Derrick up” and “Telescope in” can be switched on. Refer to
Figure 4-13.

Check ring

Operation Superstructure
Hoisting limit
switch weight –
Check ring

Dangerous operation
(Be switched off)
Bypassed
(Return to safe operation)

Figure 4-13 Hoisting limit switch

Activate the bypass key switch to bypass the switch-off during commissioning and
maintenance.

WARNING
Do not use the bypass key switch when you do usual crane operations.

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 Operator’s Manual for Truck Crane

The connection and installation of hoisting limit switches on the jib and rooster sheave are as
follows:
a) When the jib is used:
1) Remove a plug at the tail of box jib section.
2) Connect the plug to the socket at the main boom head.
Refer to Figure 4-14.

# #

# #

# #
#

# # #

#
# #
#

# # # # # # # # # #
# # # # # # # # # #
# # # #
#

# # # #

# # # #
# # # # # # # # # #
# # #
# # # # # # # # # # # #

# # # #

#
# # # #
#
#
#
#
# # # #
#
#
#

# # # # # #
# #
#

# #
# # # # #

# #
# #

# # # #

# # # # #

# #

#
#

Cable harness of adaptor #

# #
#

Cable of box jib section

Operation Superstructure

Figure 4-14 Installation of hoisting limit switch on the jib

–
CAUTION
Under jib working condition, connect the cable harness of hoisting limit switch of
auxiliary winch to the cable harness of jib in advance. And thus the hoisting limit switch
of auxiliary winch is valid.
Before dismantling of jib, disconnect the cable harness of hoisting limit switch of
auxiliary winch to the cable harness of jib lest the cable harness is broken.

b) When the rooster sheave is used:

1) Remove the hoisting limit switch on the jib and install it as the figure below.
2) Connect the plug of hoisting limit switch to the socket at main boom head.
Refer to Figure 4-15.

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 Operator’s Manual for Truck Crane

#
#
#
#
#

# #

# #

# #

# #

# #
#

#
#
#

#
#
#

Cable of hoisting limit switch

# #

# #

# #

# #

# #

#
#
# #

# #

# #

# #

# #
#
#

#
#
#
#

of auxiliary winch

#
#
#
#
# #

# #

# #

# #

# #

#
#
#
#

#
#
#
#

#
#
#
#

#
#
#

#
#
#

#
#
#

#
#

#
#
#
#

#
#

#
#

#
#

#
#
#
#
#
Figure 4-15 Installation of hoisting limit switch on the rooster sheave

4.4.4 Lowering limit switch

In order to prevent the wire rope from being spooled up automatically after being reeled off
completely, the lowering limit switches installed on the winches will automatically switch off the

Operation Superstructure
movements “Reel winches off” if there are only 3 wraps of rope on the winches.
In this case, the warning light lights up, the buzzer sounds alarm and only the upward –
movement of the hook is permitted. During commissioning and maintenance, activate the
lowering limit bypass switch to bypass the switch-off. Refer to Figure 4-16.

WARNING
Do not use the bypass key switch when you do usual crane operations.

Winch

Lowering limit switch

Figure 4-16 Lowering limit switch

ZTC800R532 Truck Crane 4-21

 Operator’s Manual for Truck Crane

4.4.5 Hydraulic safety devices

4.4.5.1 Relief valves in hydraulic system

The relief valves in the hydraulic system can prevent the pressure in the circuit from rising too
high, thus avoid the hydraulic pump and hydraulic motor from being damaged and the hydraulic
system from being overloaded.

4.4.5.2 Outrigger locking device

If the high-pressure oil pipe which is connected to vertical cylinder is damaged, the two-way
hydraulic lock in the outrigger hydraulic circuit can block the pressure oil in both sides of
outrigger cylinder to prevent the outrigger from retracting or extending, and thus ensure the
safe operation of the crane.

4.4.5.3 Locking device for crane movement “Derrick up”

If the high-pressure oil pipe in the hydraulic circuit of derricking cylinder is damaged, the
balance valve in the hydraulic circuit can lock the hydraulic oil in the piston side of derricking
cylinder immediately to prevent the boom upward movement from being down, and thus ensure
the safe operation of the crane.
Operation Superstructure

4.4.5.4 Locking device for crane movement “Telescope out”

– If the high-pressure oil pipe in the hydraulic circuit of telescoping cylinder is damaged, the
balance valve in the hydraulic circuit can lock the hydraulic oil in the piston side of telescoping
cylinder immediately to prevent the telescopic sections from retracting naturally, and thus
ensure the safe operation of the crane.

4.4.5.5 The 5th outrigger overpressure warning system

In order to prevent the vehicle front from bending and deformation caused by overpressure on
the 5th outrigger, a pressure relay is installed on the oil cylinder for the 5th outrigger. When you
carry out a lift operation over front, the pressure detecting device installed on the 5th outrigger
can detect the pressure in the hydraulic system and send the pressure signal to the crane
control system. Once the pressure exceeds the set safety value, the warning light “The 5th
outrigger pressure high” lights up and the buzzer sounds.

WARNING
Do not carry out lifting operation over front when the warning light “The 5th outrigger
pressure high” lights up and the buzzer sends out acoustic warning.

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 Operator’s Manual for Truck Crane

4.4.5.6 System pressure monitoring

The maximum pressures are as follows:
Pressure of spooling up oil circuit in main / auxiliary winch: 30 MPa, pressure of reeling off oil
circuit in main / auxiliary winch: 5 Mpa – 6 MPa
Pressure of derricking up oil circuit: 28 MPa, pressure of derricking down oil circuit: 2 MPa – 5
MPa
Pressure of telescoping out oil circuit: 15 MPa, pressure of telescoping in oil circuit: 18 MPa
Pressure of slewing oil circuit: 13 MPa
Pressure of control oil circuit: 3.5 MPa

4.4.6 Emergency stop button

You can find the emergency stop button on the switch
panel in the operator’s cab. When you push the button,
all crane operations immediately STOP (includes the
engine). Turn the button clockwise to release it and
continue usual crane operations.

Operation Superstructure
WARNING
Only use the button in a clear emergency! –

ZTC800R532 Truck Crane 4-23

 Operator’s Manual for Truck Crane

4.5 Crane operation

4.5.1 Preparations for crane operation
Make sure that following checks are performed before operation:
a) Assess the load condition prior to lifting it.
b) Examine the crane position, ground condition and surface bearing condition.
c) Examine wire ropes (including wire rope end, winding drum and pulleys).
d) Examine the liquid level and power source of the crane.

CAUTION
(1) Examine the fuel gauge to ensure the fuel reserve is more than 1/4 of the tank
capacity.
(2) The oil level in hydraulic oil tank should be between MIN. and MAX. marks in
driving condition.

e) The loading and working area should be visible and without obstacles within it. Examine
the communication system of operator and supervisor to make sure that nothing will hinder
the operation.
Operation Superstructure

f) Examine safety devices for function.

– g) Remain the communication between the operator and the rigger.

WARNING
Risk of accident!
Danger of damaging the crane!
Always operate the joysticks slowly and sensitively.

DANGER
Make sure that there are no obstacles in the crane working area and no persons in
danger zone. Give a short warning signal (horn) before starting a crane movement.

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 Operator’s Manual for Truck Crane

4.5.2 Outrigger
Both sides of the vehicle chassis frame have the items below:
– Accelerator control switch
– Outrigger control levers
– Level gauge.
You can operate the control levers to extend or retract the outriggers simultaneously or
independently. Refer to Figure 4-17.

5
e
achin
em
ndth
deda
xten
bee vel.
ust pingle
gersm lesco R缩 ET
utrig ete
fo gers, ckth
all o outrigracket. gandlo伸
tion, .
peralledup tracting oombgliftin 腿 EXT
eforeo ve rre nb urin 前支
1. Bust belendingo yedogersd FO
m xte st bestautrig 右前
hene u ulatingo FRO
告 2. W oomm anip
警 NING 持水平； theb it m 左前
WAR 使车架保 rohib FLO
,并 架上； 3. P 右后
腿
支
下 支 。
须先放 于吊臂 缩手柄 RRO
业前必 必须位 锁紧伸 左后
起重作腿时,吊臂 纵支腿并 RLO
放支 禁操
2. 收作业时，严
起重
3.

