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Zoomlion QY30V - User Manual

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II
ForewordForeword
Thanks very much for trusting ZOOMLION brand and purchasing ZOOMLION truckThanks very much for trusting ZOOMLION brand and purchasing ZOOMLION truck
crane.crane.
These operating instructions are intended to put you in a position to operate the craneThese operating instructions are intended to put you in a position to operate the crane
safely and correctly and utilize the reliable usage options that it provides. We shouldsafely and correctly and utilize the reliable usage options that it provides. We should
adhere to the operating instructions during operation and maintenance.adhere to the operating instructions during operation and maintenance.
The accidents occurring during the crane operation are mostly caused by ignoring theThe accidents occurring during the crane operation are mostly caused by ignoring the
precautionary measures and safety regulations. Therefore, do take enough steps inprecautionary measures and safety regulations. Therefore, do take enough steps in
earnest to avoid such accidents. Incorrect operation, service and maintenance are allearnest to avoid such accidents. Incorrect operation, service and maintenance are all
dangerous and might cause life-threatening hazards. Therefore, do read, understanddangerous and might cause life-threatening hazards. Therefore, do read, understand
and master the precautionary measures and notes prior to operating the crane.and master the precautionary measures and notes prior to operating the crane.
Operations, checks and maintenance must be carried out carefully. The operator’sOperations, checks and maintenance must be carried out carefully. The operator’s
motto must always be Safety first!motto must always be Safety first!
aa
Only operate or maintain the crane if you Only operate or maintain the crane if you have reahave read, understand andd, understand and
mastemastered the operating instructiored the operating instructions;ns;
bb
Incorrect operationIncorrect operation , se, service and maintenance are rvice and maintenance are all dangerous and mighall dangerous and mightt
cause life-threatecause life-threatening ning hazahazards;rds;
cc
AlAlwaways kys k eep teep theshese ope operateratining ig insnstrtrucuctitionons hs handandy iy in tn the ohe operperatoator'r's cs cab. Thab. Thee
operaoperating instructing instruc tions belong wittions belong wit h the crane!h the crane!
TThhe e ccoonntteenntts s ccoonncceerrnniinng g aabboouut t ssaaffeetty y aarre e mmaarrkkeed d wwiitth h " " “..
The following terms that are used in these operating instructions "The following terms that are used in these operating instructions "DangerDanger", "", "WarningWarning",",
and "and "CautionCaution" are intended to point out certain important rules of conduct to all persons" are intended to point out certain important rules of conduct to all persons
who work with the crane. The meanings of the terms are as follows:who work with the crane. The meanings of the terms are as follows:
The term "Danger" is used to provide a warning about life-threatening hazards, seriousThe term "Danger" is used to provide a warning about life-threatening hazards, serious
damage to pdamage to propertyroperty..
The term "Warning" is used to provide a warning about potentially serious personalThe term "Warning" is used to provide a warning about potentially serious personal
injury or damage injury or damage to property.to property.
The term "Caution" is used to provide a warning about potential minor or mediumThe term "Caution" is used to provide a warning about potential minor or medium
personal injurypersonal injury, or damage to , or damage to machinery or parts.machinery or parts.
In order to avoid any mechanical damage or personal injury, the user should operate theIn order to avoid any mechanical damage or personal injury, the user should operate the
Caution
Caution
WarningWarning
DangerDanger
WarningWarning
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Summary

Foreword and Safety Terms

Safety Terms and Warnings

Explains "Danger", "Warning", and "Caution" terms and safety symbols used in the manual.

Chapter 1 Description of Crane

Model and Name Plate Identification

Details about the crane's model, name plate, VIN, engine, and their locations.

Crane Chassis Components

Identifies and illustrates the main components of the crane chassis.

Crane Superstructure Components

Identifies and illustrates the main components of the crane superstructure.

Technical Specifications

Provides detailed technical data, parameters, and specifications for the crane.

Rated Lifting Capacity Tables

Presents various tables detailing the crane's rated lifting capacities under different conditions.

Lifting Height Chart

Visual chart showing lifting height capabilities based on working radius and boom length.

Working Areas

Illustrates the defined working areas for crane operations (front, side, rear).

Chapter 2 Safety

Safety Instructions and Signs

Outlines essential safety instructions and the proper use and maintenance of safety signs.

Crane Operation Planning

Emphasizes the importance of meticulous planning for safe crane operations.

Break-in Instructions

Provides guidelines for the initial break-in period to ensure proper vehicle adaptability and performance.

