XCMG Rough Terrain Crane XCR90_E Operation and Maintenance Manual

[Hyundai]

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XCMG Rough Terrain Crane XCR90_E Operation and Maintenance Manual
Size: 125.45 MB
Format: PDF
Language: English
Brand: XCMG
Type of Machine: Rough Terrain Crane
Type of Manual: Operation and Maintenance Manual, Electric and Hydraulic Diagrams
Model: XCMG XCR90_E Rough Terrain Crane
Number of Pages: 1026 Pages

Contents:
1 Preface

1.1 Preface​

1.2 Manufacturer information​

1.3 Safety symbols and their meanings​

1.4 Data recording device​

1.5 Intended use of the crane​

1.6 Unintended use of the crane​

1.7 Residual risks​

1.8 Prohibited operations​

1.9 Reasonably foreseeable misuse​

1.10 Scope of usage limitations​

1.11 Operational aids​

1.12 Unit conversion chart​

2 Manual description

2.1 About the manual​

2.2 Text structure and symbols of the manual​

2.3 Supplementary information​

2.4 Other text types​

3 General safety information explanation

3.1 Highway traffic regulation​

3.2 Breaking in a new vehicle​

3.3 Driving safety​

3.4 Planning the job​

3.5 Responsible party​

3.6 General requirements for all responsible parties​

3.7 Responsibilities and duties of responsible parties​

3.7.1 Manufacturer​

3.7.2 Authorized agent​

3.7.3 Authorized representative​

3.7.4 Owner​

3.7.5 Operator​

3.7.6 User​

3.7.7 Maintenance personnel (technician/engineer)​

3.8 Personal protective equipment (PPE)​

3.9 Risks and hazards on the crane​

3.9.1 Fire and explosion hazards​

3.9.2 Lightning stroke​

3.9.3 Mechanical injury​

3.9.4 Scald hazards​

3.9.5 Chemical burns​

3.9.6 Asbestos dust hazard​

3.9.7 Poisoning and suffocation hazard​

3.9.8 Hazards involving the battery​

3.9.9 Safety rules for battery and battery disconnect switch​

3.9.10 Environmental risk​

3.10 Obstacles around the crane​

3.11 Safety distance to overhead power lines​

3.12 Safe distance from underground power supply lines/water supply systems​

3.13 Working near transmitters​

3.14 Working near aerodromes/airfields​

3.15 Grounding the crane​

3.16 Response measures in dangerous situations​

3.16.1 Brief introduction​

3.16.2 Machine in contact with power line​

3.16.3 Machine on fire​

3.16.4 Handling abnormalities​

3.17 Safety signs and labels​

3.17.1 Brief introduction​

3.17.2 Mandatory signs​

3.17.3 Prohibition signs​

3.17.4 Warning signs​

3.17.5 Rescue signs​

3.17.6 Fire-fighting signs​

3.17.7 Signs on the machine​

4 Safety guidelines and safe operation

4.1 Safety requirements​

4.1.1 Exits for emergency escape​

4.1.2 Fire extinguisher and first-aid kit (if equipped)​

4.1.3 Safety hammer​

4.1.4 Delivery requirements​

4.1.5 General requirements about safe crane operation​

4.1.6 Safety at the construction site​

4.1.7 Jobsite requirements for setting up the crane​

4.1.8 Setting requirements for slopes and trenches​

4.1.9 Influence of the wind​

4.1.10 Lifting operation with two or more cranes​

4.1.11 Hand signs​

4.2 Safe access of crane​

4.2.1 Walking surfaces and stepping surfaces​

4.2.2 Access​

4.3 Ladder​

4.3.1 Safety guidelines​

4.3.2 Notes on usage​

4.3.3 Three-point support​

4.3.4 Light work and heavy work​

4.3.5 Platform ladder​

4.3.6 Herringbone ladder​

4.3.7 Herringbone ladder (fixed-type)​

4.4 Safety inspections before operation​

4.4.1 Safety rules​

4.4.2 Safety devices​

4.4.3 Ensuring good visibility​

4.4.4 Children safety​

4.5 Start the machine safely​

4.5.1 Preparation and inspection before boarding​

4.5.2 Safely boarding the machine​

4.5.3 Seat adjustment​

4.5.4 Fasten the seat belt (if equipped)​

4.5.5 Inspections before starting the engine​

4.5.6 Safety rules for starting the engine​

4.5.7 Safety rules for engine start in cold weather​

4.5.8 Safety rules for starting the engine with auxiliary cables​

4.5.9 Inspections after starting the engine​

4.6 Installation and assembly safety​