2
7
3

Operation Superstructure
–

Figure 4-17 Outrigger

Pos. Description Pos. Description

1 Accelerator control switch 5 Horizontal cylinder

2 Outrigger control levers 6 Sliding beam

3 Level gauge 7 Vertical cylinder

4 Horizontal cylinder 8 Vertical cylinder

NOTICE
Extend the outriggers before crane operation.
Make sure that you do all of the work on level ground that is hard. The ground must hold
more than the load bearing capacity.
Use material (such as wooden timbers) below the outrigger pads if the work area is soft
or not flat.

ZTC800R532 Truck Crane 4-25

 Operator’s Manual for Truck Crane

4.5.2.1 Outrigger control levers

As for the outrigger control nameplate, please refer to Figure 4-18.

Figure 4-18 Outrigger control nameplate, left

1.
起重
作
警
2.
收放 业前必 WARN 告
支 须 IN
3.
起重 腿时 先放 G
缩 作业 , 吊臂 下支
RE
时， 必须 腿, 并 1.
B ef
T 严禁 位于 使车 or
e
操纵 吊臂 架保 mu operat
支腿 支架 持2.水 st be ion,
伸 并锁 上； W平hen ； levelle all of
EX
紧伸 ex d
u ou
T 前支 缩 te
手柄 the bo nding p. tr ig
ge
腿 3.。 om or rs
mu
FO P ro re
mu
h ib tr ac st
Operation Superstructure

it st be
man be st tin ex
左前 ipu ay
g
ou
ten
ed tr ig de
FL lati on d
O ng ge an
ou bo rs d
th
右前 trigge om br , e
mac
FR rs ac h in
du ke
O t. e
rin
左后 g liftin
R LO g
an
d
lock
右后 th
e
tele
RR sc
O op
in g

–
leve
l.

2
3
4
5
6

Figure 4-19 Outrigger control levers, left

Outrigger control levers are shown in Figure 4-19.

a) Operating illustrations and points for attention are printed in the outrigger label.
b) Control lever 1: extend or retract the horizontal or vertical cylinder
1) Move lever 1 upwards: retract the horizontal / vertical cylinder.
2) Neutral position: stop the cylinder’s movement.
3) Move lever 1 downwards: extend the horizontal / vertical cylinder.
c) Control lever 3: select the right front outrigger
Control lever 4: select the left front outrigger
Control lever 5: select the right rear outrigger
Control lever 6: select the left rear outrigger

4-26 ZTC800R532 Truck Crane

 Operator’s Manual for Truck Crane

Move levers 3, 4, 5 and 6 together with lever 1 to initiate corresponding movements.

1) Move levers 3, 4, 5 and 6 upwards and move lever 1 upwards or downwards: extend /
retract the horizontal cylinders.
2) Move levers 3, 4, 5 and 6 downwards and move lever 1 upwards or downwards:
extend / retract the vertical cylinders.
d) Control lever 2: select the 5th outrigger
th
Move lever 2 downwards and move lever 1 upwards: retract the 5 outrigger
Move lever 2 downwards and move lever 1 downwards: extend the 5th outrigger.

CAUTION
(1) During the operation of the outriggers, turn the accelerator control switch clockwise
to increase their work speeds.
(2) When you retract any of the vertical cylinders, the 5th outrigger cylinder will be
retracted simultaneously.

WARNING
Do not extend or retract horizontal cylinders after the outrigger pads are in contact with

Operation Superstructure
the ground!
–
4.5.2.2 Outrigger extension
a) Remove the pin of the sliding beam. Refer to Figure 4-19.
b) Do the following steps as follows:
1) Stand on the left (or right) side of the crane.
2) Move levers 3 and 5 (or 4 and 6) upwards.
3) Move lever 1 downwards till the mid-position marks “ ” are exposed, that is to say
the sliding beams are intermediately extended.
4) Continue moving lever 1 to fully extend the sliding beams.
5) Move the levers to neutral positions after the sliding beams are fully extended.
6) Extend the sliding beams on the other side of the crane in the same steps.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion bra ing
rat up. tin
g
m
伸
T
ope d rac boo g lift EX
ore levelle ret on du rin 腿
Bef or yed s 前支
1. st be ing sta rigger FO
mu end be
en
ext
mu
st g out 前
tin 右
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
左前
W AR 架保 Pro
hib
FLO
,并
使车 3.
放下
支腿 上；
支架 柄。 右后
吊臂 O
须先 RR
前必 位于 紧伸缩手
必须
作业
起重 时,吊臂 支腿并锁 左后
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
3 2
6 54

Figure 4-19 Extend horizontal cylinder

ZTC800R532 Truck Crane 4-27

 Operator’s Manual for Truck Crane

WARNING
The mid-position marks “ ” on sliding beams must completely exposed and the
pins must be secured if the crane is working with outriggers intermediately
extended. Otherwise, the crane may topple.

c) Do the following steps as follows:

1) Stand on the left (or right) side of the crane.
2) Move levers 3 and 5 (or 4 and 6) downwards.
3) Move lever 1 downwards to fully extend the vertical cylinders.
4) Walk to the other side of the crane to extend vertical cylinders on the other side.
Refer to Figure 4-20.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion . g bra ing 伸
rat up tin m T
ope d rac boo g lift EX
ore levelle ret on durin 腿
Bef or s 前支
1. st be ing yed
sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
左 前
W AR
hib
架保 Pro FLO
使车
,并 上； 3.
支腿 右后
放下 吊臂支架 柄。 O
须先 缩手 RR
前必 必须位于 紧伸
作业
起重 时,吊臂 支腿
并锁 左后
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
Operation Superstructure

3 2
6 54

–
Figure 4-20 Extend vertical cylinder

d) Look at the level gauge to tell if the crane is level. If the bubble in the level gauge does not
show a level indication, you can move the outrigger to make the crane level.
Move the levers to neutral positions after the complete vehicle is leveled.
How to level the vehicle:
For example: If vehicle right side is higher than the left one, do the steps that follow (Refer
to Figure 4-21):
1) Move levers 4 and 6 downwards slowly.
2) Move lever 1 upwards and monitor the level gauge at the same time.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion bra ing
rat up. tin
g
m
伸
T
ope
elle
d rac boo g lift EX
ore ret on durin 支腿
Bef be lev or yed s 前
1. st ing sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
左前
W AR 架保 Pro
hib
FLO
,并
使车 3.
支腿 上；
支架 柄。 右后
放下
吊臂 O
须先 RR
前必 位于 紧伸缩手
必须
作业
起重 时,吊臂 支腿并锁 左后
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
3 2
6 54

Figure 4-21 Level the vehicle

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 Operator’s Manual for Truck Crane

e) When the bubble is at the correct position, release the lever 1 and move levers 4 and 6 to
neutral positions.
f) When the crane is working over front with the same lifting capacities as over sides and rear,
you should set up the 5th outrigger.
How to extend the 5th outrigger:
1) Move lever 2 downwards.
2) Move lever 1 downwards until the 5th outrigger is 5 – 10 mm away from the ground.
Refer to Figure 4-22.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion bra ing
rat up. tin
g
m
伸
T
ope d rac boo g lift EX
ore levelle ret on durin 支 腿
Bef or s 前
1. st be ing yed
sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
左前
W AR 架保 Pro
hib
FLO
使车
,并 上； 3.
支腿 右后
放下 吊臂支架 柄。 O
须先 RR
前必 必须位于 紧伸缩手
作业
起重 时,吊臂 支腿并锁 左后
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
3 2
6 54

Figure 4-22 Extend the 5th outrigger

Operation Superstructure
g) Install the outrigger retaining pins. The crane is ready to work.
–

CAUTION
Lever 1 can return to neutral position automatically after being released, while other
levers should be returned manually.

WARNING
Risk of accident!
If the horizontal reference of level gauge varies due to other factors such as external
forces etc., the level gauge must be aligned by specialized technicians again.
If this is not observed, a risk of accident exists.