General Safety Guidelines

Covers requirements for operators, riggers, signalmen, and general safety practices.

Selecting an Operating Site

Details crucial factors for choosing a safe and stable operating location for the crane.

Supporting the Crane

Explains the proper procedures for supporting the crane using outriggers and ensuring stability.

Working Conditions

Addresses safe operation under various ambient conditions, particularly wind speeds.

Safe Operation Points

Lists critical points and precautions to ensure safe crane operation at all times.

Hand Signals for Crane Operations

Illustrates and explains standard hand signals used for communication between operator and crew.

Chapter 3 Operation - Crane Chassis

Drivers Cab Overview

Provides an overview of the driver's cab components and their functions.

Steering Wheel Assembly Controls

Details the functions and adjustments of the steering wheel and related column switches.

Instrument Panel and Gauges

Explains the layout and function of the instrument panel, including various gauges and indicators.

Driving the Crane

Covers essential procedures for starting, stopping, driving, and general operation of the crane chassis.

Transmission and Clutch Operation

Describes the operation of the transmission, gear shifting, and clutch engagement/disengagement.

Brake System Operation

Explains the different braking systems and their proper operation for safety.

Towing Procedures

Outlines the regulations and steps for safely towing the crane.

Driving Precautions and Troubleshooting

Provides essential points for attention during driving and covers common driving-related issues.

Chapter 4 Operation - Crane Superstructure

Operators Cab Overview

Provides an overview of the operator's cab in the superstructure, including controls and displays.

Instrument Console Functions

Details the various gauges, lights, and switches on the instrument console.

Joystick Controls

Explains the operation of the left and right joysticks for controlling crane movements.

Safety Devices Operation

Covers the function and inspection of critical safety devices like limit switches and load moment limiter.

Outrigger Operation

Provides detailed instructions for extending, retracting, and leveling the outriggers.

Derricking and Telescoping Operations

Explains how to control the derricking and telescoping movements of the main boom.

Lifting and Lowering Procedures

Details how to perform lifting and lowering operations, including using capacity tables.

Rope Reeving

Explains the process of reeving the hoist ropes correctly for safe operation.

Chapter 5 Equipment

Safety Guidelines for Equipment Installation

Outlines safety precautions and prerequisites for assembling and dismantling equipment like the jib.

Jib Assembly and Angle Settings

Provides step-by-step instructions for assembling the jib and adjusting its angle.

Rooster Sheave Installation

Details the procedure for installing and assembling the rooster sheave for efficient hoisting.

Chapter 6 Additional Equipment

Air Conditioning Operation (Drivers Cab)

Explains the operating methods and functions of the air conditioning system in the driver's cab.

Air Conditioning Operation (Operators Cab)

Details the operation and controls of the air conditioning system in the operator's cab.

Heater Operation

Describes the controls, operating methods, and troubleshooting for the heater system.

Chapter 7 Maintenance and Service

After-Sales Service and Warranty

Information on ZOOMLION's after-sales service, warranty claims, and use of genuine parts.

Crane Cleaning and Service

Guidelines for cleaning the crane and its interior components using appropriate methods.

Oil and Lubrication Requirements

Details the correct types and specifications for fuel, coolant, and hydraulic oil.

Gear Oil and Transmission Lubrication

Covers the types, changing intervals, and procedures for gear oil in the winch, slewing, and transmission.

Lubricating Points and Schedule

Provides detailed tables and schedules for lubricating various chassis and superstructure components.

Adjusting, Cleaning, and Replacing Parts

Offers tables and procedures for regular adjustment, cleaning, and replacement of crane parts.

Wire Rope Maintenance

Covers wire rope inspection, take-down criteria, replacement methods, and general maintenance.

Replacing the Oil Return Line Filter Cartridge

Details the procedure and intervals for replacing the oil return line filter cartridge.

Cleaning the Diesel Oil Filter

Provides steps for cleaning the diesel oil filter, including caution for the filter cartridge.

Cleaning the Air Filter

Explains the procedures for cleaning air filter cartridges and the filter itself.

Cleaning the Cooling System

Details the process for flushing and cleaning the engine's cooling system.

Battery Maintenance and Service

Covers battery inspection, cleaning, charging, and precautions for idle periods.

Tires and Wheels Maintenance

Addresses tire inflation, wheel inspection, changing, and maintenance for safe operation.

Chapter 8 Crane Inspections

Inspection of a New Crane

Outlines the initial checks and inspections required before a new crane is put into service.