4.6.1 Brief introduction​

4.6.2 Requirements for installation and assembly personnel​

4.6.3 Installation site requirements​

4.6.4 Machine assembly​

4.6.5 Unauthorized modifications​

4.6.6 Counterweight disassembly and front-end working device​

4.7 Safe operation of the machine​

4.7.1 Pre-operation safety rules​

4.7.2 Precautions for operation​

4.7.3 Safe parking of the machine​

4.7.4 Requirements for setting up crane before operation​

4.7.5 Handling the load​

4.7.6 Stop the machine​

4.7.7 Safety rules for towing​

4.8 Safety maintenance and service​

4.8.1 Maintenance safety requirements​

4.8.2 Correct welding​

4.8.3 Keep the cab clean​

4.8.4 Keep the machine clean​

4.8.5 Environmental protection and disposal​

4.9 Precautions against disasters and measures for survival​

4.9.1 Emergency measures for fire​

4.9.2 Emergency measures for electrical accidents​

4.9.3 Emergency measures for fall from height​

4.9.4 Precautions against natural disasters​

4.9.5 Emergency measures for power failure​

4.10 Operational risks in special environments​

4.10.1 General​

4.10.2 Operating on loose ground​

4.10.3 Operation under OMs of falling, flying articles and invaders​

4.10.4 Operation in high temperature environments​

4.10.5 Operation in dusty or sandy environment​

4.10.6 Operation in rainy and humid environments​

4.10.7 Operation in snowy days​

5 General introduction

5.1 Terminology​

5.2 Crane model​

5.3 Main applications​

5.4 Operating conditions​

5.5 Product Introduction​

5.5.1 Composition of the crane​

5.5.2 Optional configurations​

5.6 Technical specifications​

5.6.1 Dimensions​

5.6.2 Main technical parameters​

5.7 Signs​

5.7.1 Introduction​

5.7.2 Product nameplates​

5.7.3 Signs​

6 Transporting and storing crane

6.1 General safety rules for transportation​

6.2 Technical specifications for transportation​

6.2.1 Overall dimensions​

6.2.2 Specifications of parts to be transported​

6.2.3 Specifications of removable parts​

6.3 Packaging and protection​

6.4 Lifting and fixing solutions​

6.4.1 Notes​

6.4.2 Lifting the crane​

6.4.3 Fastening for loading and shipping the crane​

6.4.4 Lifting and securing the jib​

6.4.5 Lifting the counterweight​

6.4.6 Hook block​

6.5 Transportation with a trailer​

6.5.1 Fastening for loading and shipping the crane​

6.5.2 Transportation with a trailer​

6.6 Waterway transportation​

6.7 Railway transportation​

6.8 Storage of crane​

6.8.1 Parking, storage and protection​

6.8.2 Crane storage in low ambient temperature​

7 Assembly and trial operation

7.1 Cautions​

7.2 Counterweight​

7.2.1 Cautions​

7.2.2 Counterweight structure​

7.2.3 Setting of counterweight self-assembly/disassembly OM​

7.2.4 Counterweight bracket assembly​

7.2.5 Placing and fixing the counterweight​

7.2.6 Counterweight fixing bracket assembly​

7.2.7 Placing counterweight on the counterweight bracket​

7.2.8 Counterweight assembly​

7.2.9 Counterweight OM setting​

7.2.10 Counterweight disassembly​

7.3 Jib​

7.3.1 Cautions​

7.3.2 Fixed jib assembly​

7.3.3 Fixed jib offset angle adjustment​

7.3.4 Disassembly of the fixed jib​

7.4 Auxiliary sheave​

7.4.1 Cautions​

7.4.2 Assembly of auxiliary sheave​

7.4.3 Stowing the auxiliary sheave​

7.5 Wire rope​

7.5.1 Cautions​

7.5.2 Introduction to wire rope sockets​

7.5.3 Replacing the wire rope​

7.5.4 Re-reeving the winch rope​

7.5.5 Correcting the rope twist​

7.6 Hook block​

7.6.1 Cautions​

7.6.2 Introduction to hook blocks​

7.6.3 Handling of hook block​

7.6.4 Assembly and disassembly of hook block​

8 Cab operation

8.1 Overview of the cab​

8.2 Breaker​

8.3 Fire extinguisher​

8.4 Sun screen​

8.5 Telescoping pedal​

8.6 Control switches​

8.7 Radio panel​

8.8 Monitoring device​

8.9 Control levers​

8.10 Ignition lock​

8.11 Touchscreen display​

8.12 Travel parameter monitoring display​

8.13 Steering mode selector switch​