ZTC800R532 Truck Crane 4-29

 Operator’s Manual for Truck Crane

4.5.2.3 Outrigger retraction

NOTICE
After crane operation, do the tasks that follow in sequence:
(1) Stop the work (safely lower the load).
(2) Retract the boom.
(3) Correctly stow the boom.
(4) Retract the 5th outrigger.
(5) Retract all the other outriggers.

a) Remove the pin of the sliding beam.

b) Retract the 5th outrigger (Refer to Figure 4-23):
1) Move lever 2 downwards.
2) Move lever 1 upwards until the 5th outrigger is fully retracted.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion
rat up. tin
g
m
bra ing 伸
T
ope
elle
d rac boo g lift 腿
EX
ore lev ret on durin
Bef or s 前支
1. st be ing yed
sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
hib 左前
W AR 架保 Pro FLO
使车 3.
,并 上；
支腿 右后
放下 吊臂支架 柄。 RR
O
须先 缩手
前必 必须位于 紧伸
作业 并锁 左后
起重 时,吊臂 支腿
Operation Superstructure

1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

–
1
3 2
6 54

Figure 4-23 Retract the 5th outrigger

c) Retract the vertical cylinders:

1) Stand on the left (or right) side of the crane.
2) Move levers 3, 4, 5 and 6 downwards.
3) Move lever 1 upwards to retract vertical cylinders completely.
Refer to Figure 4-24.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion bra ing
rat up. tin
g
m lift
伸
T
ope d rac boo g EX
ore levelle ret on durin 腿
Bef or s 前支
1. st be ing yed
sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
左前
W AR 架保 Pro
hib
FLO
使车
,并 上； 3.
支腿 右后
放下 吊臂支架 柄。 O
须先 缩手 RR
前必 必须位于 紧伸
作业
起重 时,吊臂 支腿
并锁 左后
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
3 2
6 54

Figure 4-24 Retract vertical cylinder

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 Operator’s Manual for Truck Crane

d) Retract the sliding beams:

1) Stand on the left (or right) side of the crane.
2) Move levers 3, 4, 5 and 6 upwards.
3) Move lever 1 upwards to retract sliding beams completely.
Refer to Figure 4-25.

ne
chi
ma
the
and
ed
end
ext el.
be lev
st ng
s mu opi 缩
ger esc T
rig tel RE
out
of
s,
ger t. k the
rig loc
, all out cke and
ion
rat up. tin
g
m
bra ing 伸
T
ope
elle
d rac boo g lift EX
ore ret on durin 支腿
Bef be lev or yed s 前
1. st ing sta rigger FO
mu end be
en
ext
mu
st g out 右前
tin
告G 2.
Wh
boo
m
nip
ula FRO
警 N IN 持水平； the it ma
hib 左前
W AR 架保 Pro FLO
使车 3.
,并 上；
支腿 右后
放下 吊臂支架 柄。 O
须先 缩手 RR
前必 必须位于 紧伸
作业 并锁 左后
起重 时,吊臂 支腿
1. 支腿 操纵 RLO
收放 严禁
2. 时，
作业
3. 起重

1
3 2
6 54

Figure 4-25 Retract horizontal cylinder

e) Install the outrigger retaining pins.

4.5.2.4 Install and remove the outrigger pads

Operation Superstructure
The outrigger pad is shown in Figure 4-26.
–

Vertical cylinder

Outrigger pad

Socket pin

Figure 4-26 Outrigger pad

a) Installation
Before you extend the outriggers, remove the socket pin from the outrigger pads and pull
out the outrigger floats. When the hole aligns with the vertical cylinder, install the socket
pin.
Weight of outrigger pad: about 35 kg.

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 Operator’s Manual for Truck Crane

b) Removal
After you fully retract the outriggers, remove the socket pin and push in the outrigger pad
until it is in the correct position. Install the socket pins.

CAUTION
(1) Before you move the outriggers, make sure that there is clearance to prevent injury
to personnel or damage to the crane and other objects.
(2) Make sure that you install the outrigger pads before you move the outriggers.
(3) Make sure that all the outrigger pads (except the 5th outrigger pad) contact with the
ground.
(4) You can only extend the 5th outrigger to the position where its outrigger pad is about
5 – 10 mm off the ground. It is not permitted that the two front outriggers are away
from the ground due to excessive extending of the 5th outrigger.
(5) Make sure that all the tires are off the ground (crane weight held up by the
outriggers) before you start to lift a load.
(6) When the crane is on a level area, examine the level gauge. The bubble shows in the
middle of the gauge. If not, adjust the nuts below the level gauge.
Operation Superstructure

WARNING
–
Do not operate the outrigger control levers in a lift operation.

4.5.3 Derricking
a) Turn the switch "Pre-selection of telescope / derricking” to the right position. Refer to
Figure 4-27.

Figure 4-27 Switch “Pre-selection of telescope / derricking”

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 Operator’s Manual for Truck Crane

b) The right joystick controls the derricking gear.

– Neutral position: stop the derricking movements
– Move the joystick leftwards (direction ③).
Result:
The telescopic boom is derricked up.
– Move the joystick rightwards (direction ④).
Result:
The telescopic boom is derricked down.
Refer to Figure 4-28.

Operation Superstructure
Figure 4-28 Right joystick

The speed of derricking up movement is changed by: –

– Right joystick – how far you move the joystick leftwards

– Engine control pedal – Increase or decrease the engine RPMs.
Note:
Do not apply the engine control pedal when the travel distance of control lever is short.
Do not change the derricking speed rapidly.

CAUTION
The speed of derricking down movement is not dependent upon the travel distance of
engine control pedal.

The angle indicator and the angle detector attach to the side of the main boom. Refer to Figure
4-29. The operator can see the angle indicator from the operator’s cab. The angle detector is
an electronic device that sends the boom angle data to the load moment limiter. The boom
angle shows on the display screen.

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 Operator’s Manual for Truck Crane

0
10
20
30

40
0 50
80 70 6

Length / angle detector Main boom Angle indicator Operator’s cab

Figure 4-29 Safety devices on the main boom

WARNING
(1) Do all derricking movements smoothly. You can cause damage to the crane if you
Operation Superstructure

move the load up or down with quick stops.

(2) The derricking angle and working radius should be restricted according to the
–
lifting capacity tables.

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4.5.4 Telescoping
The main boom has five parts to it: a basic boom and four telescopic sections.
To extend and retract the boom, a telescoping system is attached in the boom structure. The
components of the telescoping system are as follows:
– Telescoping cylinders
– Boom extension ropes
– Boom retraction ropes.
The movements “Telescope boom in / out” are controlled by two telescoping cylinders and the
wire ropes used together.
Figure 4-30 shows the telescoping principle:

Basic boom Telescopic section 3

Telescopic section 1
Boom retraction rope I Telescopic section 2 Telescopic section 4

Operation Superstructure
–

Boom Boom Boom

Telescoping cylinder I Telescoping cylinder II extension rope I retraction rope II extension rope II

Figure 4-30 Telescoping

a) Turn the switch "Pre-selection of telescope / derricking” to the left position. Refer to Figure
4-31.

Figure 4-31 Switch “Pre-selection of telescope / derricking”

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 Operator’s Manual for Truck Crane

b) The right joystick controls the telescoping system.

– Neutral position: stop the telescoping movements.
– Move the joystick leftwards (direction ③).
Result:
The telescopic sections are telescoped in.
– Move the joystick rightwards (direction ④).
Result:
The telescopic sections are telescoped out.
Refer to Figure 4-32.

③
Operation Superstructure

Figure 4-32 Left joystick

–
CAUTION
(1) When you extend the boom and the hook block touches the hoisting limit switch
weight, the items below occur:
– A warning noise sounds.
– A warning light illuminates.
– Boom extension is cut off.
If you must extend the boom more, use the reel-off function to lower the hook block.
(2) The speed of the telescoping movement is changed by:
– Right joystick – how far you move the joystick forwards or backwards
– Engine control pedal – increase or decrease the engine RPMs.
Do the telescoping movement smoothly. You can cause damage to the crane if you
change speed rapidly.
(3) Telescope the boom stably and at constant speed.
(4) When the boom is fully retracted, it can be two seconds before the boom starts to
move.
(5) The bypass key switch can only be activated during commissioning and
maintenance. Do not use the bypass key switch when you do usual crane
operations.

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(6) The operator should strictly carry out the telescoping operation according to lifting
capacity tables. Otherwise, the crane may topple or be damaged.
(7) When you retract the boom, retract the telescoping cylinders in the following
sequence:
– Telescoping cylinder II
– Telescoping cylinder I
If this is not observed, a risk of boom shake exists.
(8) When you retract the boom over sides, do not retract the telescoping cylinders in
the following sequence:
– Telescoping cylinder I
– Telescoping cylinder II
Otherwise, a risk of boom shake exists.
(9) When you extend the boom to lift the load, the telescoping system undergoes the
elastic deformation and the boom retracts a little. This is a normal phenomenon.
After the load is stable, the boom will stop retracting automatically.