Re-inspections and Safety

Explains the necessity of re-inspections, the role of competent inspectors, and risks involved.

Steel Bearing Structures Inspection

Details the inspection requirements for critical steel bearing components like the boom and slewing table.

Inspection During Break-in Period

Specifies inspections and maintenance to be performed after the initial 200 hours of operation.

Periodic Crane Inspections Schedule

Provides a comprehensive schedule for periodic inspections of various crane systems.

Brake System Inspections

Covers structural, functional, and performance tests for the brake system, including intervals.

Hoist and Slewing Mechanisms Inspection

Details the inspection procedures for hoist and slewing mechanisms, including oil evaluation.

Hook Inspection

Specifies criteria for inspecting hooks, including wear, damage, and deformation.

Wire Rope Pulley Inspection

Outlines the annual inspection requirements for wire rope pulley assemblies.

Crane Wire Rope Inspection

Details regular checks for wire ropes, including break criteria and damage assessment.

Load Bearing Equipment Mounting Inspection

Covers inspection of mounting bolts for slewing ring, reducers, and winches.

Oil and Fuel Reservoirs Inspection

Addresses the annual inspection of oil and fuel reservoirs for leaks and overall condition.

Hydraulic System Inspection

Details checks for hydraulic system components like pumps, valves, and piping.

Electrical System Inspection

Outlines the inspection schedule for electrical components like battery, wiring, and lights.

Safety Devices Inspection

Describes functional tests for load moment limiter, hoisting, and lowering limit switches.

Chassis Inspection Intervals

Provides a detailed table for inspection intervals of various chassis components.

Superstructure Inspection Intervals

Provides a detailed table for inspection intervals of various superstructure components.

Chapter 9 Diagnostics

General Troubleshooting

Provides general guidance on diagnosing and troubleshooting crane operation failures.

Chassis Troubleshooting

Addresses common problems and remedies related to the crane chassis.

Clutch Troubleshooting

Lists common clutch problems, their causes, and suggested remedies.

Transmission Troubleshooting

Details problems related to the transmission, their causes, and solutions.

Propeller Shaft Troubleshooting

Covers common issues with the propeller shaft, including abnormal noise and wear.

Intermediate and Rear Axles Troubleshooting

Addresses problems related to intermediate and rear axles, such as noise, heat, and oil leakage.

Steering System Troubleshooting

Lists common steering system issues, their causes, and remedies for hard or erratic steering.

Brake System Troubleshooting

Details common brake system problems, including bias, locking, and invalid responses.

Electrical System Troubleshooting

Covers troubleshooting for electrical system issues, including lights, horns, and warning indicators.

PTO Troubleshooting

Addresses problems related to the PTO, such as oil leakage and failure to operate.

Tires Troubleshooting

Details common tire issues like wear, damage, and alignment problems.

Superstructure Electrical System Troubleshooting

Covers troubleshooting for electrical issues specific to the crane superstructure.

Hydraulic Pump Troubleshooting

Addresses problems related to the hydraulic pump, such as abnormal noise and oil issues.

Outrigger Troubleshooting

Details common issues with outrigger operation, movement speed, and cylinder retraction.

Slewing Mechanism Troubleshooting

Covers problems with the slewing mechanism, including brake issues and slow movement.

Derricking Mechanism Troubleshooting

Addresses issues with the derricking cylinder, such as extension or retraction problems.

Telescoping Mechanism Troubleshooting

Details problems related to boom telescoping, including extension, retraction, and cylinder leaks.

Hoisting Mechanism Troubleshooting

Covers issues with the hoisting mechanism, such as the hook not lifting or lowering.

Chapter 10 Transportation and Storage

Transportation Precautions

Provides essential points and warnings for safely transporting the crane.

Storage Conditions and Procedures

Outlines protective measures and procedures for storing the crane during idle periods.

Summary

Foreword and Safety Terms

Safety Terms and Warnings

Explains "Danger", "Warning", and "Caution" terms and safety symbols used in the manual.

Chapter 1 Description of Crane

Model and Name Plate Identification

Details about the crane's model, name plate, VIN, engine, and their locations.

Crane Chassis Components

Identifies and illustrates the main components of the crane chassis.

Crane Superstructure Components

Identifies and illustrates the main components of the crane superstructure.

Technical Specifications

Provides detailed technical data, parameters, and specifications for the crane.

Rated Lifting Capacity Tables

Presents various tables detailing the crane's rated lifting capacities under different conditions.

Lifting Height Chart

Visual chart showing lifting height capabilities based on working radius and boom length.