8.14 Reading light in the cab​

9 Chassis operation

9.1 Before driving​

9.1.1 Operation of battery disconnect switch​

9.1.2 Opening and closing the door​

9.1.3 Steering wheel adjustment​

9.1.4 Adjustment of seat​

9.1.5 Adjust the armrest box​

9.1.6 Rearview mirror adjustment​

9.1.7 Inspection of lights​

9.1.8 Operation of lights​

9.1.9 The use of seat belt​

9.1.10 Inspection of engine fuel level​

9.1.11 Inspection of engine coolant level​

9.1.12 Inspection of engine oil level​

9.1.13 Inspections of AdBlue/DEF solution level​

9.1.14 Inspection of transmission oil level​

9.1.15 Transmission oil filling port​

9.1.16 Inspection of filters​

9.1.17 Inspection of tires​

9.2 Chassis operation​

9.2.1 Engine start​

9.2.2 Engine stop​

9.2.3 DPF regeneration operation​

9.2.4 Transmission operation​

9.2.5 Steering operation​

9.2.6 Operation of four-wheel drive mode​

9.2.7 Braking operation​

9.2.8 Towing operation​

9.2.9 Operation of the windshield wiper​

9.3 Accelerator operation​

9.4 HVAC operation​

9.5 Suspension operation​

9.6 Breaking in a new vehicle​

9.7 Winter operation​

10 Crane operation

10.1 Safety devices​

10.1.1 Load moment indicator (LMI)​

10.1.2 Outrigger pressure and length detection​

10.1.3 Slewing angle encoder​

10.1.4 Lowering Limiter (counter)​

10.1.5 Pilot control switch​

10.1.6 Electronic level gauge​

10.1.7 Engine oil pressure warning​

10.1.8 Winch monitoring device​

10.1.9 Turntable locking device​

10.2 Preparation for crane operation​

10.2.1 Precautions for operation​

10.2.2 Conditions for lifting operation​

10.2.3 Inspection of safety devices​

10.2.4 Inspections of wire ropes​

10.2.5 Inspection of the slewing brake switch​

10.2.6 Inspection before lifting operations​

10.3 Outrigger control devices​

10.3.1 Outrigger control (cab)​

10.4 Outrigger control​

10.4.1 Crane jobsite​

10.4.2 Outrigger OM selection​

10.4.3 Adjusting the outrigger floats​

10.4.4 Outrigger control under full extension OM​

10.4.5 Outrigger control under 75% extended, half-extended or fully-retracted OM​

10.5 Operation of turntable locking device​

10.6 Operating winches​

10.7 Boom telescoping operation​

10.8 Boom luffing operation​

10.9 Slewing operation​

10.10 Combined movement operation​

10.11 Operation of the crane on tires​

10.12 Operation of the crane traveling with a suspended load​

10.13 Operations after lifting operation​

11 Maintenance and service

11.1 Safety instructions​

11.1.1 Safety​

11.1.2 Personnel​

11.1.3 Description of intervals and tasks​

11.1.4 Maintenance intervals​

11.1.5 Securing against start up​

11.1.6 Securing against falls​

11.1.7 Preventing fires​

11.1.8 Protecting against burns​

11.1.9 Protecting from scalding​

11.1.10 Rotating parts​

11.1.11 Using permissible service fluids​

11.1.12 Protecting against the hazards of service fluids​

11.1.13 Replacing damaged crane components​

11.1.14 After replacement of components​

11.1.15 Tire size​

11.2 Warranty and coverage​

11.3 XCMG after-sales service​

11.4 Taking an oil sample​

11.5 Crane maintenance​

11.5.1 Cleaning the crane​

11.5.2 Anti-corrision​

11.5.3 Protecting the crane against corrosion for storage​

11.5.4 Protecting the crane against corrosion for shutdown​

11.6 Storage​

11.6.1 Storage conditions​

11.6.2 Pre-storage processing​

11.6.3 Maintenance during storage​

11.6.4 Returning to service​

11.7 Safe disposal proposal​

11.7.1 Safe disposal of service fluids and lubricants​

11.7.2 Batteries​

11.7.3 Disposing of the machine​

11.8 Regular maintenance and inspections​

11.8.1 Checklist for crane operator​

11.8.2 Checklist for crane maintenance personnel​

11.9 Maintenance tasks of crane operator​

11.9.1 Safety​

11.9.2 Engine​

11.9.3 Cooling system​

11.9.4 Air filtration system​

11.9.5 Fuel system​

11.9.6 AdBlue/DEF system​

11.9.7 Air intake and exhaust systems​

11.9.8 Transmission​