WARNING

Operation Superstructure
Do not telescope the telescopic boom with a suspended load. Otherwise:
(1) The telescoping cylinder and boom extension / retraction ropes may be damaged.
–
(2) The crane may topple.

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 Operator’s Manual for Truck Crane

4.5.5 Lifting / lowering

4.5.5.1 Preparations
Read Lifting capacity tables and Lifting height chart in Chapter 1 before lifting / lowering
operation.
Lifting capacity table (Refer to Figure 4-33)
How to look up lifting capacity in the Lifting capacity table:
Look up the main boom length according to the lifting height and working radius in lifting height
chart.
Look up the lifting capacity according to the checked main boom length in the lifting capacity
tables.
If the jib is fitted, look up the lifting capacity according to the boom angle in the table.
For example:
If outriggers are fully extended and the main boom is over sides and rear, look up the lifting
capacity:
The rated lifting capacity with working radius of R 2 :
If the main boom length is L 2 , the lifting capacity is W 2 kg.
The rated lifting capacity with working radius of R 3 :
Operation Superstructure

If the main boom length is L 3 , the lifting capacity is W 3 kg.

– Refer to Figure 4-35.

CAUTION
(1) Look up the corresponding lifting capacity according to actual working conditions.
(2) Observe the notes shown below the lifting capacity table.

Supposed height above ground: about H (m) Boom length: L (m)

Supposed radius: about R (m) Boom angle: About θ (°)

Figure 4-33 Look up lifting capacity

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 Operator’s Manual for Truck Crane

CAUTION
All the working radius and lifting height in lifting height charts do not include the
deflection of main boom and jib.

Lifting capacities are changed with working radius.

Working radius without load

Working radius with load

Operation Superstructure
–
Figure 4-34 Working radius change

额 定 起 重 量 表 RATED LIFTING CAPACITY TABLE

工作 主 臂 (m) BOOM
幅度(m ) I缸伸至100%，支腿全伸，侧方、后方作业

WORKING Cylinder I fully extended, with outriggers fully extended, side & rear working area
RADIUS(m)
L1 L2 L3 L4 L5 ...... Ln
R1
R2
R3 W3

......
Rn

Note: L 3 refers to the main boom length. W 3 refers to the rated lifting capacity.

Figure 4-35 Rated lifting capacity table

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 Operator’s Manual for Truck Crane

4.5.5.2 Spooling up / reeling off main winch

a) The right joystick controls the main winch.
– Neutral position: stop spooling up / reeling off main winch.
– Move the joystick forwards (direction ①).
Result:
Main winch is reeled off.
– Move the joystick backwards (direction ②).
Result:
Main winch is spooled up.
Refer to Figure 4-36.

②
Operation Superstructure

– Figure 4-36 Right joystick

b) The main hoist gear is working. Refer to Figure 4-37.

Figure 4-37 Main hoist gear operation

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 Operator’s Manual for Truck Crane

4.5.5.3 Spooling up / reeling off auxiliary winch

a) The left joystick controls the auxiliary winch.
– Neutral position: stop spooling up / reeling off auxiliary winch.
– Move the joystick forwards (direction ①).
Result:
Auxiliary winch is reeled off.
– Move the joystick backwards (direction ②).
Result:
Auxiliary winch is spooled up.

Operation Superstructure
Figure 4-38 Left joystick
–
b) The auxiliary hoist gear is working.

Figure 4-39 Auxiliary hoist gear operation

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 Operator’s Manual for Truck Crane

After you complete the movement, move the joystick to the neutral position slowly to stop the
movements.
The speed of the main winch / auxiliary winch movement is changed by:
– Joystick – how far you move the joystick forwards or backwards
– Engine control pedal – increase or decrease the engine RPMs.
Note:
Spool up / reel off the winches smoothly. You can cause damage to the crane if you change
speed rapidly.
Do not apply the engine control pedal when the joystick travel distance is short.
A warning noise sounds and a warning light illuminates if the items below occur:
– The main or auxiliary winch is in the spool-up mode and the hook block touches the
hoisting limit switch weight.
– The sensor senses that the winch has 3 wraps of wire rope on it.
– The sensor senses that the load weight is more than the load weight in the system.
When the warning occurs, the winch operation is cut off. The crane can only work towards safe
directions till the dangerous operation is deactivated.
Operation Superstructure

CAUTION
(1) Choose the correct reeving for the boom length and load weights in accordance
–
with the lifting capacity tables. Before you change the reeving numbers, fit the
hoisting limit switch weight.
(2) Keep a minimum of 3 wraps of rope on the winch while you operate the crane.
(3) Lift the load vertically. Do not drag the load that is still on the ground. Do not pull a
load at an angle.
(4) Monitor the area as you lift a load. Do not move a load unless the conditions are
safe. Do not derrick the boom up and extend the boom at the same time if:
– The crane has a part of the load weight.
– The crane is connects to a load on the ground.
(5) Do not change quickly between "Reel off" and "Spool up". Let the winch stop before
you continue to move the hook. Otherwise, the machine will be damaged.
(6) The slings must be of enough strength. The lifting capacity includes the mass of the
hook and slings.
(7) Do not use the crane to lift personnel.
(8) If the hook turns because of the rope, put the load on the ground. Do not lift the load
until the rope is straight.

WARNING
Do not do a lifting operation with the main winch and auxiliary winch at the same time.

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4.5.6 Slewing

4.5.6.1 Operation
The left joystick controls the slewing gear.
– Neutral position: stop the slewing movements.
– Move the joystick leftwards (direction ④).
Result:
Slew to the left.
– Move the joystick rightwards (direction ③).
Result:
Slew to the right.
Refer to Figure 4-40.

Operation Superstructure
–

Figure 4-40 Left joystick

The speed of the slewing movement is changed by:

– Left joystick – how far you move the joystick leftwards or rightwards
– Engine control pedal – increase or decrease the engine RPM.
Note:
Do not apply the engine control pedal when the joystick travel distance is short.
Do the slewing movement smoothly. You can cause damage to the crane if you change speed
rapidly.

CAUTION
(1) During slewing superstructure, operator’s field of vision will be limited to some
extent. Do operate the crane carefully.
(2) Make sure that work-site personnel and equipment are clear from crane slewing
area (within slewing radius R). Give a short warning signal (horn) before starting a
crane movement.

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 Operator’s Manual for Truck Crane

4.5.6.2 Slewing lockout device

The slewing lockout device attaches on the front of the slewing table. Make sure that the
superstructure is unpinned before initiating the slewing movement. Insert and secure the pin
after finishing this operation. Refer to Figure 4-41.

Pin

Slewing lockout device

Retaining seat

Figure 4-41 Slewing lockout device

Operation Superstructure

CAUTION
–
(1) Make sure that you do not make fast movements or suddenly stop the turn.
(2) When you operate a new crane, make sure that you examine the slewing bearing
bolts at these intervals: 100, 500, 1000 hours of operation.
– The torque on the bolts must be 1350 N·m.
(3) The crane can slew with load. Do not try to lift the load diagonally. Do not pull a load
across the ground.
(4) Make sure that the outriggers are in the correct position before you slew the
superstructure with a load on the boom.
(5) Monitor the area as you move a load. Do not move a load unless the conditions are
safe.
(6) Lubricate the slewing bearing at regular intervals.

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4.5.7 Simultaneous crane movements

The crane can do two operations or more at the same time. This increases the quantity of work
that the crane can do and improves the work efficiency.
There are 9 simultaneous crane movements. For the details, please refer to the table below.
Before you start, make sure that you examine or do the items that follow:
– Make sure that you increase the engine RPM (Apply the engine control pedal).
– Do not move the joysticks to their limit positions.

WARNING
You can only use simultaneous crane movements when you lift the load away from the
ground.
Do not telescope the boom with a suspended load!

Operation Superstructure
–

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 Operator’s Manual for Truck Crane

Table 4-1 Simultaneous crane movements

Simultaneous Illustrations
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a) Move the left joystick and

right joystick to make
auxiliary winch and main
① ① winch initiate relevant
movements simultaneously
Auxiliary winch ② ② (Refer to the left figures).
1
+ Main winch b) Left joystick:
① Reel auxiliary winch off.
② Spool auxiliary winch up.
c) Right joystick:
① Reel main winch off.
② Spool main winch up.
a) Turn the switch
Operation Superstructure

"Pre-selection of telescope /
derricking" to the right
–
position.
b) Move the left joystick and
right joystick to make
① ④
auxiliary winch and

③ derricking gear initiate

Auxiliary winch ②
2 relevant movements
+ Derrick
simultaneously (Refer to the
left figures).
c) Left joystick:
① Reel auxiliary winch off.
② Spool auxiliary winch up.
d) Right joystick:
③ Derrick up.
④ Derrick down.