Working Areas

Illustrates the defined working areas for crane operations (front, side, rear).

Chapter 2 Safety

Safety Instructions and Signs

Outlines essential safety instructions and the proper use and maintenance of safety signs.

Crane Operation Planning

Emphasizes the importance of meticulous planning for safe crane operations.

Break-in Instructions

Provides guidelines for the initial break-in period to ensure proper vehicle adaptability and performance.

General Safety Guidelines

Covers requirements for operators, riggers, signalmen, and general safety practices.

Selecting an Operating Site

Details crucial factors for choosing a safe and stable operating location for the crane.

Supporting the Crane

Explains the proper procedures for supporting the crane using outriggers and ensuring stability.

Working Conditions

Addresses safe operation under various ambient conditions, particularly wind speeds.

Safe Operation Points

Lists critical points and precautions to ensure safe crane operation at all times.

Hand Signals for Crane Operations

Illustrates and explains standard hand signals used for communication between operator and crew.

Chapter 3 Operation - Crane Chassis

Drivers Cab Overview

Provides an overview of the driver's cab components and their functions.

Steering Wheel Assembly Controls

Details the functions and adjustments of the steering wheel and related column switches.

Instrument Panel and Gauges

Explains the layout and function of the instrument panel, including various gauges and indicators.

Driving the Crane

Covers essential procedures for starting, stopping, driving, and general operation of the crane chassis.

Transmission and Clutch Operation

Describes the operation of the transmission, gear shifting, and clutch engagement/disengagement.

Brake System Operation

Explains the different braking systems and their proper operation for safety.

Towing Procedures

Outlines the regulations and steps for safely towing the crane.

Driving Precautions and Troubleshooting

Provides essential points for attention during driving and covers common driving-related issues.

Chapter 4 Operation - Crane Superstructure

Operators Cab Overview

Provides an overview of the operator's cab in the superstructure, including controls and displays.

Instrument Console Functions

Details the various gauges, lights, and switches on the instrument console.

Joystick Controls

Explains the operation of the left and right joysticks for controlling crane movements.

Safety Devices Operation

Covers the function and inspection of critical safety devices like limit switches and load moment limiter.

Outrigger Operation

Provides detailed instructions for extending, retracting, and leveling the outriggers.

Derricking and Telescoping Operations

Explains how to control the derricking and telescoping movements of the main boom.

Lifting and Lowering Procedures

Details how to perform lifting and lowering operations, including using capacity tables.

Rope Reeving

Explains the process of reeving the hoist ropes correctly for safe operation.

Chapter 5 Equipment

Safety Guidelines for Equipment Installation

Outlines safety precautions and prerequisites for assembling and dismantling equipment like the jib.

Jib Assembly and Angle Settings

Provides step-by-step instructions for assembling the jib and adjusting its angle.

Rooster Sheave Installation

Details the procedure for installing and assembling the rooster sheave for efficient hoisting.

Chapter 6 Additional Equipment

Air Conditioning Operation (Drivers Cab)

Explains the operating methods and functions of the air conditioning system in the driver's cab.

Air Conditioning Operation (Operators Cab)

Details the operation and controls of the air conditioning system in the operator's cab.

Heater Operation

Describes the controls, operating methods, and troubleshooting for the heater system.

Chapter 7 Maintenance and Service

After-Sales Service and Warranty

Information on ZOOMLION's after-sales service, warranty claims, and use of genuine parts.

Crane Cleaning and Service

Guidelines for cleaning the crane and its interior components using appropriate methods.

Oil and Lubrication Requirements

Details the correct types and specifications for fuel, coolant, and hydraulic oil.

Gear Oil and Transmission Lubrication

Covers the types, changing intervals, and procedures for gear oil in the winch, slewing, and transmission.

Lubricating Points and Schedule

Provides detailed tables and schedules for lubricating various chassis and superstructure components.

Adjusting, Cleaning, and Replacing Parts

Offers tables and procedures for regular adjustment, cleaning, and replacement of crane parts.

Wire Rope Maintenance

Covers wire rope inspection, take-down criteria, replacement methods, and general maintenance.

Replacing the Oil Return Line Filter Cartridge

Details the procedure and intervals for replacing the oil return line filter cartridge.

Cleaning the Diesel Oil Filter

Provides steps for cleaning the diesel oil filter, including caution for the filter cartridge.

Cleaning the Air Filter

Explains the procedures for cleaning air filter cartridges and the filter itself.

Cleaning the Cooling System

Details the process for flushing and cleaning the engine's cooling system.