11.9.9 Steering system​

11.9.10 Wheel​

11.9.11 Maintenance and service of the cab wiper​

11.9.12 Maintenance and service of the cab​

11.9.13 Chassis hydraulic system​

11.9.14 Hydraulic hose lines​

11.9.15 Boom​

11.9.16 Winch system​

11.9.17 Slewing system​

11.9.18 Check the slewing bearing connection​

11.10 Maintenance tasks of crane maintenance technician​

11.10.1 Safety​

11.10.2 Engine​

11.10.3 Cooling system​

11.10.4 Air filtration system​

11.10.5 Fuel system​

11.10.6 AdBlue/DEF system​

11.10.7 Air intake and exhaust systems​

11.10.8 Transmission​

11.10.9 Steering system​

11.10.10 Axle​

11.10.11 Braking system​

11.10.12 Maintenance and service of the cab​

11.10.13 Electrical system​

11.10.14 Drive shaft​

11.10.15 Wheel​

11.10.16 Chassis hydraulic system​

11.10.17 Slewing bearing connection​

11.10.18 Slewing system​

11.10.19 Winch system​

11.10.20 Boom telescoping system​

11.10.21 Rope sheave​

11.10.22 Wire rope​

11.10.23 HVAC in the cab​

11.10.24 Maintenance and service of the cab wiper​

11.10.25 Adjustment of outrigger sliders​

11.11 Plans for oil filling and lubrication​

11.11.1 Filling amounts​

11.11.2 Lubrication guidelines​

11.11.3 Lubrication operation modes​

11.12 Operating fluids and lubricants​

11.12.1 Oil brands and filling amount​

11.12.2 Comparison between foreign and domestic oil brands​

12 Periodic inspections

12.1 General introduction​

12.2 Inspection plan​

12.3 Inspection of steel structures​

12.3.1 Basic principles and procedure​

12.3.2 Repair welding​

12.3.3 Inspection points​

12.3.4 Inspections of lifting points and fixing points​

12.4 Inspections of boom telescoping system​

12.5 Checking boom sliders and bolts​

12.6 Inspections of hook blocks​

12.7 Inspections of sheaves​

12.8 Inspections of rollers​

12.9 Inspections of telescoping conditions of outriggers​

12.10 Winch system inspections​

12.11 Inspections of safety ropes​

12.12 Inspection of wire ropes​

12.13 Inspection of accumulator​

12.14 Inspections of pin connections​

12.15 Inspections of load-bearing equipment installation​

12.15.1 Inspections of mounting bolts for tightness​

12.15.2 Inspections of mounting bolts for damage​

12.16 Inspections of slewing bearing connection​

12.17 Inspections of load handling equipment and assembly aids​

12.18 Inspections of fastening equipment​

12.19 Inspections of fuel tank and hydraulic oil tank​

12.20 Inspections of hydraulic line​

12.20.1 Safety guidelines​

12.20.2 Interval​

12.20.3 Inspections of service life​

12.20.4 Inspections of hydraulic hose lines for damage and leakages​

12.20.5 Documenting the inspection results​

12.20.6 Replacing hydraulic hose lines​

12.21 Inspections of ladders​

12.22 Inspection chart for cranes​

13 Common troubles and trouble-shooting

13.1 Troubleshooting rules​

13.2 Display fault code​

13.2.1 Engine faults and solutions​

13.2.2 Transmission faults and solutions​

13.2.3 LMI faults and solutions​

13.2.4 Controller faults and solutions​

13.3 Common troubles and solution​

13.3.1 Power system​

13.3.2 Axle and suspension system​

13.3.3 Braking system​

13.3.4 Steering system​

13.3.5 Outrigger system​

13.3.6 Slewing system​

13.3.7 Winch system​

13.3.8 Luffing system​

13.3.9 Electrical system​

13.3.10 Hydraulic system​

13.3.11 Other systems​

14 Decommissioning and disposal

14.1 Proper disassembly of equipment​

14.2 Disposal​

15 Appendix

15.1 EC Declaration​

15.2 Wire rope certificate​

15.3 Hook block certificate​

15.4 Tightening torque of main bolts​

15.5 Maintenance checklist​

16 Schematics

16.1 Overview of the hydraulic and electrical components with identification​

16.2 Schematics for the superstructure electrical system​

16.3 Schematics for the chassis electrical system​

16.4 Schematics for the hydraulic system​

16.5 Schematic for the steering hydraulic system​

16.6 Schematic for the braking hydraulic system​