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Simultaneous Illustrations
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a) Turn the switch

"Pre-selection of telescope /
derricking" to the left
position.
b) Move the left joystick and
right joystick to make
① ④
auxiliary winch and

③ telescoping system initiate

Auxiliary winch ②
3 relevant movements
+ Telescope
simultaneously (Refer to the
left figures).
c) Left joystick:
① Reel auxiliary winch off.
② Spool auxiliary winch up.
d) Right joystick:

Operation Superstructure
③ Telescope in.
④ Telescope out. –
a) Turn the switch
"Pre-selection of telescope /
derricking" to the left
position.
b) Move the left joystick and
right joystick to make
④ ④
slewing gear and
telescoping system initiate
Slew + ③ ③
4 relevant movements
Telescope
simultaneously (Refer to the
left figures).
c) left joystick:
③ Slew to the right.
④ Slew to the left.
d) Right joystick:
③ Telescope in.
④ Telescope out.

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 Operator’s Manual for Truck Crane

Simultaneous Illustrations
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a) Turn the switch

"Pre-selection of telescope /
derricking" to the right
position.
b) Move the left joystick and
④ ④ right joystick to make
slewing gear and derricking
③ ③
gear initiate relevant
5 Slew + Derrick
movements simultaneously
(Refer to the left figures).
c) Left joystick:
③ Slew to the right.
④ Slew to the left.
d) Right joystick:
③ Derrick up.
Operation Superstructure

④ Derrick down.

– a) Move the left joystick and

right joystick to make
slewing gear and main
④ ① winch initiate relevant
movements simultaneously
Slew + ③ ② (Refer to the left figures).
6
Main winch b) Left joystick:
③ Slew to the right.
④ Slew to the left.
c) Right joystick:
① Reel main winch off.
② Spool main winch up

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 Operator’s Manual for Truck Crane

Simultaneous Illustrations
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a) Turn the switch

"Pre-selection of telescope /
derricking" to the right
position.
b) Move the right joystick to
make derricking gear and
⑦
main winch initiate relevant
⑥
movements simultaneously
⑤
Derrick + ⑧ (Refer to the left figure).
7
Main winch c) Right joystick:
⑤ Derrick down / spool
main winch up.
⑥ Derrick up / reel main
winch off.
⑦ Derrick down / reel main

Operation Superstructure
winch off.
⑧ Derrick up / spool main
–
winch up.
a) Turn the switch
"Pre-selection of telescope /
derricking" to the left
position.
b) Move the right joystick to
make telescoping system
⑦ and main winch initiate
⑥
relevant movements
⑤
simultaneously (Refer to the
Telescope + ⑧
8 left figure).
Main winch
c) Right joystick:
⑤Telescope out / spool
main winch up.
⑥Telescope in / reel main
winch off.
⑦Telescope out / reel main
winch off.
⑧Telescope in / spool main
winch up.

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 Operator’s Manual for Truck Crane

Simultaneous Illustrations
Ser.
crane Operating instructions
No.
movements Left joystick Right joystick

a) Move the left joystick to

make slewing gear and
auxiliary winch initiate
relevant movements
⑦ simultaneously (Refer to the
⑥ left figure).
⑤
Slew + b) Left joystick:
⑧
9 ⑤ Slew to the left / spool
Auxiliary winch
auxiliary winch up.
⑥ Slew to the right / reel
auxiliary winch off.
⑦ Slew to the left / reel
auxiliary winch off.
⑧ Slew to the right / spool
auxiliary winch up.
Operation Superstructure

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4.5.8 Rope reeving

Before you start to change the wire rope reevings:
– Support the crane on outriggers.
– Fully retract the boom and move it to the side or rear of the crane.
Refer to Figure 4-42.

a b c d

Operation Superstructure
Figure 4-42 Rope reeving

Change the wire rope reevings as follows:

–
a) Derrick boom down and put the hook (a) on the ground.
b) Remove the pins (b) on the hook block and boom head to let the wire rope unreeve.
c) Remove hoisting limit switch weight (c).
d) Remove the wedge and socket assembly (beckett).
e) Dead end the rope on the hook block for an odd reeving number, and on the boom head
for an even reeving number.
f) Change rope reevings (d).

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 Operator’s Manual for Truck Crane

CAUTION
(1) You must change the location of the hoisting limit switch weight if you have a
different number of wire rope reevings. Refer to Figure 4-43.

Even reeving number Odd reeving number

Figure 4-43 Location of hoisting limit switch weight

(2) Put the wire rope on the winch spool smoothly and in sequence.
Operation Superstructure

(3) For methods of installing socket and rope clamp, please refer to Figure 4-44.

D – Rope diameter

Figure 4-44 Rope clamp installation

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Truck Crane Operator’S Manual

Chapter 5 Equipment
 Operator’s Manual for Truck Crane

Chapter 5 Equipment

5.1 Safety technical guidelines for assembly

a) Reeve the hoist rope between the rope pulley on the boom head and hook pulley in
accordance with the corresponding reevings specified in lifting capacity tables.
b) Assemble the counterweight plates according to lifting capacity tables.
c) If the jib is not in contact with ground during assembly and disassembly, put appropriate
and stable materials below the jib.

DANGER
(1) Do the assembly work with suitable aids (scaffolding or lifting platforms, etc.)!
If this is not observed, personnel could fall and suffer life-threatening injuries.
(2) Do not stand beneath the boom especially when the jib is being pinned or
unpinned.

d) Perform the safety measure checks before supporting the crane.

e) Before setting-up and taking-down the jib, make sure that the following prerequisites are
met:
1) The crane is properly supported and level.
2) The telescopic boom is fully telescoped in.
3) The jib has been fitted in accordance with lifting capacity tables.
4) All pinned connections have been secured.
5) All limit switches have been correctly fitted and are fully operational.
6) The hoist rope has been correctly placed in the rope pulleys with the rope securing

Equipment
tubes to prevent it from jumping out.
7) There are no loose parts on the boom and jib.

DANGER
(1) In winter, the boom, jib and associated components (limit switches, cable
drums, corner marker light, anemometer etc.) must be kept free of snow and
ice.
(2) Incorrectly fitted or faulty limit switches and falling parts (pins, spring-loaded
safety pins, ice etc.) can cause injury!

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 Operator’s Manual for Truck Crane

5.2 Jib
5.2.1 General
Jib is one of the important components of truck crane. With the jib assembled, the load can be
lifted to a higher height and the working radius can be enlarged via offset changed.
The crane has a 2-section jib. Jib section 1 is a quadrangle lattice structure and jib section 2 is
a triangle one. During driving, jib section 2 is secured into jib section 1 via pins and the whole jib
is installed on the right side of the main boom via pins. Meanwhile, jib section 2 can also fix on
right side of main boom individually.

WARNING
You cannot use the jib when you lift a load if the outriggers are not in the correct
position.

5.2.2 Assembly
You can assemble the jib at an angle of 0°, 15° or 30° to the telescopic boom according to work
requirements.
Assemble the jib (Take 0° offset for example). Refer to Figure 5-1 to Figure 5-13.
a) Extend the outriggers and make the crane level with the level gauge.
b) Retract the boom fully.
c) Move the boom to the side or rear of the crane and position it to -2°.
d) Make sure there is 30 m slewing radius.
Equipment

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Figure 5-1 Jib assembly

e) Adjust the limit bolt on the left side of main boom head (viewed from travelling direction) till
the clearance between the end surface of limit bolt and the bearing block at the boom
head is between 1 – 2 mm. After that, tighten the locking nut. Refer to Figure 5-2.

Equipment

Limit bolt

Figure 5-2 Limit bolt adjustment

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f) Remove the pin I. Extend the intermediate bracket and install the removed pin I. See
Figure 5-3.

Pin I

Figure 5-3 Extend the intermediate bracket

g) Remove the pins I and II. See Figure 5-4.