Battery Maintenance and Service

Covers battery inspection, cleaning, charging, and precautions for idle periods.

Tires and Wheels Maintenance

Addresses tire inflation, wheel inspection, changing, and maintenance for safe operation.

Chapter 8 Crane Inspections

Inspection of a New Crane

Outlines the initial checks and inspections required before a new crane is put into service.

Re-inspections and Safety

Explains the necessity of re-inspections, the role of competent inspectors, and risks involved.

Steel Bearing Structures Inspection

Details the inspection requirements for critical steel bearing components like the boom and slewing table.

Inspection During Break-in Period

Specifies inspections and maintenance to be performed after the initial 200 hours of operation.

Periodic Crane Inspections Schedule

Provides a comprehensive schedule for periodic inspections of various crane systems.

Brake System Inspections

Covers structural, functional, and performance tests for the brake system, including intervals.

Hoist and Slewing Mechanisms Inspection

Details the inspection procedures for hoist and slewing mechanisms, including oil evaluation.

Hook Inspection

Specifies criteria for inspecting hooks, including wear, damage, and deformation.

Wire Rope Pulley Inspection

Outlines the annual inspection requirements for wire rope pulley assemblies.

Crane Wire Rope Inspection

Details regular checks for wire ropes, including break criteria and damage assessment.

Load Bearing Equipment Mounting Inspection

Covers inspection of mounting bolts for slewing ring, reducers, and winches.

Oil and Fuel Reservoirs Inspection

Addresses the annual inspection of oil and fuel reservoirs for leaks and overall condition.

Hydraulic System Inspection

Details checks for hydraulic system components like pumps, valves, and piping.

Electrical System Inspection

Outlines the inspection schedule for electrical components like battery, wiring, and lights.

Safety Devices Inspection

Describes functional tests for load moment limiter, hoisting, and lowering limit switches.

Chassis Inspection Intervals

Provides a detailed table for inspection intervals of various chassis components.

Superstructure Inspection Intervals

Provides a detailed table for inspection intervals of various superstructure components.

Chapter 9 Diagnostics

General Troubleshooting

Provides general guidance on diagnosing and troubleshooting crane operation failures.

Chassis Troubleshooting

Addresses common problems and remedies related to the crane chassis.

Clutch Troubleshooting

Lists common clutch problems, their causes, and suggested remedies.

Transmission Troubleshooting

Details problems related to the transmission, their causes, and solutions.

Propeller Shaft Troubleshooting

Covers common issues with the propeller shaft, including abnormal noise and wear.

Intermediate and Rear Axles Troubleshooting

Addresses problems related to intermediate and rear axles, such as noise, heat, and oil leakage.

Steering System Troubleshooting

Lists common steering system issues, their causes, and remedies for hard or erratic steering.

Brake System Troubleshooting

Details common brake system problems, including bias, locking, and invalid responses.

Electrical System Troubleshooting

Covers troubleshooting for electrical system issues, including lights, horns, and warning indicators.

PTO Troubleshooting

Addresses problems related to the PTO, such as oil leakage and failure to operate.

Tires Troubleshooting

Details common tire issues like wear, damage, and alignment problems.

Superstructure Electrical System Troubleshooting

Covers troubleshooting for electrical issues specific to the crane superstructure.

Hydraulic Pump Troubleshooting

Addresses problems related to the hydraulic pump, such as abnormal noise and oil issues.

Outrigger Troubleshooting

Details common issues with outrigger operation, movement speed, and cylinder retraction.

Slewing Mechanism Troubleshooting

Covers problems with the slewing mechanism, including brake issues and slow movement.

Derricking Mechanism Troubleshooting

Addresses issues with the derricking cylinder, such as extension or retraction problems.

Telescoping Mechanism Troubleshooting

Details problems related to boom telescoping, including extension, retraction, and cylinder leaks.

Hoisting Mechanism Troubleshooting

Covers issues with the hoisting mechanism, such as the hook not lifting or lowering.

Chapter 10 Transportation and Storage

Transportation Precautions

Provides essential points and warnings for safely transporting the crane.

Storage Conditions and Procedures

Outlines protective measures and procedures for storing the crane during idle periods.

Zoomlion QY30V Specifications

General IconGeneral
ModelQY30V
TypeTruck Crane
Max Lifting Capacity30 tons
Maximum Travel Speed75 km/h
Maximum Working Radius32 m
Engine TypeDiesel
TransmissionManual
Axles3
Weight31 t

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