Equipment

Pin I

Pin II

Figure 5-4 Pins I and II removal

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h) Remove the pin III. See Figure 5-5.

Pin III

Figure 5-5 Pin III removal

i) Move the front of the jib away from the main boom (jib pivots at pin IV). See Figure 5-6.

Pin IV

Equipment

Figure 5-6 Move the front of the jib away from the main boom

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j) Align the end of the jib with the connection points on the right side of the main boom head.
Install the pin V and the retaining clip. See Figure 5-7.

Pin V

Figure 5-7 Pin V installation

k) Remove the pin IV. See Figure 5-8.

Pin IV
Equipment

Figure 5-8 Pin IV removal

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l) Move the jib (pivots at pin IV) to the front of the main boom. See Figure 5-9.

Pin V

Figure 5-9 Jib rotation

m) Align the end of the jib with connection points on the left side of main boom head. Install
the pin VI and the retaining clip. See Figure 5-10.

Equipment
Pin VI

Figure 5-10 Pin VI installation

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n) If the jib section II is to be used, remove the pin VII and the retaining clip β connecting jib
section I to section II. See Figure 5-11.

Retaining clip β

Pin VII

Figure 5-11 Pin VII removal

o) The jib section 2 rotates from pin VIII to the jib section 1 right ahead. Refer to Figure 5-12.

Pin VIII
Equipment

Figure 5-12 Jib section 2 rotation

p) Align the end of the jib section 2 with the connection points on the left side of the jib section
1 head. Install the pin IX and the retaining clip. See Figure 5-13.

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Pin IX

Figure 5-13 Pin IX installation

q) Reeve the wire rope from the auxiliary winch through the end of the jib. Install the auxiliary
hook and the hoisting limit switch.

DANGER
Do not stand under the jib during the slewing operation!
The jib and other components – due to an assembly error – can fall down and cause
fatal injuries.

Equipment
5.2.3 Angle settings
Change the jib offset from 0° to 30°. Refer to Figure 5-14.
a) Take out the auxiliary hook from the hook holder.
b) Pay out the auxiliary hoist rope for 2 m to 3 m at low speed.
c) Remove the pins and retaining clips from the pull bracket of adapter at jib end.
d) Derrick the boom up slowly until the long groove of the pull bracket aligns with the pin
bores for 30°.
e) Put the pins and retaining clips at the point for the 30° position.

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30°
Equipment

Figure 5-14 Offset positions

5.2.4 Disassembly
After you complete the jib operation, disassemble the jib in reverse order of the assemble
steps.

CAUTION
Do not excessively spool up the auxiliary winch when you disassemble the jib.

After the assembly and disassembly of jib, adjust the limit bolt on the left side of main boom
head (viewed from travelling direction) till the clearance between the end surface of limit bolt

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and the bearing block at the boom head is equal or more than 5 mm in order to prevent from
damaging the limit bolt during boom telescoping.

5.2.5 Reeving in the auxiliary hoist rope

a) Reeve the wire rope from the auxiliary winch through the rope guide on the basic boom.
b) Reeve the wire rope through rope guide pulleys to the jib section I head pulley or the jib
section II head pulley, and then reeve it under the rope securing tubes I and II or the rope
securing tubes III and IV.
c) Remove the rope securing tube II and its retaining clip.
d) Install the wedge and socket assembly.
e) Install the auxiliary hook.
f) Install the rope securing tube II and retaining clip.
See Figure 5-15.

Rope securing tube I

Rope securing tube II

Rope guide pulley I

Rope guide pulley II

Equipment
Figure 5-15 Rope securing tubes

5.2.6 Connection of hoisting limit switch

For the connection of hoisting limit switch, please refer to Figure 5-16 and Figure 5-18.
Under the jib working condition with the jib section 1 used (Refer to Figure 5-16.):
a) Remove the cable plug at the tail of jib adaptor.
b) Plug it into the socket on main boom head.
c) Remove the cable plug at the tail of jib section 1.
d) Plug it into the socket on jib adaptor head.

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Cable of jib section 1 Adapter cable

Figure 5-16 Cable harness connection of jib section 1

Under the jib working condition with the jib section 2 used (Refer to Figure 5-17.):
a) Properly connect the cable harness of jib section I according to the above-mentioned
methods.
b) Remove the cable plug at the tail of jib section 2.
c) Connect it to the socket at the head of the jib section 1.

Cable of hoisting
limit switch for Cable of jib
section 2 Cable of jib section 1 Adapter cable
auxiliary winch

Figure 5-17 Cable connection with jib section 1 and jib section 2

Under the jib working condition with the extension and two jib sections used (Refer to Figure
Equipment

5-18.):
a) Remove the cable plug at the tail of jib adaptor.
b) Plug it into the socket on main boom head.
c) Remove the cable plug at the tail of extension.
d) Plug it into the socket on jib adaptor head.
e) Properly connect the cable harness of jib sections I and II according to the
above-mentioned methods.

Cable of hoisting Cable of jib Cable of jib Cable of Adapter cable

limit switch for section 2 section 1 extension
auxiliary winch

Figure 5-17 Cable connection with extension and jib sections 1 & 2

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NOTICE
Before you assemble, retract or dismantle the jib, disconnect the all the cables.
Otherwise, the cable may be broken!

Equipment

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5.3 Rooster sheave

The components of the rooster sheave are as follows:
– Bracket
– Sheave spindle
– Sheave
– Pins.
When it is not necessary to use the rooster sheave, make sure that it is attached to the side of
the top boom section.
When the crane is to lift a light load, use the rooster sheave. This is the most efficient way to
move a lighter object.

5.3.1 Assembly
a) Fully retract the boom.
b) Move the boom over sides and over rear and set the boom to the -2° position.
c) Remove the securing pin and move the bracket to the front of the boom. Align the
connection points. Install the connecting pin. See Figure 5-19.
d) Reeve auxiliary hoist rope through the upper rope pulley and the rooster sheave. Install
the auxiliary hook and the hoisting limit switch. Make sure that all connections are tight.

Top boom section

Equipment

Connecting pin
Securing pin

Rooster sheave

Figure 5-19 Rooster sheave assembly

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5.3.2 Disassembly
When it is not necessary to use the rooster sheave, make sure that it is attached to the side of
the boom. Disassemble it in the reverse order of the assemble procedure.

5.3.3 Connection of hoisting limit switch

Under the rooster sheave working condition:
a) Remove the hoisting limit switch on the jib.
b) Install it in the place shown in the following figure.
c) Connect its cable plug to the socket at the head of the main boom.
Refer to Figure 5-20.

#
#

# # # # # #
# # # # #
# #
#

# #
#

# # # # # # #
# # # # # # # # # #
# # # # # # #

# #

# #

# #
#
#
#
#
#
#
#
#
#
#

# #
Cable of hoisting limit switch for auxiliary winch # #

# #

# #
# #

# #
# #
#
#

# #
# #

# #
# #
#
#

# #
#

#
# # #

# #
#

# #
#
#

Figure 5-20 Cable connection with rooster sheave

Equipment
NOTICE
Before you assemble or dismantle the rooster sheave, disconnect all cables. Otherwise,
the cable may be broken!

CAUTION
This truck crane has different driving speed limits when it travels with different
counterweights.
Traveling condition I: Traveling with fixed counterweight, it can travel at max. driving
speed.
Traveling condition II: Traveling with fixed counterweight and auxiliary counterweight,
its driving speed limits at 50 km/h.
Under traveling condition II, do not drive on the expressway. The long-term use of these
components such as axle and tire etc. will shorten their life.

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Chapter 6 Additional Equipment

 Operator’s Manual for Truck Crane

Chapter 6 Additional Equipment

6.1 Air conditioning in driver's cab

6.1.1 Operating methods
The control panel is on the center console in the driver’s cab.

Figure 6-1 Control panel, A/C and cab heater

6.1.1.1 Symbol identification

Table 6-1 Symbol identification

Symbol Description Symbol Description

Set Refrigeration

Auto 1 bar – stage 1

Temperature 2 bars – stage 2

Outer air circulation 3 bars – stage 3

Interior air circulation 4 bars – stage 4

Additional Equipment

Footwell air supply 5 bars – stage 5

Fresh air 6 bars – stage 6:

Front window air supply Vehicle body

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6.1.1.2 Buttons
a) Temperature adjustment button
Pressed:
Increase / decrease the temperature.

b) Fan speed button

Pressed:
Increase / decrease the fan speed.

c) OFF button
Pressed:
Turn off the air conditioning system.

d) AUTO button
Pressed:
Activate the auto operating mode.
Pressed again, or the A/C or front
window air supply button is
pressed:
Exit auto operating mode.

e) A/C button
Pressed:
A/C begins to refrigerate.

f) Circulation button
Pressed:
Changeover interior / outer air
circulation.

g) Front window air supply button

Additional Equipment

Pressed:
Enter the front window air supply
mode.

h) Mode button
Pressed:
Changeover different air supply
modes.

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WARNING
Do not use the cab heater during driving if engine coolant temperature is below 70ºC.

CAUTION
(1) Make sure that the A/C is in the OFF mode when the engine is OFF or at idle speed
for a long time. The battery drains in these conditions.
(2) When you move the crane for a long distance at low speed, with the A/C in the ON
mode, put the transmission in a low gear. This increases the engine RPM and
decreases the load on the transmission.
(3) Set the A/C to the OFF position when you do one of the items that follow:
– Move the crane quickly.
– Move up a long hill slope.
(4) In winter or other periods without using air conditioning, run the air conditioning for
several minutes once a month to benefit the lubricating circulation and ensure the
system in good state.
(5) Make sure that the refrigerant in the A/C system is at the correct level at regular
intervals.
(6) If there are unusual vibrations, noises or smells during operation, stop and examine
the crane immediately. Do not operate the crane that has a malfunction.
(7) Keep the surface of the condenser clean. When you clean the condenser, do not
use steam. Clean it with compressed air or cold water.
(8) Do not disassemble the belt or pipeline of compressor after when you do not use it
for a long time.
(9) In summer, close the shutoff gate valve on the hot-water pipe of cab heater at the
bottom of driver's cab. Otherwise refrigeration effect may be affected. In winter,
open the shutoff gate valve to make hot water enter into the cab heater.
Additional Equipment

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6.2 GPS terminal

GPS is the standard equipment for the cranes sold in mainland China. For its installed location,
please refer to Figure 6-2.
It is optional for the cranes sold in other regions.

CAUTION
If the crane sold in mainland China needs to work beyond the region, please contact
local Sales and Service Center of Zoomlion in advance. Otherwise, the GPS may be
unable to work normally.

GPS terminal

Figure 6-2 GPS location

The overall view of GPS is shown in Figure 6-3.

Emergency unlocking button

Additional Equipment

Error code labels

Control light,
GPS terminal state

LED

Figure 6-3 Overall view of GPS

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6.2.1 Digital display

The LED can display the state of GPS and show the error codes in digit.
The error codes and their descriptions are as follows:

Table 6-2 GPS error codes

2 Locking command
0 Main power supply 1 Locked automatically due
received from the
defective to no network signal
platform
3 Position ON signal 4 Locked due to defective
5 To be locked
defective CAN bus communication
7 RS232 communication
6 SIM card defective 8 LED self-inspection
error
9 Not used (without label
display)

6.2.2 Emergency unlocking

The GPS terminal will lock the crane automatically if the following conditions happen for a
period of time:
– The crane travels into a region without China Mobile network signal coverage.
– The SIM card inside GPS terminal is defective (including the condition that it is behind the
payment).
When the crane is locked, the engine RPM will decrease. Thus the crane cannot work normally.
If you want to use the crane, you or the service technician can temporarily unlock the crane via
the emergency unlocking procedure. Please remove the defects according to the actual
conditions or drive off the region.
How to unlock the crane in an emergency:
a) You can call the service hot line 400-800-1680 and provide us the VIN of your crane and
GPS terminal code. The service center will give you the unlocking password from the GPS
management platform.
Additional Equipment

b) Press the emergency unlock button and hold for 5 seconds, the LED flashes “A”. Release
the button, GPS begins to clock the emergency unlocking operation. Press the button
again within 5 seconds to enter the first numeral of the password. The numeral increases
as the button is pressed. If the button is pressed for more than 9 times, the numeral
returns to 0.
c) The password consists of 4 numerals. If the button is not pressed within 3 seconds, the
numeral input in this position is finished. At this time, the LED will flash the finished
numeral.
d) Continue to enter the next numeral of the password.

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e) If 4 numerals are not input completely and the button is not pressed within 10 seconds, the
password input is supposed being finished.
When you enter the correct password:
1) The LED displays “A”.
2) The emergency unlocking operation is finished successfully.
When you enter the wrong password
1) LED displays “C” for 10 seconds.
2) The emergency unlocking operation fails.
Since the password is calculated according to the current date, make sure the red control
light flashes during emergency unlocking operation.

6.2.3 Control lights – GPS terminal state

GPS terminal is fitted with 3 control lights (amber, red and green ones). When the GPS terminal
works normally, all the control lights flash. When the GPS terminal works abnormally, obey the
items in the table to remove the defect:

Table 6-3 Troubleshooting

State of the control light Problems Causes

The GPS is off-line. The
Illuminates / GSM cannot receive the network of
Amber signal and text fail to be
extinguishes China Mobile.
sent out.
The GPS terminal cannot
GPS receives weak network signal
Illuminates / navigate and the position
Red due to poorly connected GPS
extinguishes information may be
antenna.
incorrect.
The GPS is off-line. The
Illuminates / The terminal fails to make
Green signal cannot be sent out.
extinguishes connection with the server.
But the text can be sent out.
Additional Equipment

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6.3 Air conditioning in operator's cab

In order to provide a comfortable environment, the operator’s cab is equipped with air
conditioning and cab heater. Adjust the room temperature via the control panel.
The control panel is behind the auxiliary control switch panel in the operator’s cab. There are
three rotary switches on it. Refer to Figure 6-4.

OFF OFF 1
2
3

CAB HEATER CAB COOLER A/C FAN

POWER SWITCH POWER SWITCH SPEED SWITCH

Figure 6-4 A/C control panel

6.3.1 Air conditioning

Do the items that follow.
a) Turn the A/C FAN SPEED SWITCH to position “1”, “2” or “3”.
b) Clockwise turn the A/C FAN SPEED SWITCH to increase the refrigerating capacity.
A/C starts to refrigerate and the room temperature in the cab begins to drop.

6.3.1.1 Operating instructions

a) Refrigeration mode
– Set the A/C FAN SPEED SWITCH to position “3”.
– After 5 minutes, clockwise set the CAB COOLER POWER SWITCH to any position
towards snowflake marking.
Additional Equipment

Result:
The refrigeration mode is ON.
b) Set the CAB COOLER POWER SWITCH to position “OFF” when you get necessary
temperature.
Result:
The compressor stops work.
When the temperature in the cab is higher than the set value:
– The compressor starts automatically.
– The cooling system begins to work.
You can adjust the angle of the air outlet to change the direction of the cold wind. And you
can use the A/C FAN SPEED SWITCH to control the evaporator fan speed: 1, 2 and 3.

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When the air conditioning is used, do not turn the CAB COOLER POWER SWITCH to
position “SNOWFLAKE” while the A/C FAN SPEED SWITCH is at “LOW” position.
Otherwise, the evaporator may get frost to impair the cooling effect.

CAUTION
(1) Do not disassemble an A/C system without consent from the A/C manufacturer.
(2) You must clean the condenser at regular intervals.
(3) You must use the same type of refrigerant and compressor oil when you replace the
parts.
(4) You must use the same type of refrigerant when you add or replace the refrigerant.
(5) Set the FAN mode to HI when you first start to cool the cab. Set the FAN mode to
MID or LOW when you keep the appropriate cab temperature.
(6) Do not use the parts to repair the A/C system that are not approved by the
manufacturer.
(7) When you use the A/C function where it is cool and has a high level of humidity,
examine the evaporator at a regular interval. In these conditions, the evaporator
freezes and causes a blockage for the air that goes through it.
(8) If you operate the crane in a cold area or in the winter season, set the A/C system to
ON for 10 minutes each month.

6.3.1.2 Requirements for periodic maintenance

Table 6-4 Requirements for periodic maintenance

Item Maintenance Repair interval

Condenser fan motor Examine and repair. Every quarter

Evaporator fan motor Examine and repair. Every quarter

Every month or increase the
Condenser Examine and clean. maintenance frequency according to
Additional Equipment

the working conditions

Every quarter or increase the
Evaporator Examine and clean. maintenance frequency according to
the working conditions
Make sure that the connector is
Connector Every month
set in place.

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CAUTION
(1) Evaporator – air outlet in the cab
(2) Condenser – the device is used for the exchange of the hot air outside the driver’s
cab. In some vehicles, it is mounted between water tank and fan (without the
condenser fan motor). While in others, it is on the side of the vehicle (with the
condenser fan motor).
(3) Condenser fan motor – it is mounted with the condenser to help the hot air
exchange.

6.3.2 Cab heater

Do the items that follow.
a) Turn the A/C FAN SPEED SWITCH to position “1”, “2” or “3”.
b) Turn the CAB HEATER POWER SWITCH from position “OFF” to position “SUN”.
The heater system starts to work and the room temperature in the cab begins to rise.
Refer to Figure 6-4.

6.3.2.1 Operating conditions

a) Ambient temperature ≥ -40ºC, height above sea level ≤ 3000 m.
b) It cannot be immerged into water and be washed with water directly.
c) The cab heater should use the antifreeze or the diesel oil that is suitable for the ambient
temperature.

WARNING
Do not use gasoline.

6.3.2.2 Fuel and antifreeze selection

a) For the fuel selection, please refer to Table 6-5.

Table 6-5 Fuel selection

Additional Equipment

Ambient
Above 5ºC Above -5ºC Above -15ºC Above -30ºC Above -40ºC
temperature
Fuel 0# diesel oil 10# diesel oil 20# diesel oil 35# diesel oil 50# diesel oil

b) For the selection of the antifreeze fluid, please refer to Table 6-6.

Table 6-6 Antifreeze selection

Ambient temperature Above -25ºC Above -40ºC

Antifreeze -25ºC antifreeze -40ºC antifreeze

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6.3.2.3 Operating instructions

a) Turn the CAB HEATER POWER SWITCH to position “SUN”.
Result:
FAN POWER CONTROL LIGHT on the auxiliary control switch panel is ON.
The cab heater starts to work.
b) Clockwise turn the A/C FAN SPEED SWITCH.
Result:
The warm air blows out.
c) When the water temperature reaches 80ºC.
The cab heater stops work automatically and the control light "Cab heater state"
extinguishes.
d) When the water temperature is lower than 65ºC.
The cab heater starts again.
In this way, the process is repeated in circles.
When the cab heater is used in cold season for the first time, examine the items below:
– There is no blockage in the air passage.
– The cab heater operates smoothly.
– There is no dirt in combustion air inlet and exhaust outlet.
When the cab heater is not used, press the CAB HEATER POWER SWITCH in OFF position to
stop the heater. At the same time, the control light “Cab heater state" extinguishes after 3
minutes.

Figure 6-5 Control light “Cab heater state”

NOTICE
Additional Equipment

Turn off the cab heater only after the control light “Cab heater state" extinguishes.
Otherwise, the cab heater will be defective due to heat dissipation failure.

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6.3.2.3 Troubleshooting for common failures

Table 6-7 Troubleshooting for common failures

Problems Causes Remedy

The A/C FAN SPEED SWITCH Turn on the A/C FAN SPEED
No warm air blows out. on the air conditioning control SWITCH on the air conditioning
panel is not turned on. control panel.
The cab heater does not The solenoid valve is dirty or
Clean oil pipe and examine the
stop working within 60 cannot be closed completely, or
connection, the control box and
seconds after the fuel the flame detector is
the flame detector.
supply is cut off. short-circuited.
Examine whether the power
The wave of power supply is big supply is stable (especially when
The power is unstable.
and unstable. the stabilized power supply is
applied), or replace control panel.
The voltage of cab heater is
Examine voltage. If the voltage is
higher than 32 V for 5 seconds
high, examine voltage regulator of
The voltage is high. (for the cab heater whose rated
the engine. If it is not high, replace
voltage is 12 V, it means that the
the control box.
voltage is higher than 16 V).
The voltage of cab heater is lower
Start the engine and cab heater,
than 20 V for 5 seconds (for the
and then examine the generator
The voltage is low. cab heater whose rated voltage is
and line voltage. If the voltage is
12 V, it means that the voltage is
not low, replace control panel.
lower than 10 V)
When the cab heater does not Examine whether the line is
The flame detector is
work, the flame detector still short-circuited, replace flame
short-circuited.
shows working state. detector or control panel.
When the relay of motor
Additional Equipment

The contact point is connected, or

is switched off, it is still Replace control panel.
the control switch is defective.
electrified.
The solenoid valve relay
is still electrified when it The contact point is connected or
is switched off or the the coil breaks off, or the control Replace control panel or its coil.
solenoid valve coil panel is defective.
breaks off.
The fuse breaks off, the wire is Reset the fuse, examine
The fuse breaks off. disconnected, or the control panel connection or replace control
is defective. panel.

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Problems Causes Remedy

When the relay of

solenoid valve is
The control panel is damaged. Replace control panel.
electrified, it cannot
output signals.
When the motor relay is
The relay or control panel is
electrified, it cannot Replace control panel.
defective.
output signals.
Examine motor connection. Pull
out plug to examine the motor, if it
The main motor cannot work after
cannot work or the rotational
The motor cannot work. it is electrified or the rotational
speed is low, replace motor.
speed is low.
Otherwise, replace the control
panel.
The water temperature
There is water in sensor or the
sensor is Replace sensor or control box.
circuit board is wet.
short-circuited.
Circuit of the water
The sensor line breaks off or the
temperature sensor Replace sensor or control box.
circuit board fails.
breaks.
Examine connection of flame
The flame detector The flame detector does not
detector, replace the detector or
cannot be ignited. output flame signal.
control panel.
If the oil tank is short of oil, add
Flame extinguishes Flame extinguishes during oil. If the oil pipe leaks, tighten or
during burning. burning and cannot burn again. replace it. Replace short-circuited
flame detector and control box.
Close other interference source,
Strong interference Other interferences
Additional Equipment

replace control panel.

The ignition plug The ignition plug burn out or the Fasten connection, replace
breaks. line looses. ignition plug.
The ignition plug is
It is short-circuited. Examine it.
short-circuited.
The ignition plug relay The relay or the control panel is
Replace control panel.
has no output signal. defective.

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Chapter 7 Transportation and Storage

 Operator’s Manual for Truck Crane

Chapter 7 Transportation and Storage

7.1起Transportation
重
You can move the crane by its power for road-driving or by other carriers for a long distance.
机
说
During transportation, chock the wheels and make the crane safe with wire ropes. Fully close
明
the windows and door to keep rain and moisture out of the cab. Lock the door and windows.
Do these items that follow before lifting. It is recommended to use special lifting device.
a) Extend four sliding beams to about 4800 mm.
b) Wind the outriggers with wire rope.
c) The hook is above the center of gravity of complete vehicle.
Refer to Figure 7-1.

Lifting points

100
3020
40
50
807060

Line of the center of gravity of complete vehicle

Lifting points of outriggers
Special lifting device

Sling

Figure 7-1 Lifting points

WARNING
Before you lift, make sure that the slings have sufficient strength to hold the crane.
Transportation and Storage

ZTC800R532 Truck Crane 7-1

 Operator’s Manual for Truck Crane

7.2 Storage
Do the steps that follow if you do not use the crane for a long time:
a) Lock the doors and the windows, and switch off control instruments.
b) Clean contamination off the crane.
c) Fully retract all the cylinder pistons (except vertical cylinders).
d) Fully extend the vertical cylinders to lift the tires away from the ground.
e) Inflate the tires to specified pressure and put wooden blocks below the tires.
f) Turn off the engine and switch off the battery master switch.
g) If the battery is not used over a month, disconnect its connecting wire to the electrical
system. If the crane is not used for a long period of time, charge it every three months.
h) You must lubricate the surfaces of all the exposed metal components to prevent corrosion.
i) Remove all contamination (dust and sand) from the wire ropes and lubricate them with
ZG-3 calcium based graphite grease.
j) Store the crane in a garage. If not, protect the crane from the rain, thunder and freeze.
k) If you do not operate the crane for more than three months:
Operate the engine at idle speed for one hour in the three month interval.
l) If you do not operate the crane for more than 18 months:
1) Keep the crane clean and do the usual maintenance.
2) Replace aged seal components.
3) Do a general inspection of the engine to see if you must replace the coolant, diesel oil,
and air filters.
m) Make sure that one person keeps the crane prepared for operation.
Transportation and Storage

7-2 ZTC800R532 Truck Crane